ATG (Nov/Dec14) - DS Not Moving

This is a multi-part question and answer.

Question: I have a 1999 Club Car DS that when I turn on the switch and put it in F or R and depress the foot pedal I can hear the solenoid click but it will not move at all. When I replaced the controller the solenoid was not clicking. Now all I get is the click but nothing is moving. I checked out the motor and it tested well but I did have another one here so I replaced it just to be sure. Still is not running. I looked at the F/R switch and it seems to be working properly. Any ideas?

Roger Asks: Series or Shunt? Meaning, does the car shift with a lever or rocker switch? I have to know that before I comment.

Roger, It has the rocker switch, and it has two solenoids. The second solenoid without the spring resistor (the driver side solenoid has the spring type Resistor) is not working at this time. I am going to swap it with a new one and see if that helps. I am not very familiar with this specific setup and I am not certain what that second solenoid (on the passenger side) does. But I do know that through all of the functions it never made contact.

Answer: That is called Regenerative Braking System 2 (Power Drive Plus) and is the second generation Shunt Wound Motor System often referred to REGEN 2. Now we can talk.

System Pin-Outs:

To test this system it is just a matter of confirming pin-out voltages. Notice the controller has a 23 pin connector and each pin has a voltage value. You will need self-penetrating wire leads as shown in the photo. The industry has moved into that style of testing and you can purchase at Grainger, Digi-Key, Mouser Electronics or any electronic supply warehouse. The right tool makes the job easier. I made a view of the 23 pin for ease of recognition and as a guide. But refer to Club Car chart for exacts, and the connector is numbered.

As with any trouble shooting procedure you must confirm the Known Factors. Later you look for Unknown Factors.

Known Factors:

Knowing what positive inputs we see at pins 1 and 2 if we do not have a positive voltage at that point we have an open in the Run/Tow wiring and or switch.

Knowing what positive input we see at pin 3 and if we do not have a positive voltage with the accelerator pedal pushed the accelerator pedal wiring or switch is open.

Positive input should be seen at pins 4 and 5 and if we do not we have loss of voltage in the forward and reverse wiring or switch.

Used on Club Car is a positive OBC input to power up the system (pin 6). It can also be used as a key switch positive input.

The Potentiometer inputs at 7, 8, and 9. Pin 7 is the wiper, pin 8 is negative (low side) pin 9 is positive (high side). The voltage value is listed in the appropriate PDP diagram. Or you can do a resistive reading on a 20K scale at pins 7 to 9. You should see 5K to 0 pedal up to pedal down.

Positive pulse at pin 14 from the speed sensor. This is typically a 5 volt pulse and is very difficult to see and difficult to test. Mainly just confirm a voltage is present.

Positive voltage at pin 15 that Club Car says in 5 volts G.E. refers to it being 12 volts. Just confirm you have a constant voltage. If that voltage is missing that means the controller is not sending that voltage.

Negative output at pin 16 to the speed sensor. If missing the controller is not working based on good inputs.

Negative output at pin 17 for solenoid activation. If missing the controller is not working, inputs missing or computer lock out is seen.

By knowing the pin-out values we can locate the problem.

The unknown factors missing voltages. As an example of missing voltage say at pin 3. That is not the controller that is the foot pedal circuit. Foot switch or associated wiring. What other wiring or switches are in that same circuit? Looking at the diagram we see a key switch and run/tow switch in that same circuit. So you have to test that circuit to confirm where voltage is missing.

Unknown would be pin 6 output/input from and to the on-board computer. That is the lockout from the computer and shuts car down when on charge. What I do on those is cut that yellow wire and then, connect a positive to it and see if the car runs. If so you have a defective computer. See the correct PDP diagram for other computer wires needed for by-pass (not just signally the yellow wire at pin 6).

So finding Unknown Factors are done after Known Factors is completed.

Yes the customer did repair the car!

