GOLF CAR OWNER’S/ OPERATORS MANUAL G19E 12/01/00 1PC - G19E O/M LIT196260076 *LIT196260076* USA Yamaha Motor Corp., USA Cypress, California made in YAMAHA MOTOR MANUFACTURING CORP. OF AMERICA LIT-19626-00-76 Printed in U.S.A.
G19e O_M 9/19/00 3:40 PM Page 1 INTRODUCTION Congratulations on your purchase of a Yamaha golf car. This manual contains information you will need for proper operation, maintenance, and care of your golf car. A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha. If you have any questions about the operation or maintenance of your golf car, please consult a Yamaha dealer.
G19e O_M 9/19/00 3:40 PM Page 2 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations: ! The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the golf car occupants, a bystander, or a person inspecting or repairing the golf car.
G19e O_M 9/19/00 3:40 PM Page 3 CONTENTS WARRANTY 1 IMPORTANT LABELS 2 OPERATOR SAFETY 3 MAINTENANCE SAFETY PROGRAM 4 CONTROLS 5 PRE-OPERATION CHECKS 6 OPERATION 7 MAINTENANCE 8 1 STORAGE 9 SPECIFICATIONS 10 WIRING 11 iii G19E 95%
G19e O_M 9/19/00 3:40 PM Page 4 WARRANTY YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA G19E LIMITED WARRANTY 1 2 3 4 5 6 Yamaha Motor Manufacturing Corporation of America hereby warrants that any new G19E Yamaha Golf Car purchased from an authorized Yamaha dealer in the United States, will be free from defects in material and workmanship for the period of time stated herein, subject to the stated limitations.
G19e O_M 9/19/00 3:40 PM Page 5 IMPORTANT LABELS SAFETY AND INSTRUCTION LABELS 1 3 4 2 1 2 WARNING Y-654 5 1 Please read the following labels carefully before operating your golf car, and promptly replace any labels which become damaged or removed.
G19e O_M 9/19/00 3:40 PM Page 6 IMPORTANT LABELS GOLF CAR SERIAL NUMBER 1 JR1 The golf car serial number is stamped in the location shown. 2 3 Y-102b 4 NOTE: 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 dealer.
G19e O_M 9/19/00 3:40 PM Page 7 ! OPERATOR SAFETY Yamaha golf cars are designed to be simple to operate. However, be sure to observe the following: 1 2 BEFORE OPERATING THE GOLF CAR ● Read this Owner’s/Operator’s manual and all safety and instruction labels on the golf car before operating. ● Perform the pre-operation checks found in Section 6 of this manual. ● Only authorized people should drive the golf car, from the driver’s side only, and only in designated areas.
G19e O_M 9/19/00 3:40 PM Page 8 ! OPERATOR SAFETY 1 2 3 ● 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. ● Vary the speed of the golf car to match the terrain of the course. ● Avoid turning the steering wheel too sharply at higher speeds. ● Always drive slowly straight up or straight down slopes – never at an angle.
G19e O_M 9/19/00 3:40 PM Page 9 ! MAINTENANCE SAFETY PROGRAM Like all machines, golf cars can cause injury if improperly used or maintained. This section contains broad safety practices required for safe golf car operation. Before golf cars are operated, golf course personnel should establish any additional safety practices that may be required for safe operation. Experience has shown that golf cars are safe when operated in accordance with the safety warnings affixed to every golf car.
G19e O_M 9/19/00 3:40 PM Page 10 ! MAINTENANCE SAFETY PROGRAM 1 ● Loose Terrain. Loose terrain may cause a golf car to lose traction and may affect stability. Repair loose terrain, chain or rope off these areas, or identify loose terrain with a suitable warning. ● Golf Car and Pedestrian Interference. Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent accidents.
