Yamaha DRIVE 2 SUPER HAULER 2019 Owner's/Operator's Manual
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Yamaha DRIVE 2 SUPER HAULER 2019 Owner's/Operator's Manual

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2019
MODEL YEAR
OWNER'S / OPERATOR'S MANUAL
UTILITY VEHICLE
Read this manual carefully before operating this vehicle.
SUPER HAULER
DR2E SUPER HAULER
LIT-19626-A0-24
J2F-F8199-11

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Summary of Contents for Yamaha DRIVE 2 SUPER HAULER 2019

  • Page 1 2019 MODEL YEAR OWNER’S / OPERATOR’S MANUAL UTILITY VEHICLE Read this manual carefully before operating this vehicle. SUPER HAULER DR2E SUPER HAULER LIT-19626-A0-24 J2F-F8199-11...
  • Page 3 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 OWNER’S/OPERATOR’S MANUAL © 2019 by Yamaha Golf-Car Company 1st edition All rights reserved.
  • Page 4 If you have any avoid possible injury or death. questions concerning this manual, please consult your Yamaha dealer. A WARNING indicates a hazardous situation which, if not avoided, Read and understand this manual...

  • Page 5: Table Of Contents

    CONTENTS WARRANTY IMPORTANT LABELS OPERATOR SAFETY SAFETY CONSIDERATIONS CONTROLS PRE-OPERATION CHECKS OPERATION MAINTENANCE STORAGE SPECIFICATIONS WIRING...

  • Page 6: Warranty

    Any charges incurred in transporting a golf car or charger to and from an authorized Yamaha golf car dealer for service or in performing field service are also excluded from this warranty.
  • Page 7 THE PROVISIONS OF THIS LIMITED WARRANTY SHALL Yamaha Golf-Car Company (herein referred to as “YGC”) hereby warrants to the Original Retail Purchaser or Lessee of a YAMAHA The NOT APPLY IF BATTERIES ARE SUBJECTED TO ANY OF THE FOLLOWING CONDITIONS:...

  • Page 8: Important Labels

    • This vehicle was not manufactured for use on public streets and does not comply with federal motor vehicle safety standards applicable to passenger cars. • This vehicle is capable of speeds over 15 mph (24 kph) and therefore does not conform to standards for golf cars (ANSI Z130.1). YAMAHA J0D-K7762-00...
  • Page 9 IMPORTANT LABELS...
  • Page 10 IMPORTANT LABELS...
  • Page 11 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- Y-2940 Car Company dealer.

  • Page 12: Operator Safety

    ! OPERATOR SAFETY Yamaha Super Haulers 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 OPERATING THE SUPER HAULER •...
  • Page 13 ! OPERATOR SAFETY • Keep your hands on the steering wheel and your eyes on the path ahead. • Use extra care in congested areas or when backing up. Always back up slowly, and watch carefully. • Avoid starting or stopping abruptly. •...

  • Page 14: Safety Considerations

    ! SAFETY CONSIDERATIONS Like all machines, the Super Hauler HAZARD PREVENTION can cause injury if improperly used or Drivers should be mindful of road maintained. hazards, and avoid dangerous Experience has shown that Super situations that may include the Haulers are safe when operated in following: accordance with the safety warnings Steep Grades –...
  • Page 15 ! SAFETY CONSIDERATIONS Loose Terrain – Avoid areas of loose • Ventilation. Properly ventilate all terrain which may cause a Super maintenance and storage areas Hauler to lose traction and affect in accordance with applicable fire stability. Take notice of conditions codes and ordinances to avoid fire and reduce speed when driving on hazards.
  • Page 16 • If new nameplates, warnings or movement. instructions are needed, contact • When working on the battery, do your Yamaha dealer. not smoke, or allow any sparks or open flames near the vehicle, to STORAGE AND avoid any fires or explosions.