TS (NovDec14) - EVs

By: Matt Vallez

There is a brand new car in my driveway. It has no gas tank or exhaust pipe, and I drive it to work on the freeway every day since I brought it home. Unfortunately, for my wallet, it was not manufactured in Augusta or Newnan Georgia. However, there will be more than just golf cars that the big three golf car manufactures will be manufacturing in the future and some already are. The car I am talking about is a Nissan Leaf, 100% electric car with no gas engine; complete with a charger that resembles an oversized laptop brick charger. Testing it on the open road, I have had it up to 95 miles per hour. It has impressive speed going from 0 to 60. While it’s not the same feeling of power from 60 to 90, never the less it is quick by any standard. By far, it is the quietest car I have ever owned, or driven before. The electric motor noise is barely detectable at takeoff or when rapidly decelerating. Most of the time you can’t hear a thing. My ultimate goal was to see if I could make something like this a viable option for my commute to and from work because I have a 40-plus mile commute each day. Even with the limits of the current electric car, only 90 miles per charge, so far so good. Being a bit of a skeptic, I have to admit, I am not “all in” on the purported benefits of electric technology so the car is a leased vehicle.

Regardless, I took the plunge and got one. This got me thinking; if I can use this type of car to travel 23 miles each day to work, one way, who else might be doing this too? My bet is a lot of people. With the price of gas where it is now my commute in a traditional-style automobile was costing me around $300 a month in gas alone. With this in mind, I set out to find an electric vehicle. During my search I discovered there are many choices of electric cars for lease, mostly on the west coast at this point, averaging between $179 and $250 a month with a $2500 down payment. Almost every manufacture now has a model available in their line that is fully electric. As an incentive to buy or lease our government is offering a $7,500 instant credit as part of any deal. Even with these enticements it is still a roll of the dice. I had a lot of questions, like; will I have to do something with the battery pack before I turn this in? How much will my monthly utility bill go up? Whether this works for me or not, only time will tell on these important aspects of the economics of this type of transportation.

The important question for most is how far this goes, as a trickle-down effect. Prior to the last few years an electric car replacing a gas-powered one was only happening in a few communities around the US, such as Sun City, AZ, Villages, FL and Peach Tree City, GA. Having large retirement populations, these areas are known for couples moving in and replacing at least one of their two gas automobiles with an electric golf car. In some cases a gas golf car is purchased, but let’s stick with the electric example so we don’t muddy the waters. Many cars purchased are just stock golf cars with an enclosure and set of lights. Other cars come from one of the big three golf car manufactures and have settings for 25 mph or 15 mph. My personal favorites are the electric fleet golf cars that have been modified to go 35 miles per hour and beyond. The point is they are cars mostly manufactured in Augusta or Newnan replacing something made in Detroit, or Japan.

Lucky for us, we now have a lot of electric options, from the Tesla model S to a stock electric golf car. I did not use a brand name here for obvious reasons… okay MELEX. Now when a consumer decides he or she wants an electric vehicle as part of their own personal fleet of cars, they can buy any number of different options, provided it will get the job done. At present, I could not make my 23-mile commute that includes highway travel in an electric E-Z-GO. However, let’s say I was a lifeguard living at the beach, and I only needed to travel a few miles per day, an E-Z-GO would be a viable option. Laws are changing fast across the country; LSV’s are popping up everywhere, in beach communities, subdivisions and other neighborhoods with low-speed areas. Places where the weather is warmer most of the year are quickly allowing LSV’s, NEV’s and the like on their streets. Recognizing trends like these, E-Z-GO has been manufacturing a hybrid golf car for a while. The Freedom RXV featuring Exceed™ Hybrid Technology is just one example of a golf car vehicle that “fills the gap” between an automobile and a golf car. This begs the question, what is next? Are the movers and shakers in Augusta and Newnan going to be able to fill in more of the gaps with road-ready vehicles that replace our gas-powered automobiles, or will companies like Nissan, Toyota and Ford be the ones doing that? If so, will the government allow us to ride around in golf cars without roll protection and air bags? What regulations might be on the horizon for the use of more convenient, cost-effective and environmentally friendly transportation on our roads? Whatever the answers are, it seems clear the future of electric-powered vehicles is brighter than ever. The only question that remains is who is going to lead us into the future of electric travel?

Industry News - November/December 2014

PRECEDENT GOLF CARS NOW POWERED BY BEST-IN-CLASS EFI ENGINE

Boost Your Fleet’s Power and Reliability. Cut Maintenance Costs and Emissions.

When shopping for gasoline-powered fleet golf cars, remember this: other vehicles have engines with electronic fuel injection (EFI), but there are big differences in these engines.

