Yamaha YDR Cruise AC 2021 Owner's/Operator's Manual

Ac 48 volt golf car

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OWNER'S / OPERATOR'S

MANUAL

READ THIS MANUAL CAREFULLY!

It contains important safety information.

YDR Cruise AC

AC 48 VOLT GOLF CAR

J1C-F8199-E1

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Summary of Contents for Yamaha YDR Cruise AC 2021

Page 1 OWNER’S / OPERATOR’S MANUAL READ THIS MANUAL CAREFULLY! It contains important safety information. YDR Cruise AC AC 48 VOLT GOLF CAR J1C-F8199-E1...
Page 3 INTRODUCTION Congratulations on your purchase of a Yamaha golf car. This manual contains information you will need for proper oper- ation, maintenance, and care of your golf car. A thorough understanding of these simple instructions will help you to ob- tain maximum enjoyment from your new Yamaha golf car.
Page 4: Important Manual Information
Obey all safety your golf car and this manual. If you messages that follow this symbol to have any questions concerning this avoid possible injury or death. manual, please consult a Yamaha dealer. WARNING A WARNING indicates a hazardous WARNING...
Page 5: Table Of Contents
CONTENTS IMPORTANT LABELS OPERATOR SAFETY SAFETY CONSIDERATIONS CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE CARE AND STORAGE SPECIFICATIONS WIRING...
Page 6: Important Labels
IMPORTANT LABELS Q SAFETY AND INSTRUCTION LABELS WARNING Please read the following labels carefully before operating your golf car, and promptly replace any labels which become damaged or removed. Death or serious personal injury can result from failing to read and com- ply with the safety instruction labels.
Page 7 IMPORTANT LABELS...
Page 8 The first three digits of the serial number are for model identification; the remaining digits are the unit pro- duction number. Keep a record of these numbers for reference when ordering parts from a Yamaha Golf- Car Company dealer. Y-2791...
Page 9: Operator Safety
Q OPERATOR SAFETY Yamaha golf cars are designed to be simple to operate; however, be sure to observe the following to reduce the risk of serious injury or death due to loss of control and other hazards: BEFORE USING THE GOLF CAR 9 Read this Owner’s/Operator’s man-...
Page 10 Q OPERATOR SAFETY WHILE OPERATING THE GOLF CAR 9 Keep your entire body inside the golf car, remain seated, and hold on when the car is in motion. 9 Do not start the golf car until all occupants are seated. 9 Keep your hands on the steering wheel and your eyes on the path ahead.
Page 11: Safety Considerations
Q SAFETY CONSIDERATIONS Like all machines, golf cars can WARNING cause injury if improperly used or Do not operate golf cars when maintained. under the influence of alcohol or This section contains broad safety drugs. Death or serious personal practices required for safe golf car injury can result from failing to operation.
Page 12 Q SAFETY CONSIDERATIONS 9 Wet Areas. Wet grass may cause 9 Personnel. Allow only qualified, a golf car to lose traction and may trained and authorized personnel affect stability. Golf car operators to inspect, adjust and maintain the should reduce speed in wet areas golf car.
Page 13 9 If new nameplates, warning or movement. instruction labels are needed, con- tact your Yamaha Golf-Car Compa- 9 When working on the battery, do ny dealer. not smoke, or allow any sparks or open flames near the vehicle, to STORAGE AND avoid any fires or explosions.
Page 14: Controls
CONTROLS FEATURES 1 Main switch 2 Drive select switch 3 Steering wheel 4 Battery gauge 5 Brake pedal 6 Parking brake pedal 7 Accelerator pedal 8 Batteries 9 Seat 0 Tow switch q DC charger receptacle w Front tire e Front bumper r Front body t Rear tire y Rear bumper...
Page 15: Main Switch
CONTROLS MAIN SWITCH The main switch controls the follow- ing items: “OFF” All electrical circuits are switched off (motor controller unit remains ener- BATTERY gized). The golf car cannot be oper- ated. The key can be removed only in this position. “ON”...
Page 16: Battery Gauge
CONTROLS BATTERY GAUGE The battery gauge displays how much charge is left in the batteries. When the batteries are at full charge, BATTERY all the segments will light up A . As the battery energy decreases, the segments will move to the left toward the “E”.
Page 17: Drive Select Switch
CONTROLS DRIVE SELECT SWITCH The drive select switch is used to shift the golf car into forward or re- verse. After coming to a complete BATTERY stop, move the switch to the desired position. Switch Position Car Movement FORWARD REVERSE The reverse alarm will sound when the drive select switch is pressed to the “REV”...
Page 18: Parking Brake Pedal
