Yamaha DRIVE 2 SUPER HAULER 2019, Owner'S/Operator'S Manual

Page 1: ...ERATOR S MANUAL Read this manual carefully before operating this vehicle SUPER HAULER J2F F8199 11 LIT 19626 A0 24 DR2E SUPER HAULER UTILITY VEHICLE 2019 MODEL YEAR 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 2: ... 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 3: ...btain maximum enjoyment from your new Yamaha If you have any questions about the operation or maintenance of your Super Hauler please consult a Yamaha dealer Yamaha Golf Car Company DR2E SUPER HAULER 2019 by Yamaha Golf Car Company 1st edition All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Golf Car Company is expressly prohibited Printed in U S A LI...

Page 4: ...ge to the four passenger vehicle or other property TIP A TIP provides key information to make procedures easier or clearer TIP Yamaha continually seeks advancements in product design and quality therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your vehicle and this manual If you have any questions c...

Page 5: ... 1 WARRANTY 2 IMPORTANT LABELS 3 OPERATOR SAFETY 4 SAFETY CONSIDERATIONS 5 CONTROLS 6 PRE OPERATION CHECKS 7 OPERATION 8 MAINTENANCE 9 STORAGE 10 SPECIFICATIONS 11 WIRING 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 6: ... Installation of parts or accessories that are not original equipment x Fading rust or deterioration due to exposure or ordinary wear and tear x Modifications or alterations that affect the car s condition operation performance or durability x Damage due to improper transportation x Acts of God e g lightning hail damage flooding fire etc This Limited Warranty does not cover any parts replaced due ...

Page 7: ...in the use of any battery a prudent owner will read and study the charger owner s manual the vehicle owner s manual the operator s instructions and the battery warning labels and will exercise due care in working on or around batteries THE PROVISIONS OF THIS LIMITED WARRANTY SHALL NOT APPLY IF BATTERIES ARE SUBJECTED TO ANY OF THE FOLLOWING CONDITIONS s Abuse or neglect such as improper fluid leve...

Page 8: ...t use on such pathways without specific permission from golf course management Read the warning label on the beverage holder panel before operating Be sure occupants are seated Select FORWARD OR REVERSE then turn main switch to ON Press the accelerator pedal to start moving The motor will start and the parking brake will release automatically To stop release the accelerator pedal and press the bra...

Page 9: ...only This vehicle is restricted to 2 occupants per bench seat Do not start vehicle until all occupants are seated Remain fully seated and hold on when in motion Keep entire body inside vehicle Drive slowly in turns Drive slowly straight up and down slopes Set parking brake before leaving vehicle Turn main switch to OFF and remove key when not in use Do not operate while under the influence of alco...

Page 10: ...D PRODUCTS CO LTD 200 1 SAKAGAWA KAKEGAWA JAPAN MODEL VEHICLE WEIGHT kg lb BATTERY WEIGHT MAX kg NOMINAL SYSTEM VOLTAGE V MAX POWER hp kW LOAD CAP kg lb G V W kg lb This vehicle complies with ANSI ITSDF B56 8 2011 Part III F4236 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 11: ...ed in the location shown TIP The first three digits of the serial number are for model identification the remaining digits are the unit production number Keep a record of these numbers for reference when ordering parts from a Yamaha Golf Car Company dealer 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 12: ...the driver s side only and only in designated areas Do not allow more than two occupants per seat This Super Hauler is restricted to two occupants unless equipped with a rear seat Do not operate the Super Hauler while under the influence of alcohol or drugs their effect on vision and judgment make operating a Super Hauler dangerous Do not operate the Super Hauler on public streets roads or highways...

Page 13: ...he Super Hauler to match the terrain Avoid turning the steering wheel too sharply at higher speeds to avoid tipping or rolling the vehicle Always drive slowly straight up or straight down slopes never at an angle to avoid tipping or rolling the vehicle Do not make any modification or addition which affects capacity or safe operation or make any changes not in accordance with the owner s operator s ...

