ATG (MarAp11) - Solenoid Testing (Part 2)

QUESTION:
T Z from Colorado asked:
I still do not understand solenoid testing? I put 3 on and it still will not run

dcs-solenoid-wiringANSWER:
Continuing on, a solenoid (contactor, relay, whatever you choose to call it) does one thing and one thing only: It opens and closes a circuit by electrical activation. They are either a single pole double throw or single pole single throw in the golf car market. How the solenoid is activated is the key to troubleshooting. Again, that activation is only related to the small terminals. As I was saying in part one, some systems receive activation potentials from the controller. It is imperative you have the correct wiring diagram for the system you are testing. A simple example I can use is an E-Z-GO Direct Drive Control system (DCS). When you look at the wiring diagram for this system you can plainly see where the positive potential comes from. This is a very simplistic system and notice you have four colors of wire connected to the solenoid (YEL/WHT, RED, BLUE and YEL). Yellow/White, Yellow, and Red are connected together on one terminal and the Blue wire is connected to the opposite terminal. Notice the three Y, Y/W, and R are a positive potential. Positive is delivered from the ignition interlock switch to run/tow switch, directional switch, key switch, solenoid, accelerator switch and pin 6 on the controller. With R/T, F/R, K, in the closed position you should read battery positive on the solenoid. Before closing the accelerator switch (foot switch) you will read battery positive voltage on both terminals. If you do not the coil is open (replace the solenoid). If you do not read positive voltage on either terminal you have an open on the positive circuit we just talked about. You must go back to the start of that positive circuit and confirm positive voltage from the first connection point which is the ignition interlock switch. Next confirm positive voltage at the R/T switch, key switch, and F/R switch. Repair or replace the appropriate part (or wire) that has the open. This testing is done by connecting a voltmeter negative test lead wire to battery number 6 negative terminal (or B- on controller). Select a 50 volt DC scale and place the voltmeter positive test lead wire to each point we just talked about. Do not forget to confirm battery positive with the F/S closed at pin 6 on controller.

At this point the only thing missing is how we get battery negative to the solenoid. Look at the wiring diagram there is a blue wire connected to the solenoid small terminal opposite of the positive terminal. This blue wire connection is the negative connection input from the controller. Notice it is from the controller! Connect a voltmeter black lead wire to the blue wire connection on the solenoid. Connect the red voltmeter lead wire to battery number one positive terminal (or solenoid main positive from battery number one to large solenoid terminal). Activate the system, meaning key on, R/T in the run position, F/R in forward and the accelerator activated. You should read full system voltage. If you do not you are not receiving battery negative from the controller. Now what you do next is confirm all input voltages to the controller at pins 1 through 10. If they are correct replace the controller.

So far this is a very simple thing to do. However, with some systems being used by different car manufacturers it is a tad more complicated. That is why it is so important to have the correct diagram for the system being used in the car. You will use the same procedure as we just used. Don’t always assume you have a defective controller, confirm voltage inputs first. The cost of freight is high so make of things before ordering replacement parts.

TS (MarApr11) - Battery Maintenance

By: Matt Vallez

This month I have been given some help from the Trojan Battery Company in the form an article that is both correct and informative, please read this carefully as there are some good tips on battery maintenance in particular.

Tips on Choosing the Right Battery and Proper Maintenance to Keep Your Golf Car Up and Running by Trojan Battery Company

Users of electric golf cars want their vehicles to be reliable. Unexpected downtime can cost both money and enjoyment. Choosing the right battery and knowing proper maintenance are two easy, yet often overlooked, ways to ensure the operation of your electric golf car. To help guarantee the biggest return on your battery investment, follow these simple guidelines from Trojan Battery Company to get the maximum performance and life from your deep cycle batteries.

Choosing the Right Battery for Golf:

First determine the appropriate voltage and connections. Usually there is no choice in battery voltage and connection, as the golf car manufacturer has designed the car to fit specific battery sizes in series. For a 36V system you will typically need six 6V batteries in series to make up the 36V. In a 48V system you will typically see six 8V or four 12V batteries in series; however some cars have been made to fit eight 6V batteries.

Next consider capacity—rated in minutes or ampere-hours (AH). It is quite simple: The longer you drive the car the more capacity you’ll need. You could use the capacity the golf car manufacturer uses as a baseline, knowing the capacity required is for two rounds of golf a day. If your daily demand is more than that you may need a higher capacity battery, and if you need less you may be able to get away with a lower capacity battery. Keep in mind that although two rounds a day may seem like more than you use, it can actually be less. When driving two rounds on the golf course you may actually only have the pedal down for 30 minutes per round; the car may be idle during much of the time spent on a round of golf. However, if you drive your golf car around your community—perhaps to the golf course and back—you may be using much more energy than it takes for a round of golf. Therefore, when choosing the right battery for golf, veer on the safe side and oversize a battery for capacity. Undersizing a battery can get you stranded, while oversizing will simply get you longer life.