CONTROLS BRAKE PEDAL Press down on the brake pedal to stop the golf car. B Brake pedal Y-21a PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the golf car. C Parking brake pedal Y-22a Release the parking brake by press- ing the accelerator pedal.
Page 19: Tow Switch
CONTROLS TOW SWITCH Before operating the car, make sure the tow switch is in the “RUN” posi- tion. A Tow switch NOTICE Ensure that the drive select switch is in the “FWD” position and then move the tow switch to “TOW” be- fore towing.
Page 20: Pre-Operation Checks
PRE-OPERATION CHECKS Pre-operation checks should be made each time you use your golf car. Get in the habit of performing the following checks in the same way so that they become second nature. WARNING To keep car from moving while performing pre-operation checks: 9 Remove main switch key.
Page 21: Tire Condition
PRE-OPERATION CHECKS BATTERIES Charge batteries before each use. See charging steps in Chapter 7, “MAINTENANCE”. Check that the batteries are held securely in place to prevent the bat- teries from being damaged from vi- bration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the batteries.
Page 22: Steering System
BATTERY Y-2805 PEDAL OPERATION Check the following pedal controls for proper operation. If a pedal does not work properly, consult a Yamaha dealer. Accelerator Pedal Make sure the accelerator pedal op- erates smoothly. When checking the accelerator pedal operation, make sure the main switch is OFF position.
Page 23: Body And Chassis
PRE-OPERATION CHECKS Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its orig- inal position when released. B Brake pedal Y-21a Parking Brake Pedal Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed.
Page 24: Operation
OPERATION STARTING 1. With the parking brake applied, turn the drive select switch to “FWD” for forward, or “REV” for BATTERY reverse. Y-2806 NOTICE Do not shift from “FWD” (forward) to “REV” (reverse) while the golf car is moving. Transmission dam- age can result.
Page 25 OPERATION STOPPING To stop the golf car gradually press down on the brake pedal. A Brake pedal NOTICE Do not hold the golf car on an Y-65b incline with the accelerator – use the brake. Transmission damage can result. When the car has come to a stop, apply the parking brake pedal and turn the main switch to “OFF”.
Page 26: Maintenance
Check shock absorbers for oil leaks and damaged springs * 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.
Page 27 Inspect brake shoes and adjust or replace if necessary * 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.
Page 28: Battery Care
MAINTENANCE Battery Care 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 vegeta- ble oil.
Page 29 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 read- ings are found, or if readings vary more than one point between cells.
Page 30: Battery Charging
MAINTENANCE Battery Charging WARNING Read and understand the own- er’s manual provided with your golf car’s battery charger before charging batteries. Death or serious personal injury can result from failing to comply with the safety instructions in this manual. WARNING Explosive hydrogen gas is pro- duced while batteries are being charged.
Page 31 2. 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 golf cars. Serious battery damage can result. Thoroughly read and understand the user manual sup- plied with your 48-volt charger.
Page 32: Battery Installation
MAINTENANCE 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 explosion of the battery. 1. Install the battery hold-down plates and tighten to 16 Nm, 1.6 m·kg as shown.
Page 33: Fuse Replacement
MAINTENANCE 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 34: Prepare For Emergencies
MAINTENANCE BATTERY CHARGER Multi-Charge Steps: Ensures a con- sistent and repeatable charge. Prepare for Emergencies Step 1: Pre-test: Tests several Be prepared for possible injury or conditions before charging begins. fire. Keep the following items handy: If a problem is detected, charging is terminated.
Page 35: Installation
MAINTENANCE Installation WARNING The AC line connected to the char- The output of chargers with great- ger must be capable of supplying er than 48-volt may pose an en- 12 A to the charger. AVOID connect- ergy and/or shock hazard under ing a charger and another device to normal use.
Page 36 MAINTENANCE Mounting WARNING This charger is not designed for on-board use. Improper mounting or installation could result in a risk of fire or damage to the golf car. Mount the charger on a shelf or on the wall with adequate ventilation. Ideally it will be mounted horizontally with airflow from below.