Page 14: ...structions affixed to the Super Hauler HAZARD PREVENTION Drivers should be mindful of road hazards and avoid dangerous situations that may include the following Steep Grades Where steep grades exist restrict the Super Hauler to designated roadway or path and descend slowly with foot on the brake Descend steep grades slowly with foot on brake Death or serious personal injury can result from failing ...

Page 15: ... trained and authorized personnel to inspect adjust and maintain the Super Hauler Parts and Materials Use only replacement parts and materials recommended by the manufacturer Ventilation Properly ventilate all maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards Ventilation is required to remove hydrogen gas from the Super Hauler storage areas d...

Page 16: ...se safety devices as supplied by the manufacturer After each maintenance or repair the car must be driven by a qualified trained and authorized person in an area free of pedestrian traffic to ensure proper operation and adjustment Record all maintenance performed in a maintenance record log by date name of person performing maintenance and type of maintenance Periodically inspect maintenance log to ...

Page 17: ...select switch 4 Battery gauge 5 USB ports 6 Accelerator pedal 7 Brake pedal 8 Parking brake pedal 9 Horn switch a Reflector b Batteries c Seat d Front body e Headlights f Front tire g Front bumper h DC charger receptacle i Amber flasher light j Tow switch k Rear tire l Rear cargo area m Taillights Y 2944 21 10 22 20 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 18: ...not be operated The key can be removed only in this position ON Electrical circuits are switched on The vehicle can be driven ON WITH LIGHTS The functions for this position are the same as for the ON position however this position will activate the headlights and taillights BATTERY GAUGE The battery gauge displays how much charge is left in the batteries å When the batteries are at full charge all...

Page 19: ...or example if 7 of the 9 LED lights are lit batteries still have approximately 47 4 volts left When the batteries fall to 43 4 volts or less 1 LED will blink on and off meaning the batteries should be charged immediately DRIVE SELECT SWITCH The drive select switch is used to shift the vehicle into forward or reverse After coming to a complete stop move the switch to the desired position Switch Pos...

Page 20: ...er Hauler Brake pedal PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the Super Hauler ç Parking brake pedal TIP Release the parking brake by depressing the accelerator pedal The parking brake will automatically release when the accelerator pedal is depressed If the main switch is in the ON position depressing the accelerator may suddenly cause the Super Hauler to move A...

Page 21: ... 15 seconds minimum before switching again Failure to do so may lead to drive system damage while towing HEADLIGHT TAILLIGHT ON POSITION Turn the main switch all the way to the right to the second ON position This will activate the headlights and taillights USB PORTS A USB port is located inside the dash on the driver side and passenger side These can be used to power or charge USB devices or acce...

Page 22: ...N SWITCH The horn is located adjacent to the brake pedal and is activated by depressing with your foot å Horn switch TIP It is advisable to sound the horn when approaching blind corners 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 23: ...n the same way so that they become second nature To keep vehicle from moving while performing pre operation checks Remove main switch key Apply parking brake PRE OPERATION CHECKS Refer to the Periodic Maintenance charts on pages 8 1 and 8 2 ENGINE ACCESS COVER Open the engine access cover for checking and servicing 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 24: ...ery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN TIRE CONDITION Tire Air Pressure Check the tire air pressure before operating the Super Hauler Tire pressure 152 kPa 1 52 kgf cm2 22 psi ...

Page 25: ...g sounds which may indicate loose steering components consult a Yamaha dealer REVERSE ALARM Check the reverse alarm by moving the drive select lever to R for reverse The alarm should sound PEDAL OPERATION Check the following pedal controls for proper operation If a pedal does not work properly consult a Yamaha dealer Accelerator Pedal With the main switch in the OFF position make sure the accelera...

Page 26: ... positive click and releases when the accelerator pedal is pressed ç Parking brake pedal TIP Release the parking brake by depressing the accelerator pedal Headlights Taillights Ensure the headlights and taillights are operational Never operate the Super Hauler at night or during inclement weather without properly working headlights taillights Horn Switch Make sure the horn operates correctly å Hor...