Tips for Proper Maintenance:

1. Safety

• Always wear protective clothing, safety glasses, and gloves while performing battery maintenance

• Never add acid to battery

• Keep battery clean and dry

• Keep sparks, flames and cigarettes away from battery

• Keep vent caps tight except when checking electrolyte or adding water

• Charge only in well ventilated areas

• Skin contact with electrolyte should be avoided

2. Charging

• Follow charger manufacturer instructions

• Charge after each use

• Ensure electrolyte level is above the plates

• Tighten vent caps before charging

• Do not interrupt charge cycle

• Never charge a frozen battery

• Avoid charging at temperatures above 120°F (49°C)

3. Watering (flooded batteries only)

• Add water only after fully charging the battery

• The proper electrolyte level is 1/8 below the bottom of the fill well to maximum level indicator

• Never allow the electrolyte level to fall below the plates

• Use distilled water

4. Cleaning

• Tighten all vent caps before cleaning

• Clean the battery and cable lugs with a solution of baking soda and water

• Do not allow anything to get inside the battery

• Rinse with water and dry

• Thinly coat all cable connections with petroleum jelly or anti-corrosion spray

5. Torque

• Tighten all wiring connections per the manufacturer’s specifications

• Over-tightening can result in post breakage. Under-tightening can result in post meltdown or fire

• Make sure there is good contact with the terminals

6. Equalizing

• Do not equalize Gel or AGM batteries

• Equalize when low or wide ranging specific gravity (+/-.015) is detected after a full charge

• Connect battery to charger, set to equalize mode, and start the charge cycle

• Take voltage readings every hour

• Equalization is complete when voltage no longer rises

• If charger does not have an equalization setting call Trojan technical support

7. Storage

• Completely charge battery before storing

• Store batteries in a cool, dry location

• Avoid locations where freezing temperatures are expected

• Keeping batteries fully charged prevents freezing

• Avoid direct exposure to heat sources, such as radiators or heaters

• While storing, charge batteries every six weeks

Want to learn more? For live support, call 800-423-6569 or visit www.trojanbattery.com.

Industry News - March/April 2011

TOMBERLIN® ANNOUNCES 2011 MODEL YEAR E-MERGE PRODUCT LAUNCH
Augusta
, Georgia -December 10th, 2010 -In keeping with their brand promise of leading the market in Safety, Styling and Performance, Tomberlin has announced the launch of the 2011 model year for all Tomberlin E-Merge LSV’s. Featuring four new proprietary models and value-added enhancements to their current market-leading line of LSV’s, Tomberlin offers ten unique models of LSV’s, in addition to their recently introduced street-legal Vanish electric utility vehicle.

“As the market leader, our Dealers expect us to continue to drive product innovation and performance, while offering the safest low speed vehicles on the market” states Tomberlin’s Chris Plummer. “We believe we have hit the target with the launch of the 2011 models”. Leading the 2011 model year is the new Collector’s Edition Blackwood™ model. With production limited to only 100 units, the Blackwood features Tomberlin’s new TEC Entertainment Center with a complete JBL® stereo system, custom upholstered ultra-suede embroidered seats, 13-inch steel-belted radial tires with aluminum wheels, and a stunning custom-painted matte black finish with a complimenting interior – all as standard features. In addition to the new Blackwood, Tomberlin also launched their new Luxury Sport and Luxury Sport Pearl models offering stylish combinations of upgraded seating, tire and wheel packages and other value-added performance features.

Tomberlin also announced a significant enhancement to their warranty program, extending its E-Merge warranty to 4 years. And to further enhance performance and serviceability, Tomberlin has added the BFS® single-point watering system to its entire 2011 product line as a standard feature. Plummer also stated, “One thing we have learned over the last decade is we must continue to drive innovation, customer value and Dealer margins. Our Dealers have come to expect us to lead the market in value and performance without sacrificing our leading safety position. By enhancing our existing products while introducing new, feature-rich models we hope to exceed their expectations.”

To experience the new 2011 E-Merge line of Tomberlin Low Speed Vehicles go to Tomberlin.net.

To see the full line of Tomberlin® ATV’s, Schwinn™ Scooters and America’s leading electric platforms, please visit www.tomberlin.net or a local Tomberlin® dealer.

CartWeasel.com REACHES DEALER MILESTONE IN FIRST 6 MONTHS OF OPERATION
When you have a great idea, it catches on in a hurry. CartWeasel.com is no exception. Created as the Internet’s first web portal devoted exclusively to the promotion and advancement of its dealer-members, CartWeasel.com (the “Weasel”) has grown to a nationwide network of fifty golf cart dealer-members in twenty-one states in just six months.

