Yamaha CONCIERGE 4 2023 Owner's/Operator's Manual
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Yamaha CONCIERGE 4 2023 Owner's/Operator's Manual

Yamaha CONCIERGE 4 2023 Owner's/Operator's Manual

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2023
MODEL YEAR
OWNER'S / OPERATOR'S MANUAL
PERSONAL TRANSPORT VEHICLE
Read this manual carefully before operating this vehicle.
CONCIERGE 4
DR2 4PA POWERTECH AC
LIT-19626-A2-83
J2D-F8199-15

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  • Page 1 2023 MODEL YEAR OWNER’S / OPERATOR’S MANUAL PERSONAL TRANSPORT VEHICLE Read this manual carefully before operating this vehicle. CONCIERGE 4 DR2 4PA POWERTECH AC LIT-19626-A2-83 J2D-F8199-15...
  • Page 2 This product can expose you to chemicals including phthalates and lead which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov...
  • Page 3 INTRODUCTION Congratulations on your purchase of a Yamaha four-passenger vehicle. This manual contains information you will need for proper operation, maintenance, and care of your vehicle. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha.

  • Page 4: Important Manual Information

    A TIP provides key information to make procedures eas- ier or clearer. 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.

  • Page 5: Table Of Contents

    CONTENTS CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING...

  • Page 6: Warranty

    • • WARRANTY TRANSFER: EMISSION CONTROL SYSTEM WARRANTY: or workmanship which arise solely as a result of owner abuse and/ or lack of proper maintenance are not covered by this warranty. YAMAHA GOLF-CAR COMPANY, KENNESAW, GEORGIA 30144 EFFECTIVE DATE: 07/01/20...
  • Page 7 ONE YEAR FROM THE DATE OF PURCHASE. THE REPLACEMENT OF THE BATTERY IS THE EXCLUSIVE REMEDY UNDER THIS WRITTEN WARRAN- TY OR ANY IMPLIED WARRANTY. YAMAHA MAKES NO OTHER REPRESENTATION OR WARRANTY OF ANY KIND, AND NO REPRESENTATIVE, EMPLOYEE, DISTRIBUTOR OR DEALER OF YAMAHA HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION, PROMISE OR AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY.

  • Page 8: Important Labels

    IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS Read the following labels carefully before operating your utility vehicle. If any of these labels are damaged or missing, contact a Yamaha dealer for replace- ments.
  • Page 9 IMPORTANT LABELS...
  • Page 10 “TOW”, attendre un minimum de 15 seconds avant de le remettre. ***-K8298-** DATE OF CONSTRUCTION: **** **** MY**** YAMAHA MOTOR POWERED PRODUCTS CO., LTD 200-1 SAKAGAWA, KAKEGAWA, JAPAN MODEL: ****** ***** **** MAX. BATTERY WEIGHT: *** kg MAX.POWER: *** hp (*** KW) NOMINAL SYSTEM VOLTAGE: **V...
  • Page 11 DEATH: • Operating tire pressure: set with tires cold. Recommended Tire size Front Rear 205/65-10, 4ply 151 kPa, 22 psi / 151 kPa, 22 psi 18x8.50-8, 4ply 137 kPa, 20 psi / 137 kPa, 20 psi YAMAHA ***-F1696-**...
  • Page 12 Keep a record of these numbers for reference when ordering parts from a Yamaha Golf-Car Company dealer. 1. Vehicle serial number SERIAL NO.: Serial number: JXX-XXXXXX YAMAHA MOTOR POWERED PRODUCTS CO., LTD 1. Vehicle serial number...

  • Page 13: Safety Information

    SAFETY INFORMATION Yamaha vehicles are designed to be simple to oper- ate. However, be sure to observe the following: BEFORE USING THE FOUR- PASSENGER VEHICLE • Read this Owner’s/Operator’s manual and all safety and instruction labels on the vehicle before oper- ating.
  • Page 14 SAFETY INFORMATION WHILE OPERATING THE FOUR- PASSENGER VEHICLE • Keep your entire body inside the vehicle, remain seated and hold on when the vehicle is in motion. • Do not start the vehicle until all occupants are seat- • Keep your hands on the steering wheel and your eyes on the path ahead.

  • Page 15: Driver Qualifications

    SAFETY INFORMATION Like all machines, four-passenger vehicles can cause injury if improperly used or maintained. This section contains broad safety practices required for safe vehicle operation. Experience has shown that four-passenger vehicles are safe when operated in accordance with the safety warnings affixed to every vehicle.