Page 37 MAINTENANCE Grounding Charging The battery charger must be ground- WARNING ed to reduce the risk of electric shock. The charger is equipped with To reduce the risk of an electric a 3-prong AC cord set. The AC cord shock, connect only to a properly set must be connected to an appro- grounded, single-phase (3-wire) priate receptacle that is properly in-...
Page 38 MAINTENANCE WARNING WARNING Visually and manually inspect to Whenever removing AC or DC verify that the DC output cord, cord set plugs from receptacles, plug and battery charging recepta- pull from the plug body and not cle are in good working condition from their respective cords.
Page 39 MAINTENANCE Under normal charge circumstances, the LEDs operate as follows: Ammeter Displays approximate scale (Amber) of current output during Step 2. Blinking: High internal charger temperature. Current output reduced. 80 % Charge 80 % charged, Step 2 complete. Begin (Amber) Step 3.
Page 40: Troubleshooting
MAINTENANCE Troubleshooting 1. 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 be- fore attempting any maintenance or cleaning.
Page 41 MAINTENANCE 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 con- dition and reset charger (in- terrupt DC connection for 15 seconds).
Page 42 MAINTENANCE 2. 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 dam- aged.
Page 43: Transaxle Oil
8. Install the oil level plug. 9. Install the rear floor cover 2 and secure with two bolts 1 . For transaxle oil replacement, con- sult a Yamaha dealer or other quali- fied mechanic. 7-18...
Page 44: Wheel Replacement
MAINTENANCE 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 Y-57 injury. To remove and install a wheel on your golf car: 1.
Page 45: Brake Pedal Free Play Adjustment
MAINTENANCE WARNING Consult a Yamaha dealer before using your golf car 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 46 MAINTENANCE Parking Brake Release Adjustment NOTICE Before performing parking brake release adjustment, adjust brake pedal free play. 1. Apply 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 Y-2823 bolt counterclockwise until it con- tacts the sector.
Page 47: Care And Storage
CARE AND STORAGE Care Clean the golf car after use so that others can use it comfortably later. WARNING Do not let wax and other oils/ greases attach to the rubber parts on the floor, etc. It may cause slip- ping and fall, resulting in injury.
Page 48 CARE AND STORAGE Windshield care Use an air gun, etc., to blow away and remove the dust particles stick- ing to the windshield surface, and then wipe the windshield gently with a finely-woven soft cloth and water. NOTICE 9 Do not use neutral detergent to clean the windshield.
Page 49 CARE AND STORAGE Storage Perform the following steps if the golf car is not going to be used for an ex- tended period of time. 9 Clean each part thoroughly. 9 Check the bolt/nut at each part for looseness, and securely tighten the bolt/nut if found loosened.
Page 50: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS Items YDR Cruise AC Dimensions: Overall length 2380 mm Overall width 1200 mm Overall height (steering height) 1785 mm Height of floor 295 mm Wheelbase 1640 mm Tread: Front 890 mm Rear 980 mm Minimum ground clearance 105 mm Weight: Dry weight (without battery)
Page 51 SPECIFICATIONS TRANSMISSION Items YDR Cruise AC Differential/reduction gear Secondary reduction system helical gear Secondary reduction ratio: Forward 12.44:1; Reverse 12.44:1 Differential type bevel gear Lubricant/capacity Yamalube SAE 90 gear oil/355 cc (355 mL) BATTERIES Items YDR Cruise AC Battery GS - Golf Car Type BV150Z (4 × 12-volt) RC: minimum 85 Ah @56 A...
Page 52 SPECIFICATIONS CHASSIS Items YDR Cruise AC Steering system: Type Rack and pinion Steering angle (L.H.) 1.85 turn Steering angle (R.H.) 1.85 turn Brakes: Brake system Mechanical drum brake on each rear wheel with self-adjusters Type of brake Dual internal expanding shoe Leading/trailing shoes (self-adjusting) Brake pedal free play linkage 50–55 mm...
Page 53: Battery Charger
SPECIFICATIONS BATTERY CHARGER General Specifications 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 – auto-reset Short Circuit Electronic current limit AC Input Voltage - max (Vrms) 85–265...
Page 54: Mechanical Drawings
SPECIFICATIONS BATTERY CHARGER Mechanical Drawings 278 ±3 mm 196 ±3 mm 260 ±3 mm 3 ±1 mm M4 (4 mm) Grounding Stud (Ref.)
Page 55: Wiring Diagram
WIRING WIRING DIAGRAM 10-1...
Page 56 NOTES 10-2...
Page 57 NOTES 10-3...
Page 58 NOTES 10-4...
Page 60 Printed in Thailand 2020-NK Yamaha Motor Powered Products Co., Ltd.

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