“We knew we were on to something when, with little to no promotion, dealers from around the country started signing up to become CartWeasel.com members,” said Jennifer Carr, Director of Member Services. “CartWeasel.com has given our dealer-members the ability to sell surplus inventory and to network with other dealer-members throughout the country; creating a powerful community devoted to providing unparalleled product selection and customer service. Our goal was to have fifty dealer-members in twelve months. We are extremely proud to announce that we have reached our goal in half the time.”

CartWeasel.com is the industry’s premier pre-owned golf cart Internet search engine. With its rapidly growing dealer-member base, it provides unequalled access to a nationwide inventory of pre-owned E-Z-Go, Club Car, and Yamaha carts. CartWeasel.com dealers are able to offer their customers greater selection, faster shipment and better service than those without access to the Weasel’s impressive business and profit-building capabilities.

Dealers wanting to find out more about the advantages of becoming a CartWeasel.com member can do so by going online to www.cartweasel.com.

CURTIS INTRODUCES RAPID CONVERTIBLE SYSTEM FOR KAWASAKI TERYX
Cab provides maximum flexibility in all weather conditions

Curtis Industries, LLC has introduced a modular cab system for the Kawasaki Teryx utility vehicle that allows rapid transformation from a fully enclosed cab to an open-air ride in 60 seconds. The Curtis Rapid Convertible System (RCS) allows the user to choose one or all components for maximum flexibility as the weather changes.

A simple ROPS base frame with cab receiver mounts provides safety and easy installation of the modular components. The roof, windshield and rear panel feature a unique, easy on, no-tools, pin to slot connection and a heavy duty quick release latch. The strong but lightweight hard-coated polycarbonate windshield quickly vents for varying temperatures and is designed and tested for full speed travel with the windshield open or closed. An optional wiper kit is also available.

Cab panels are designed using advanced technology and materials. The Rapid-Convertible System uses thermoformed TPO material (not ABS plastic or fiberglass) for all body panels. TPO offers superior low-temperature impact resistance, higher heat-deflection and greater dimensional stability than ABS or fiberglass. Side doors quickly convert to half doors – no tools required – providing greater safety and protection than with an open cockpit.

Available in black, cab components – base frame, roof, windshield, doors, and rear panel – can be purchased separately or as a complete cab.

For more information on Curtis products please visit www.curtisindustries.net.

STAR EV INTRODUCES THE STAR EV SELECT
Star EV (A division of JH Global Services, Inc.) has launched their Star EV Select customized paint offering. Now dealers can order any vehicle with any color starting from only $350 extra for 2 passenger models.

Star EV uses environmentally friendly water borne paint from BASF. “Our new 104,000 sq. ft. facility contains two paint booths. “We are excited to offer this service to our dealers” stated Joe Wallington, VP of Sales and Marketing for Star EV.

Please contact Star EV for more details at www.starev.com.

TEAM INDUSTRIES, FALLBROOK TECHNOLOGIES PARTNER TO DEVELOP ELECTRIC VEHICLE TRANSMISSION PROTOTYPES
Fi
rst initiative with Tomberlin Anvil™ vehicle

TEAM Industries along with technology development company, Fallbrook Technologies (Fallbrook) announced today their partnership to develop electric vehicle transmission prototypes.

The first initiative under the agreement is for the Tomberlin Anvil™, a street-legal Neighborhood Electric Vehicle (NEV) offering a range of more than 40 miles.

“We are equally committed to improve both the performance and battery life of electric vehicles,” said Rob Smithson, Fallbrook’s Vice President of Business Development and CTO. “Our NuVinci® product line is ideal for this purpose, and designed to allow an electric car motor to operate in a more efficient manner by continuously optimizing the electric powertrain for driving conditions.”

Production of the resulting powertrain will occur at TEAM Industries’ Minnesota-based facilities. “Working with Fallbrook on this initiative makes perfect sense for us,” said Tony Passanante, Senior Director of Marketing and Strategic Planning for the company. “Our core competency is designing and manufacturing systems that transmit power and put it to work quietly and efficiently.”

Unlike conventional gear and clutch transmissions, the NuVinci continuously variable planetary transmission (CVP) uses a set of rotating and tilting balls positioned between the input and output components of the transmission that tilt to vary the speed of the transmission resulting in a seamless and continuous transition to any ratio within its range.

“TEAM Industries is committed to developing innovative products that advance electric vehicle driveline systems,” said Passanante.

“We’re continually searching for leading suppliers capable of providing technologies to make our eco-friendly automobiles more compelling and exciting than anything else like it on the market,” said Michael Tomberlin, CEO of Tomberlin. “That means offering improved hill climbing, acceleration and towing capacity as well as other rider benefits in our vehicles. Developing systems that enable electric vehicles to enhance performance is a key step towards achieving that goal, thus we are very pleased to support the Fallbrook-TEAM development initiative for that reasons.”