Page 27: ...forward to REV reverse while the Super Hauler is moving Transmission damage can result 2 Turn the main switch to ON Do not depress the accelerator pedal when turning on the main switch or the Super Hauler may suddenly start moving 3 Check that your path is clear in the direction you plan to go and slowly depress the accelerator pedal The Super Hauler will start to move å Accelerator pedal TIP The ...

Page 28: ... Brake pedal When the Super Hauler has come to a stop apply the parking brake pedal and turn the main switch to OFF Parking brake pedal NOTICE Do not hold the Super Hauler on an incline with the accelerator use the brake Transmission damage can result A B 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 29: ...Y MONTH EVERY 6 MONTHS 4 3 8 5 8 6 6 2 8 3 6 4 8 11 6 3 6 3 6 2 7 1 8 3 8 4 Items without a page number reference should be serviced by a Yamaha dealer or other qualified mechanic This manual does not contain these procedures They are contained in the Service Manual CS CHECK CA CHECK AND ADJUST R REPLACE S SERVICE CL CLEAN AND LUBRICATE L LUBRICATE Clean battery tops check for tightness of hold do...

Page 30: ... contain these procedures They are contained in the Service Manual CS CHECK CA CHECK AND ADJUST R REPLACE S SERVICE CL CLEAN AND LUBRICATE L LUBRICATE Check wheel nut tightness front wheel bearing play Check transaxle oil level and inspect for leakage Perform a discharge test Apply Terminal protectant Inspect brake shoes and adjust or replace if necessary Replace transaxle oil S S S S S S CA CS CS...

Page 31: ...ame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Six 8 volt deep cycle batteries provide power for your electric vehicle and must be properly maintained and recharged for maximum performance and service life To maintain your batteries 1 Clean the tops of the batteries with a solution of baking...

Page 32: ...ly as a dipstick to help determine this level Clean replace and tighten all vent caps NOTICE Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water 3 Using a hydrometer check the specific gravity of the battery fluid in each cell against the readings on the chart below Consult a Yamaha dealer if any low readings are found or if readings vary more ...

Page 33: ...nal injury can result from failing to comply with the warning labels in this manual To charge the batteries in your vehicle follow the instructions contained in your battery charger s owner s manual The following is a summary of the charging steps NOTICE Do not attempt to recharge your vehicle s batteries without thoroughly reading and understanding the owner s manual provided with your charger 1 ...

Page 34: ...s manual insert the DC output into the DC charger receptacle Do not disconnect the DC output cord from the DC charger receptacle when the charger is on or an arc could occur that may cause an explosion 4 The charger will turn off automatically when the batteries reach full charge 5 After the charger has turned off disconnect the DC output plug from the DC charger receptacle by grasping the plug bo...

Page 35: ...ry ç Battery hold down plate 2 Connect the wire leads and torque to 9 10 Nm 0 9 1 0 m kg 80 89 in lb as shown When installing batteries Carefully place battery cables and hold downs making sure that cables do not lay across vent caps Always remove the negative cable to the motor controller first and install it last A spark can occur causing an explosion or fire at the battery NOTICE Do not over tigh...

Page 36: ... a fire hazard NOTICE When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting and electrical system damage 1 Locate the in line fuse holder on the main wire harness adjacent to the tow switch 2 Pull fuse holder cover off 3 Pull fuse out inspect and replace if necessary å Fuse holder Fuse 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 37: ...tically boosts battery pack when individual cell voltages are not balanced and restores pack capacity BATTERY CHARGER Prepare for Emergencies Be prepared for possible injury or fire Keep the following items handy G First aid kit G Fire extinguisher G Emergency phone numbers Read the text located on the case of the charger before operating or using the charger Features Switch Mode Design High effic...