G19e O_M 9/19/00 3:40 PM Page 11 ! MAINTENANCE SAFETY PROGRAM SAFETY PRECAUTIONS DURING MAINTENANCE When performing maintenance, follow all safety instructions contained in the manufacturer’s operation and service manuals, as well as the following safety procedures: ● Properly immobilize golf car before beginning any maintenance. ● Properly block chassis before working underneath golf car. ● Avoid fire hazards, and have appropriate fire protection equipment available.
G19e O_M 9/19/00 3:40 PM Page 12 CONTROLS FEATURES 1 2 3 16 3 Y-658 1 4 8 7 6 5 5 4 Y-659 6 7 1 Steering wheel 2 Seat 3 Batteries 4 Brake pedal 5 Parking brake pedal 6 Accelerator pedal 7 Main switch 8 Drive selector switch 9 Tow switch a Front cowl b Front tire c Front bumper d Rear cowl e Rear bumper f Rear tire g Receptacle 2 10 8 11 13 9 14 10 12 15 Y-661 Y-660 11 9 Y-662 5-1 G19E
G19e O_M 9/19/00 3:40 PM Page 13 CONTROLS MAIN SWITCH 1 The main switch controls the following items: OFF Ignition circuit is switched off. The key can be removed only in this position. OFF 3 N O REV 2 FWD 4 5 Y-663 ON Electrical circuits are switched on. The golf car can be driven.
G19e O_M 9/19/00 3:40 PM Page 14 CONTROLS DRIVE SELECT SWITCH 1 The drive select switch is used to shift the golf car into forward or reverse. After coming to a complete stop, move the switch to the desired position. OFF REV FWD N O 2 3 Y-665 Switch Position Car Movement FWD FORWARD REV REVERSE 4 NOTE: The back-up buzzer will beep when the drive select switch is depressed to the “REV” position. 5 6 Y-19 7 ACCELERATOR PEDAL A The accelerator pedal controls the golf car’s speed.
G19e O_M 9/19/00 3:40 PM Page 15 CONTROLS PARKING BRAKE PEDAL A 1 Press down on the parking brake pedal whenever parking the golf car. 2 å Parking brake pedal Y-22 NOTE: Release the parking brake by depressing the accelerator pedal. 3 4 TOW SWITCH A TOW RUN Before operating the car, make sure the tow switch is in the “RUN” position.
G19e O_M 9/19/00 3:40 PM Page 16 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. 1 2 WARNING 3 ● 4 Be sure the main switch key is removed before performing the pre-operation checks to prevent accidental starting, and apply the parking brake to keep the car from moving.
G19e O_M 9/19/00 3:40 PM Page 17 PRE-OPERATION CHECKS BATTERY 1 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. Check the battery terminals for corrosion.
G19e O_M 9/19/00 3:40 PM Page 18 PRE-OPERATION CHECKS STEERING SYSTEM 1 Check the steering system for excessive freeplay by: 2 3 4 Y-667 5 ● moving the steering wheel up and down, and back and forth. ● turning the steering wheel slightly to the right and left. If you feel excessive freeplay, or hear rattling sounds which may indicate loose steering components, consult a Yamaha dealer. BACK-UP BUZZER 6 Check the back up buzzer by moving the drive select switch to “REV” for reverse.
G19e O_M 9/19/00 3:40 PM Page 19 PRE-OPERATION CHECKS Parking Brake Pedal 1 Make sure the parking brake pedal locks in place with a positive click, and releases when the accelerator pedal is pressed. A 2 å Parking brake pedal Y-22 NOTE: Release the parking brake by depressing the accelerator pedal. 3 4 Accelerator Pedal 5 WARNING Before checking operation of the accelerator pedal, be sure the main switch is in the “OFF” position. Make sure the accelerator pedal operates smoothly.
G19e O_M 9/19/00 3:40 PM Page 20 OPERATION STARTING 1 1. With the parking brake applied, turn the drive select switch to “FWD” for forward, or “REV” for reverse. OFF REV N O 2 FWD CAUTION 3 Y-665 Do not shift from “FWD” forward to “REV” reverse while the golf car is moving. 4 2. Turn the main switch to “ON.” 5 WARNING OFF Do not depress the accelerator pedal when turning on the main switch or the golf car may suddenly start moving. N FWD O REV 6 7 Y-664 8 3.