  • Page 16: Hazard Prevention

    SAFETY INFORMATION HAZARD PREVENTION The following hazards must be made safe: Steep Grades – Where steep grades exist, restrict ve- hicles to designated pathways when possible. In addi- tion, identify steep grades with a suitable warning like: WARNING Descend steep grades slowly with foot on brake. Death or serious personal injury can result from failing to comply with the safety and warning in- structions affixed to the vehicle.
  • Page 17 SAFETY INFORMATION • 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. Ven- tilation is also required to remove hydrogen gas from the vehicle storage areas during the battery charging process.
  • Page 18 • Maintain in a legible condition all nameplates, warn- ings and instructions provided by the manufacturer. • If new nameplates, warnings or instructions are needed, contact your Yamaha Golf-Car Company dealer. STORAGE AND BATTERY CHARGING Take the following precautions to ensure maintenance worker safety: •...

  • Page 19: Controls

    CONTROLS FEATURES 1. Main switch 2. Drive select switch 3. Battery gauge 4. Accelerator pedal 5. Brake pedal 6. Parking brake pedal BATTERY 7. Horn switch 8. USB ports 1. Front seat 3 14 2. Steering wheel 3. Tow switch 4.

  • Page 20: Main Switch

    CONTROLS MAIN SWITCH The main switch controls the following items: “OFF” All electrical circuits are switched off (motor controller unit remains energized). The vehicle cannot be oper- ated. The key can be removed only in this position. BATTERY “ON” Electrical circuits are switched on. The vehicle can be driven.

  • Page 21: Drive Select Switch

    CONTROLS Use the table to determine the remaining battery ca- pacity. For 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.

  • Page 22: Accelerator Pedal

    CONTROLS ACCELERATOR PEDAL The accelerator pedal controls the vehicle’s speed. Action Car Speed Depress pedal Increase Release pedal Decrease 1. Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the vehicle. 1. Brake pedal PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the four-passenger vehicle.

  • Page 23: Tow Switch

    CONTROLS TOW SWITCH Before operating the four-passenger vehicle, make sure the tow switch is in the “RUN” position. NOTICE Ensure that the “Drive Select Switch” is in the “FWD” position and then move the “TOW Switch” to “TOW” before towing. 1.

  • Page 24: Pre-Operation Checks

    PRE-OPERATION CHECKS Pre-operation checks should be made each time you use your four-passenger vehicle. Get in the habit of performing the following checks in the same way so that they become second nature. WARNING To keep vehicle from moving while performing pre-operation checks: •...

  • Page 25: Tire Condition

    PRE-OPERATION CHECKS BATTERIES For Flooded Batteries Check that the batteries are held securely in place to prevent them from being damaged from vibration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the batteries. Check the battery terminals for corrosion and tight- ness.

  • Page 26: Steering System

    If you feel excessive free play, or hear rattling sounds which may indicate loose steering components, con- sult a Yamaha dealer. REVERSE ALARM Check the reverse alarm by moving the drive select switch to “REV” for reverse. The alarm should sound.

  • Page 27: Body And Chassis

    PRE-OPERATION CHECKS Parking Brake Pedal Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed. Release the parking brake by depressing the acceler- ator pedal. 1. Parking brake pedal HEADLIGHTS/TAILLIGHTS Ensure the headlights and taillights are operational.

  • Page 28: Operation

    OPERATION STARTING With the parking brake applied, turn the drive select switch to “FWD” for forward, or “REV” for reverse. BATTERY NOTICE Do not shift from “FWD” (forward) to “REV” (re- verse) while the vehicle is moving. Transaxle dam- age can result. Turn the main switch to “ON.”...

  • Page 29: Maintenance And Adjustment

    * Items without a page number reference should be serviced by a Yamaha dealer or other qualified me- chanic. This manual does not contain these procedures. They are contained in the Service Manual. ** Flooded Batteries only...
  • Page 30 — minal protectant * Items without a page number reference should be serviced by a Yamaha dealer or other qualified me- chanic. This manual does not contain these procedures. They are contained in the Service Manual. ** Flooded Batteries only...
  • Page 31 * Items without a page number reference should be serviced by a Yamaha dealer or other qualified me- chanic. This manual does not contain these procedures. They are contained in the Service Manual. ** Flooded Batteries only *** Do no operate vehicle if discrepancy is found.

  • Page 32: Battery Care

    MAINTENANCE AND ADJUSTMENT BATTERY CARE For Flooded Batteries WARNING Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or veg- etable oil.
  • Page 33 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 than one point between cells.
  • Page 34 MAINTENANCE AND ADJUSTMENT For AGM Batteries (Optional) WARNING Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or veg- etable oil.