Page 38: ...maximum Ampere varies depending on AC voltage Please refer to AC Input in General Specifications RISK OF FIRE Use this charger only on circuits with a 15 amp or higher branch circuit protection circuit breaker or fuse in accordance with the national electrical code ANSI NFPA 70 and all applicable local codes and ordinances When using an extension cord use only a grounded 3 wire 12 AWG cord no long...

Page 39: ...y it is recommended that the AC input cord be at the lower end of the charger Keep the charger free of oil dirt mud or dust to keep the cooling fins operating as efficiently as possible Mount the charger by the mounting plate using appropriate fasteners TIP The charger s AC plug must be locat ed at least 46 cm 18 above the ground and the display visible to the user Chargers can ignite flammable ma...

Page 40: ...ger is equipped with a 3 prong AC cord set The AC cord set must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances Improper connection of the equipment grounding conductor can result in a risk of an electric shock The conductor with insulation that has an outer surface that is green wi...

Page 41: ...cles are damaged or distressed in any way Using the charger with any of the above symptoms could result in a fire property damage or personal injury Do not disconnect the DC cord set plug from the DC charger receptacle when the charger is on If the charger must be stopped first disconnect the AC power supply cord from its AC outlet and then disconnect the charger DC cord set plug from the DC charg...

Page 42: ... AC cord set to AC power Then connect the DC cord set plug to the vehicle charging receptacle by grasping the plug handle and pushing the plug straight into the DC charger receptacle The charger will start automatically Upon connection to AC power source the lower four LEDs come on as a Power On Self Test then the AC power LED turns on Upon connection to battery pack output indicators turn on to i...

Page 43: ...rger temperature Current output reduced 80 Charge Amber On 80 charged Step 2 complete Begin Step 3 Blinking With no battery connected indicates algorithm selected by number of flashes at startup 100 Charge Green On Charging complete Charger in Storage Mode Blinking Step 3 complete Begin Step 4 AC On Amber On AC power good Fault Red Blinking Charger error Refer to Troubleshooting on next page Blink...

Page 44: ...y to determine if a malfunction may exist in the charger To reduce the risk of electric shock always disconnect the charger s AC cord set plug from AC power and its DC cord set plug from batteries before attempting any maintenance or cleaning Do not operate the charger if it is malfunctioning Personal injury or property damage could result 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 45: ...ds Charge Timeout caused by battery pack not reaching required voltage Charger output was reduced due to high temperatures Check connections Operate charger at a lower ambient temperature Check Battery Battery could not be trickle charged up to minimum voltage Check for shorted or damaged cells Over Temperature Charger shut down due to high internal temperature Ensure sufficient cooling air flow a...

Page 46: ...maged Charger does not start charging when DC cord set is plugged into charger receptacle and the Amber AC On LED is illuminated Incorrect wiring or disconnection from DC cord charger receptacle and batteries Battery voltage less than 20 Volts Ensure polarity for wiring is correct from DC cord charger receptacle and batteries Check battery pack voltage Charger runs longer than 20 hours Charger may...

Page 47: ... Do not allow foreign material to enter transaxle Serious transaxle damage can result 4 The oil level should be right at the bottom of the oil level plug hole 2 or just starting to flow out of the hole 5 If needed add YAMALUBE 80W 90 gear oil until it starts to flow from the oil level plug hole 6 Allow excess gear oil to flow out of the hole until it stops 7 Install the oil level plug 8 19 2 0 1 9 Y ...

Page 48: ...remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Wheel nut tightening torque 88 Nm 8 8 m kg 65 ft lb Brake Adjustment The brakes on your Super Hauler are self adjusting Before you operate the Super Hauler press down on the brake pedal several times to make sure the brakes are functioning properly Consult yourYamaha dealer before using your Super Hauler if y...

Page 49: ...y 1 Remove the floor mat and service lid from the floor of the Super Hauler 2 If the free play distance needs adjusting loosen the lock nut å and turn the adjusting nut in or out until the free play specification is met Then tighten the lock nut in place Do not over tighten the brake cables Over tightening will increase brake wear and affect overall performance of Super Hauler Premature brake wear ca...