G19e O_M 9/19/00 3:40 PM Page 21 OPERATION STOPPING 1 To stop the golf car, gradually press down on the brake pedal. B å Brake pedal 2 When the car has come to a stop, apply the parking brake pedal and turn the main switch to “OFF.” 3 ∫ Parking brake pedal 4 CAUTION A Y-65 Do not hold the golf car on an incline with the accelerator – use the brake.
G19e O_M 9/19/00 3:40 PM Page 22 MAINTENANCE 1 PERIODIC MAINTENANCE CHARTS Regular maintenance is required for the best performance and safe operation of your golf car. WARNING 2 Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless otherwise specified. If the owner is not familiar with machine servicing, this work should be done by a Yamaha dealer or other qualified mechanic.
G19e O_M 9/19/00 3:40 PM Page 23 MAINTENANCE FOR 19E C - CHECK CA - CHECK AND ADJUST R - REPLACE EVERY MONTH 125 rounds 125 hrs 600 mls 1000 kms (Every 6 months) Charge S S S S Clean battery tops, check for tightness of hold-down screws and terminals S S S Check brake pedal freeplay and adjust if necessary C CA Check steering operation C Check tire pressure, tread depth, tire surface for damage 1000 rounds 1000 hrs 5000 mls 8000 kms (Every 4 years) Page S S 8-5 S S S 8-3/ 6-2
G19e O_M 9/19/00 3:40 PM Page 24 MAINTENANCE Battery Care 1 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 vegetable oil. Call physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases.
G19e O_M 9/19/00 3:40 PM Page 25 MAINTENANCE D ● Before charging: only add distilled water if fluid is below the top of the plates, and then add just enough to cover plates. ● After charging: check that the fluid level is approximately 1/4 to 1/2 inch above the plates and 1/4 to 3/8 inch below the level indicator. If the fluid level is low, carefully add distilled water. Adding distilled water after charging prevents boil over.
G19e O_M 9/19/00 3:40 PM Page 26 MAINTENANCE Battery Charging 1 WARNING Read and understand the owner’s manual provided with your golf car’s battery charger before charging batteries. 2 3 WARNING Explosive hydrogen gas is produced while batteries are being charged. Only charge batteries in well ventilated areas (a minimum of 5 air changes per hour is recommended). 4 5 To charge the batteries in your golf car, follow the instructions contained in your battery charger’s owner’s manual.
G19e O_M 9/19/00 3:40 PM Page 27 MAINTENANCE 1 WARNING Do not disconnect the DC output cord from the battery receptacle when the charger is on or an arc could occur that may cause an explosion. 3. The charger will turn off automatically when the batteries reach full charge. 4. After the charger has turned off, disconnect the DC output plug from the golf car receptacle by grasping the plug body and pulling the plug straight out of the receptacle.
G19e O_M 9/19/00 3:40 PM Page 28 MAINTENANCE 1 C 2. Connect the wire leads as shown. A B å Forward ∫ To relay ç To controller and receptacle ∂ Between batteries D 2 D Y-672 3 WARNING 4 When installing batteries: ● Carefully place battery cables and holddowns making sure that cables don’t lie across vent caps. ● Always remove the negative (–) cable to the motor controller first, and install it last. 5 6 CAUTION Do not overtighten the battery holddown nuts.
G19e O_M 9/19/00 3:41 PM Page 29 MAINTENANCE Gear Box Oil 1 To check gear box oil level: 1. Place the golf car on a level surface. Y-48 2. Remove the access panel by removing the screws in the two lower corners of the panel and pulling the panel from the car. 3. Remove the oil level plug (A). 2 3 4 4. Add gear oil little by little until oil flows from the level plug hole (B). 5 Recommended oil: SAE 90 gear oil A B Y-520 6 Gearcase capacity: 0.32 US qt (0.3 L, 0.06 Imp gal) 7 5.