  • Page 17: Controls

    CONTROLS FEATURES 1 Steering c Seat wheel d Front body 2 Main/Light e Headlights switch f Front tire BATTERY 3 Drive select g Front bumper switch h DC charger 4 Battery gauge receptacle 5 USB ports i Amber flasher Y-2941 6 Accelerator light pedal...
  • Page 18 CONTROLS MAIN SWITCH The main switch controls the following items: BATTERY “OFF” Y-2838 All electrical circuits are switched off (motor controller unit remains energized). The golf car cannot be operated. The key can be removed only in this position. “ON” Electrical circuits are switched on.
  • Page 19 CONTROLS As the battery energy decreases, the LEDs will move to the left toward the “E.” When the LED light below the “E” BATTERY is the only one lit, the batteries must be charged. Y-2842 Use the table to determine the remaining battery capacity.
  • Page 20 CONTROLS ACCELERATOR PEDAL The accelerator pedal controls the Super Hauler’s speed. Action Car Speed Depress pedal Increase Release pedal Decrease Y-20A å Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the Super Hauler. ∫ Brake pedal Y-21a PARKING BRAKE PEDAL...
  • Page 21 CONTROLS TOW SWITCH Before operating the car, make sure the tow switch is in the “RUN” position. å Tow switch NOTICE Ensure that the “Drive Select Switch” is in the “FWD” position and then move the “TOW Switch” to “TOW” before towing. Y-1995 After moving switch from “RUN”...
  • Page 22 CONTROLS HORN SWITCH The horn is located adjacent to the brake pedal, and is activated by depressing with your foot. å Horn switch Y-901A It is advisable to sound the horn when approaching blind corners.

  • Page 23: Pre-Operation Checks

    PRE-OPERATION CHECKS Pre-operation checks should be made each time you use your Super Hauler. Get in the habit of performing the following checks in the same way so that they become second nature. To keep vehicle from moving while performing pre-operation checks: •...
  • Page 24 PRE-OPERATION CHECKS BATTERY Charge batteries before each use. See charging steps in Chapter 8, Maintenance. Check that the batteries are held securely in place to prevent the batteries from being damaged from vibration or jarring. Also check that no battery caps are missing to prevent battery acid from spilling from the battery.
  • Page 25 The alarm should sound. Y-2846 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 accelerator pedal operates smoothly.
  • Page 26 PRE-OPERATION CHECKS Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its original position when released. ∫ 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 27: Operation

    OPERATION BODY AND CHASSIS Before each use, visually inspect the Super Hauler body and chassis for damaged and/or missing parts. STARTING With the parking brake applied, BATTERY turn the drive select lever to “FWD” for forward, or “REV” for reverse. Y-2847 NOTICE Do not shift from “FWD”...
  • Page 28 OPERATION STOPPING To stop the Super Hauler, gradually press down on the brake pedal. å 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...