Page 50: ...pply pressure to the parking brake pedal until the brake nail catches the first latch position on the sector 2 Loosen the locknut and turn the bolt counterclockwise until it contacts the sector 3 Turn the bolt clockwise 3 8 120 degrees then tighten locknut 1 Parking brake pedal 2 Bolt 3 Locknut 4 Brake nail 5 Sector 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 51: ...screws 2 and remove the light control unit 3 Remove the four screws 3 to remove the headlight assembly from the holder 4 Remove the headlight assembly from the holder 5 Install new headlight assembly into holder and secure with the four screws 6 Install the light control unit and fasten with three screws 7 Connect the wire connector to the headlight assembly 2 0 1 9 Y a m a h a G o l f C a r C o m...

Page 52: ...ng screw 1 2 Turning the screw clockwise will lower the beam and turning the screw counter clockwise will raise the beam Replacing a Taillight Bulb 1 If a taillight bulb burns out replace the bulb assembly 1 by removing the rubber grommet 2 from the rear bumper 2 Remove the wire connector replace the bulb and reinstall by fitting the rubber grommet 2 over the bulb assembly 1 and installing in the r...

Page 53: ... a safe place CHASSIS PREPARATION 1 Verify the tire pressure is set to 152 kPa 1 5 kgf cm2 max 22 psi 2 Clean exterior of the Super Hauler and apply a rust inhibitor 3 Cover the Super Hauler with a breathable cover and store it in a dry well ventilated area BATTERY PREPARATION 1 Recharge the batteries and check the fluid levels at least once a month NOTICE Do not allow cleaning solution to enter ba...

Page 54: ... x 1194 mm x 200 mm 70 0 in x 47 0 in x 7 9 in Weight Dry weight 422 5 kg 931 5 lb Performance Factory and maximum speed setting 24 km h 15 mph Minimum turning radius 3 3 m 10 8 ft Seating capacity One occupants per seat Bed capacity 363 kg 800 lb TRANSMISSION Items DR2E19 SUPER HAULER Differential reduction gear Secondary reduction system helical gear Secondary reduction ratio Forward 12 44 Rever...

Page 55: ...e cable end play Mechanical drum brake on each rear wheel with self adjusters Dual internal expanding shoe Leading trailing shoes self adjusting 50 55 mm 1 97 2 17 in 0 004 0 02 in 0 1 0 5 mm Parking brake Type Foot type parking brake with automatic release Wheel Tire size Front Rear Rim size Tire pressure 205 65 10 4PLY 205 65 10 4PLY 7 00 I 8 00 152 kPa 1 52 kgf cm2 22 psi Lights Bulb voltage wa...

Page 56: ...10VAC 6 1A 200VAC 5 6A 220VAC 5 4A 230VAC 5 1A 240VAC Current nom Arms 10A 120VAC 6A 200VAC 5A 230VAC AC Power Factor 0 98 at nominal input current Dimensions 28 0 x 24 5 x 14 0 cm 11 x 9 7 x 5 5 Weight 5 kg 12 lbs Environmental Enclosure IP46 Operating Temperature 30 C to 50 C 22 F to 122 F derated above 30 C below 0 C Storage Temperature 40 C to 70 C 40 F to 158 F AC Input Connector IEC320 C14 r...

Page 57: ...2F 10 Mechanical Drawings 278 3 mm 196 3 mm 260 3 mm 176 3 mm 125 mm 246 3 mm 3 1 mm M4 4 mm Grounding Stud Ref 139 3 mm 111 3 mm SPECIFICATIONS BATTERY CHARGER 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 58: ...11 1 J2F 11 WIRING DIAGRAM WIRING Y 2827 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 59: ... 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...

Page 60: ...PRINTED IN USA 2018 12 0 3 2 CR E 2 0 1 9 Y a m a h a G o l f C a r C o m p a n y ...