  • Page 35: Battery Charging

    Lift up the seat and move the tow switch to the TOW position. NOTICE Use only battery chargers that are rated for use with 48-volt Yamaha vehicles. Serious battery damage can result. Thoroughly read and under- stand the user manual supplied with your 48-volt charger.
  • Page 36 MAINTENANCE AND ADJUSTMENT Check the DC output code and plug for damage. The location of the dummy pin is different between the flood battery and the AGM battery (Optional). 1. DC output plug for Flooded batteries 1. Receptacle for Flooded batteries 2.
  • Page 37 MAINTENANCE AND ADJUSTMENT With the charger properly connected and grounded (see charger’s owner’s manual), insert the DC output into the DC charger receptacle. WARNING 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.

  • Page 38: Battery Installation

    MAINTENANCE AND ADJUSTMENT BATTERY INSTALLATION WARNING When working with batteries, do not put wrenches or other metal objects across the battery termi- nals. An arc can occur causing an explosion or fire at the battery. For Flooded Batteries Install the battery holddown plates and torque to 7-9 N·m (0.7-0.9 kgf·m, 5.2-6.6 lb·ft) as shown.
  • Page 39 MAINTENANCE AND ADJUSTMENT For AGM Batteries (Optional) Install the battery hold-down plates and torque to 7-9 N·m (0.7-0.9 kgf·m, 5.2-6.6 lb·ft) as shown. Install the temperature sensor between the wire terminal and flat washer in correct place and then tighten the terminal connecting bolts to 9-10 N·m (0.9-1.0 kgf·m, 6.6-7.4 lb·ft) as shown.

  • Page 40: Fuse Replacement

    MAINTENANCE AND ADJUSTMENT FUSE REPLACEMENT WARNING Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and cre- ate a fire hazard. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.

  • Page 41: Battery Charger

    MAINTENANCE AND ADJUSTMENT Depress the locking tab of the fuse holder, and then remove the fuse holder cover. Pull the fuse out and inspect it. Replace the fuse if necessary. Install the fuse holder cover. Close the seat. 1. Fuse holder cover 2.

  • Page 42: Installation

    MAINTENANCE AND ADJUSTMENT Step 3: Constant Voltage Step: Regulated voltage “equalizes” individual battery cells, resulting in full charge delivered to the battery. Step 4: Topping Off Step: Battery pack is brought slowly to full charge without excess gassing. Step 5: Storage: Every 14th day and if voltage be- comes less than 48V, charger restarts cycle to re- fresh batteries in storage.
  • Page 43 MAINTENANCE AND ADJUSTMENT MOUNTING WARNING This charger is not designed for on-board use. Im- proper mounting or installation could result in a risk of fire or damage to the vehicle. Mount the charger on a shelf or on the wall with ade- quate ventilation.
  • Page 44 MAINTENANCE AND ADJUSTMENT GROUNDING The battery charger must be grounded to reduce the risk of electric shock. The charger is equipped with a 3-prong AC cord set. The AC cord set must be con- nected to an appropriate receptacle that is properly installed and grounded in accordance with the Nation- al Electrical Code and all local codes and ordinances.
  • Page 45 MAINTENANCE AND ADJUSTMENT WARNING Visually and manually inspect to verify that the DC output cord, plug and battery charging receptacle are in good working condition before each and ev- ery use. Do not use the charger under any of the following conditions: •...
  • Page 46 MAINTENANCE AND ADJUSTMENT The instructions printed on the charger (shown below) are for daily reference. The charger is factory preset for use with Trojan 48-volt golf car batteries. OPERATING INSTRUCTIONS PLUG AC CORD INTO A GROUNDED RECEPTACLE PLUG DC CORD INTO DC CHARGER RECEPTACLE CHARGE CYCLE WILL BEGIN AFTER A FEW SECONDS AND AMMETER WILL TURN ON...
  • Page 47 MAINTENANCE AND ADJUSTMENT Under normal charge circumstances, the LEDs operate as follows: Ammeter Displays approximate (Amber) scale of current output during Step 2. Blinking: High internal charger temperature. Current output reduced. 80% Charge 80% charged, Step 2 (Amber) complete. Begin Step 3. Blinking: With no battery connect- ed, indicates algorithm...