  • Page 29: 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 30 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 31 MAINTENANCE Battery Care 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 vegetable oil.
  • Page 32 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 33 MAINTENANCE Battery Charging Read and understand the owner’s manual provided with your vehicle’s battery charger before charging batteries. Death or serious personal injury can result from failing to comply with the warning labels in this manual. Explosive hydrogen gas is produced while batteries are being charged.
  • Page 34 MAINTENANCE NOTICE Use only battery chargers that are rated for use with 48-volt Yamaha vehicles. Serious battery damage can result. Thoroughly read and understand the user manual supplied with your 48-volt charger. With the charger properly connected and grounded (see charger’s owner’s manual),...
  • Page 35 MAINTENANCE Battery Installation When working with batteries, do not put wrenches or other metal objects across the battery terminals. An arc can occur causing explosion of the battery. Install the battery hold-down plates and torque to 7-9 Nm, 0.7-0.9 m · kg (62-80 in · lb) as shown.
  • Page 36 MAINTENANCE Fuse Replacement Be sure to use the specified fuse. Using a wrong fuse can cause electrical system damage and create 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.
  • Page 37 MAINTENANCE BATTERY CHARGER Multi-Charge Steps: Ensures a consistent and repeatable charge. Prepare for Emergencies Step 1: Pre-test: Tests several Be prepared for possible injury or fire. conditions before charging begins. Keep the following items handy: If a problem is detected, charging is terminated.
  • Page 38 MAINTENANCE Installation The AC line connected to the charger The output of chargers with must be capable of supplying 12 greater than 48 volts may pose an Amperes to the charger. AVOID energy and/or shock hazard under connecting a charger and another normal use.
  • Page 39 MAINTENANCE Mounting 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 40 MAINTENANCE Grounding Charging The battery charger must be grounded 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 grounded, single-phase (3-wire) appropriate receptacle that is properly...
  • Page 41 MAINTENANCE NOTICE Do not disconnect the DC cord set Charge only 48-volt battery plug from the DC charger systems manufactured by Trojan receptacle when the charger is on. Battery Company. Damage to the If the charger must be stopped, charger and batteries may result if first disconnect the AC power this charger is used on the wrong supply cord from its AC outlet, and...
  • Page 42 MAINTENANCE OPERATING INSTRUCTIONS 1. PLUG AC CORD INTO A GROUNDED RECEPTACLE 2. PLUG DC CORD INTO DC CHARGER RECEPTACLE 3. CHARGE CYCLE WILL BEGIN AFTER A FEW SECONDS AND AMMETER WILL TURN ON 4. CHARGER SHUTS OFF AUTO- MATICALLY WHEN BATTERIES ARE CHARGED Connect charger’s AC cord set to AC power.
  • Page 43 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. Blinking: With no battery connected,...
  • Page 44 MAINTENANCE Troubleshooting 1. LED Error Codes (For Battery Condition) 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. 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.
  • Page 45 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 condition and reset charger (interrupt DC connection for 15 seconds). Battery Low Voltage Check battery size and condition and reset charger...
  • Page 46 MAINTENANCE 2. Hardware System Faults Problem Description Cause Remedy Charger does not start. No AC power to Ensure correct voltage No LEDs illuminate or charger. at AC outlet. Check AC blink when AC cord is cord connections. connected. Replace AC cord if damaged.
  • Page 47 MAINTENANCE Transaxle Oil To check transaxle oil level: Place the vehicle on a flat, level surface. Place an oil pan under the transaxle case. Clean the area around the oil level plug 1 and then remove the plug. NOTICE Do not allow foreign material to enter transaxle.
  • Page 48 Before you operate the Super Hauler, press down on the brake pedal several times to make sure the brakes are functioning properly. Consult your Yamaha dealer before using your Super Hauler if you suspect brake problems. Brake failure could result in a serious accident.
  • Page 49 MAINTENANCE Brake Pedal Free Play Adjustment Check the brake pedal free play by pressing against the pedal with two fingers (using light force) and measuring the distance the pedal travels before resistance is felt. Brake pedal free play Å: 50-55 mm (1.97-2.17 in.) Y-62b To adjust the brake pedal free play: Remove the floor mat and...
  • Page 50 MAINTENANCE Parking Brake Release Adjustment NOTICE Before performing parking brake release adjustment, adjust brake pedal free play. Apply pressure to the parking brake pedal until the brake nail catches the first latch position on the sector. Loosen the locknut and turn the bolt counterclockwise until it Y-2823 contacts the sector.
  • Page 51 MAINTENANCE Replacing a Headlight Bulb If the headlight burns out, replace it as follows: Disconnect the wire connector 1 from the headlight assembly. Remove the three screws 2 and remove the light control unit. Remove the four screws 3 to Y-2767 remove the headlight assembly from the holder.
  • Page 52 MAINTENANCE Adjusting a Headlight NOTICE It is recommended to have the headlight adjustment performed by a Yamaha dealer. The screw can be accessed from under the fender. Using a Phillips head screwdriver, turn the adjusting screw 1. Turning the screw clockwise will...

  • Page 53: Storage

    Super Hauler for PREPARATION extended periods of time. Recharge the batteries and NOTICE check the fluid levels at least Yamaha Golf-Car Company does once a month. not approve the use of high- NOTICE pressure washers to clean the products they manufacture. Doing Do not allow cleaning solution to so may damage the finish on...

  • Page 54: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS Items DR2E19 SUPER HAULER Dimensions: Overall length 3629 mm (142.9 in.) Overall width 1357 mm (53.4 in.) Overall height (steering height) 1236 mm (48.7 in.) Floor board height 335 mm (13.2 in.) Wheelbase 2492 mm (98.1 in.) Tread: Front 883 mm (34.8 in.)
  • Page 55 SPECIFICATIONS BATTERIES Items DR2E19 SUPER HAULER Battery: Trojan - Golf Car Type T-875 (6x8 volt) RC: minimum 117 min CHASSIS Items DR2E19 SUPER HAULER 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...
  • Page 56 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 57 SPECIFICATIONS BATTERY CHARGER Mechanical Drawings 278 ±3 mm 196 ±3 mm 260 ±3 mm 3 ±1 mm M4(4 mm) Grounding Stud(Ref.) 10-4...

  • Page 58: Wiring

    WIRING WIRING DIAGRAM 11-1...
  • Page 60 PRINTED IN USA 2018.12-0.3×2 CR...

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