G19e O_M 9/19/00 3:41 PM Page 30 MAINTENANCE Wheel Replacement 1 To remove and install a wheel on your golf car: 2 1. With the wheels blocked to prevent the golf car from moving, loosen the wheel nuts. 3 2. Elevate the golf car with a jack and remove the wheel nuts and the wheel. 4 Y-57 3. Reverse the removal steps when installing the wheel. 5 Wheel nut tightening torque: 58 ft.lb (80 Nm, 8.0 m.kg) 6 Brake Adjustment The brakes on your golf car are selfadjusting.
G19e O_M 9/19/00 3:41 PM Page 31 MAINTENANCE Brake Pedal Free Play Adjustment CAUTION 1 2 Before adjusting brake pedal free play, pump the brake pedal several times to self-adjust the brakes. 3 To adjust the brake pedal free play: 1. Remove the service lid from the floor of the golf car. 4 5 Y-61 6 -30 2. 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.
G19e O_M 9/19/00 3:41 PM Page 32 STORAGE 1 2 3 4 5 Perform the following preparations when storing your golf car for extended periods of time: BATTERY PREPARATION NOTE: Turn main switch key to “OFF” position, remove key, and store key in a safe place. Move the tow switch into the “TOW” position. 1. Recharge the batteries and check the fluid levels at least once a month. CAUTION Do not allow cleaning solution to enter battery cells. CHASSIS PREPARATION 1.
G19e O_M 9/19/00 3:41 PM Page 33 SPECIFICATIONS GENERAL SPECIFICATIONS Items 1 G19E Dimensions: Overall length Overall width Overall height (steering height) Height of floor Wheelbase Tread: Front Rear 2 93.9 in. (2385 mm) 47.2 in. (1200 mm) 46.9 in. (1190 mm) 11.8 in. (300 mm) 64.1 in. (1629 mm) 3 34.3 in. (870 mm) 38.6 in. (980 mm) Min. ground clearance 4 3.8 in.
G19e O_M 9/19/00 3:41 PM Page 34 SPECIFICATIONS 1 2 3 CHASSIS Items Steering system: Type Steering angle (L.H.) Steering angle (R.H.) Worm and pin 1.5 turn 1.5 turn Lubricant/capacity Grease/3.0 US oz (0.09 L, 3.17 Imp oz) Brakes: Brake system 4 Type of brake 5 Brake pedal freeplay linkage adjustment (Brake cable end play) 6 Parking brake: Type G19E Mechanical drum brake on each rear wheel with self-adjusters. Dual internal expanding shoe. Leading/trailing shoes (self-adjusting) 25-30 mm 0.
10 + G19E 95% – – 12 Y R/B R/B R 9 R R/W R/B R/Y RY RW 5K R/Y + B 8 L O B R/Y L O B R/Y B O L 3 L O B R/W R/W Br R/W 11 9 8 7 P P P B B B 1 CONTROL BOARD ASSY 1 2 3 6 10 4 5 Br R/W Br R/W Br OFF ON 23 4 15 14 16 R G + 7 (N) 6 A2 3/4 REC MOSFET BOARD ASSY A1 (P) (A1) B F1 T A C H F2 Y R/Y W W R/Y Y R/Y W Y 1 Y REV FWD 3 2 W R/Y W R/Y Y (F1) (F2) Y-671 COLOR CODE B.....................Black L.......................Blue G...............
GOLF CAR OWNER’S/ OPERATORS MANUAL G19E 12/01/00 1PC - G19E O/M LIT196260076 *LIT196260076* USA Yamaha Motor Corp., USA Cypress, California made in YAMAHA MOTOR MANUFACTURING CORP. OF AMERICA LIT-19626-00-76 Printed in U.S.A.