More information is available at www.TEAM-IND.com or www.fallbrooktech.com.

EVANS NAMED GCSAA CHIEF EXECUTIVE OFFICER
Golf Course Superintendents Association of America (GCSAA) President James R. Fitzroy, CGCS, announced today that J. Rhett Evans has been selected as the organization’s chief executive officer.

Evans, who has served as interim CEO since late June of 2010, came to GCSAA in July 2009 as chief operating officer. Prior to joining GCSAA, he was the director of the parks, recreation and commercial facilities division for the Phoenix suburb of Mesa, Ariz., (population 490,000). He was elevated to that position in 2005, after serving as that city’s convention center and amphitheatre director beginning in 2001.

“We are excited to have Rhett Evans as our CEO,” Fitzroy said. “He has a track record of success everywhere he has been. He has experience in the golf industry, both on the facility level and from an organizational perspective. He has experience in managing a large staff and being accountable to a variety of constituents. And, he is a consensus builder. That will serve him well with GCSAA members and in the increasingly collaborative golf industry.”

While in Mesa, Evans managed all program areas including the convention center and amphitheatre; spring training baseball complex (Chicago Cubs); cemetery; recreation and aquatic complexes; and 2,600 acres of park space. Also under his watch were the operations of Dobson Ranch and Riverview golf courses. He oversaw a budget of $32.5 million and a $28 million capital budget. Fitzroy indicated GCSAA will conduct a search to fill the chief operating officer position created by Evans’ promotion, although no timetable or job description has been established.

Evans earned a bachelor’s degree in sociology with an emphasis in business, and a master’s degree in recreation management and leadership with an emphasis in public administration from Brigham Young University. He is also a graduate of the Public Assembly Facility Management School. He has experience in facility and events management, working as the director of the McKay Events Center in Orem, Utah from 1997-2001, and director of operations at the Delta Center (home of the NBA’s Utah Jazz) and Franklin Quest Field in Salt Lake City for the five years prior to that.

Evans, born Sept. 29, 1968, is a native of Prescott, Ariz. He and his wife Colleen, reside in Lawrence, Kan., with their daughter Caitlyn and son Seth.

Visit GCSAA at www.gcsaa.org.

TOMBERLIN LAUNCHES THEIR NEW 2011 GOLF SPORT MODEL
Building on the momentum of their market leading E-Merge series of Low Speed Vehicles, Tomberlin Automotive Group, Inc. has announced the introduction of the Golf Sport (GS) model golf car, offering all the safety features of their LSV’s, with optional accessories which compliment the golf course and neighborhood markets.

According to Leslie Bedenbaugh, a member of Tomberlin’s Leadership Team, “safety will always be the primary influence in product creation at Tomberlin, and we will not compromise our safety standards with the new GS model golf car.  Therefore, the GS will have front and rear disc brakes, seat belts, independent front suspension and an on-board smart charger.”  In addition, the GS model golf car has two customized speed settings.  The Golf setting is at 14 mph, and the Neighborhood setting is at 19 mph.  Furthermore, the GS comes with an acrylic windshield, as well as options for a split windshield, golf bag attachment and the new Tomberlink golf kit consisting of a sand bucket, cooler and ball washer.

“A dealer will not need an automotive license to sell the GS model golf car, because it cannot be tagged due to the specialized speed settings” says Bedenbaugh.  When asked why Tomberlin was entering the golf market, she stated “ It’s simple, whether we support the decision for our E-merge models to be on the course or not, it became clear our customers were using them for golf in several areas.  Plus, we had significant dealer demand. It may be over-engineered for golf-only use, but it will definitely meet or exceed any golfer’s expectations.”

“The introduction of the GS will open Tomberlin’s retail market to new areas while expanding brand awareness and acceptance, consumer availability and business potential “ says Nat Newsome, Tomberlin’s marketing manager. “We are building tremendous momentum in the market, with many upcoming announcements regarding product, innovation and new alliances.  These are exciting times!”

Bedenbough concluded “Dealers have recognized our broad offering provides them with a significant business opportunity. Tomberlin drives showroom traffic and more fully engages a broad range of customer lifestyles.  We recognize we need our dealers more than they need us, and we feel very fortunate to have such great dealers.”

To see the full line of Tomberlin® ATV’s, Schwinn™ Scooters and America’s leading electric platforms, please visit www.tomberlin.net or a local Tomberlin® dealer.

CS (MarApr11) - Available Batteries

Pictured are a sampling of the various battery options available. For a complete list see the 2011 Battery Guide

revised-marapr11-cover

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