  • Page 48: Troubleshooting

    MAINTENANCE AND ADJUSTMENT TROUBLESHOOTING LED Error Codes (For Battery Condition) WARNING Incorrect reassembly may result in a risk of electric shock or fire. The following procedures are intended only to determine if a malfunction may exist in the charger. WARNING 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 at- tempting any maintenance or cleaning.
  • Page 49 MAINTENANCE AND ADJUSTMENT If a fault occurs, count the number of red flashes between pauses and refer to the table below: Red Flashes Cause Solution Battery High Voltage Check battery size and condition and reset char- ger (interrupt DC connec- tion for 15 seconds).
  • Page 50 MAINTENANCE AND ADJUSTMENT Hardware System Faults Problem Description Cause Remedy Charger does not start. No AC power to charger. Ensure correct voltage No LEDs illuminate or at AC outlet. Check AC blink when AC cord is cord connections. connected. Replace AC cord if damaged.

  • Page 51: Transaxle Oil

    Allow excess gear oil to flow out of the hole until it stops. Install the oil level plug. Install the rear floor cover and secure with two bolts. For transaxle oil replacement, consult a Yamaha deal- er or other qualified mechanic. 1. Bolt 2. Rear floor cover...

  • Page 52: Wheel Replacement

    MAINTENANCE AND ADJUSTMENT WHEEL REPLACEMENT WARNING Before performing wheel or brake maintenance, verify that the main switch is in the “OFF” position. Accidental starting of the vehicle could cause the vehicle to move, causing death or serious personal injury. To remove and install a wheel on your four-passenger vehicle: With the wheels blocked to prevent the vehicle from moving, loosen the wheel nuts.

  • Page 53: Brake Adjustment

    WARNING Consult your Yamaha dealer before using your ve- hicle if you suspect brake problems. Brake failure could result in a serious accident. Death or serious personal injury can result from failing to comply with the safety instructions in this manual.
  • Page 54 MAINTENANCE AND ADJUSTMENT If the free play distance needs adjusting, loos- en the lock nut and turn the adjusting nut in or out until the free play specification is met. Then tighten the lock nut in place. WARNING Do not over-tighten the brake cables. Over-tight- ening will increase brake wear and affect overall 1.
  • Page 55 MAINTENANCE AND ADJUSTMENT REPLACING A HEADLIGHT UNIT This model is equipped with LED-type headlights. If a headlight does not come on, replace it as follows: Disconnect the wire connector from the head- light assembly. 1. Wire connector Remove the three screws and remove the light control unit.
  • Page 56 MAINTENANCE AND ADJUSTMENT ADJUSTING A HEADLIGHT NOTICE It is recommended to have the headlight adjust- ment performed by a Yamaha dealer. The screw can be accessed from under the fender. Using a Phillips head screwdriver, turn the ad- justing screw.

  • Page 57: Chassis Preparation

    Perform the following preparations when storing your vehicle for extended periods of time. NOTICE Yamaha Golf-Car Company does not approve the use of high-pressure washers to clean the prod- ucts they manufacture. Doing so may damage the finish on the body or result in doing other damage not covered by warranty.

  • Page 58: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS Items DR2 4PA POWERTECH AC Dimensions: Overall length 3230 mm (127.2 in.) Overall width 1200 mm (47.2 in.) Overall height (steering height) 1230 mm (48.4 in.) Overall height (sun top height) 1815 mm (71.5 in.) Height of floor 325 mm (12.8 in.) Wheelbase 2490 mm (98.0 in.)
  • Page 59 SPECIFICATIONS BATTERIES Items DR2 4PA POWERTECH AC Flooded battery: Trojan - T-875 (6x8-volt) RC: minimum 117 min AGM battery: Trojan - T-875 AGM (6x8-volt) (Optional) RC: minimum 118 min CHASSIS Items DR2 4PA POWERTECH AC Suspension: Front Independent (Coil-over strut type) Rear Pivoted trailing arm (mono-link) Steering system:...
  • Page 60 SPECIFICATIONS Items DR2 4PA POWERTECH AC Lights: Headlight Taillight 12 V BULB GENERAL SPECIFICATIONS (BATTERY CHARGER) DC Output – see Operating Instructions Voltage - nom (V) Voltage - max (V) 67.2 Current - max (A) Battery Type Specific to selected algorithm Reverse Polarity Electronic protection –...
  • Page 61 SPECIFICATIONS MECHANICAL DRAWINGS (BATTERY CHARGER) 278 ±3 mm 196 ±3 mm 260 ±3 mm 3 ±1 mm M4(4 mm) Grounding Stud(Ref.)

  • Page 62: Wiring

    WIRING WIRING DIAGRAM...
  • Page 64 CONTENTS WARRANTY IMPORTANT LABELS SAFETY INFORMATION CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE AND ADJUSTMENT STORAGE SPECIFICATIONS WIRING *J2DF8199150080* PRINTED IN USA 2022.11-0.3×1 CR...

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