The sophisticated but easy-to-maintain EFI engine that powers the new 2015 Club Car Precedent golf car broadens that gap.

“Club Car engineers spent a year researching major engine manufacturers’ offerings before partnering with Subaru, a world leader in building small engines with EFI,” says Rusty Risher, Marketing Manager, Golf.

Using automotive technology, Subaru designed a 14-hp-rated, 404 cc single-cylinder overhead cam engine with EFI. Designed around a unique matrix of features, it outperforms the competition and ranks best-in class in virtually every category.

Unprecedented Numbers

The new engine increased horsepower by 35 percent, fuel efficiency by 35 percent and cut carbon monoxide emissions by 30 percent over previous Precedent golf car engines. It also:

• Delivers 23 percent more power than competitive EFI vehicles.

Reduces the annual cost of ownership by $160, based on fuel usage and maintenance schedules in the owners’ manuals.

Club Car is so confident in this new engine that they have extended the warranty on both the Precedent golf car’s engine and gas transaxle to a five-year limited warranty standard, one to two years longer than competitive vehicles. “This gives course owners and managers an added layer of protection and cuts the total cost of ownership even more,” Risher says.

Why EFI?

Unlike engines with carburetors and chokes that suction fuel and can be difficult to start, EFI systems atomize fuel by forcibly pumping it through a small nozzle under high pressure. So they start right up even in frigid weather, automatically adjust for altitude and deliver power on demand. EFI systems also reduce maintenance costs, last longer and lower emissions.

The Club Car Difference

“But the design of EFI engines varies considerably,” Risher says. “Ours is engineered with overhead cams that are more automotive and precise than the outdated pushrod engines in competitive vehicles.”

The Subaru engine also:

• Features a hemispherical head design that produces more torque and power than the straight valve engines in competitive products.

• Offers capacitive discharge ignition for more precise ignition timing and better starting when cold

Improves reliability with a case-hardened steel timing chain.

• Has a splash lubrication system that eliminates the need to buy, change and dispose of oil filters.

Club Car vehicles are built on the industry’s only rustproof, corrosion-resistant aluminum frame, engineered to be stronger than steel frames. Club Car, one of the most respected names in the golf industry, is the world’s largest manufacturer of small-wheel, zero-emissions electric vehicles. Visit www.clubcar.com for more information.

E-Z-GO GIVING AWAY DREAM GOLF EXPERIENCE

Diamond Golf Getaway quiz finds your ideal golf destination

To celebrate its 60th anniversary, E-Z-GO is offering a once-in-a-lifetime golf experience for one lucky winner and three friends.

The E-Z-GO Diamond Golf Getaway will take the winner, and three friends to round out his or her foursome, on an expenses-paid trip to play their choice among a selection of renowned golf courses, including Pebble Beach Golf Links, Pinehurst No. 2, Sea Island Golf Club, or a course along Alabama’s famed Robert Trent Jones Golf Trail. The prize includes a round of golf for four at the course of the winner’s choosing, plus first-class airfare and luxury accommodations for four during the trip.

To enter the contest, participants are asked to take a short, fun online quiz at www.diamondgolfgetaway.com that matches their golf skills and vacation preferences with one of the four ultimate golf experiences. People also can take the quiz via Facebook at www.facebook.com/4ezgo. Participants also can enter the contest by visiting their local E-Z-GO Authorized Dealer, or via postcard entry. Each entrant can enter the contest up to four times.

“E-Z-GO is privileged to be the brand of choice for some of the biggest ‘bucket list’ courses in golf,” said E-Z-GO President Kevin Holleran. “We’re excited to celebrate our diamond anniversary by giving someone an opportunity to experience one of golf’s most storied and renowned destinations.”

The “Diamond Golf Getaway” promotion will end Dec. 31, 2014. More details about the promotion, including official rules and a complete list of contest entry methods, can be viewed online at www.diamondgolfgetaway.com. To find your local E-Z-GO Authorized Dealer, visit www.ezgo.com/dealer_locator.

FLOW-RITE TO EXPAND FACILITY, CREATE NEW JOBS

Flow-Rite Controls was recently awarded a performance-based grant from the State of Michigan to support the expansion of its Byron Center, MI facility by 7,500 SF. The expansion will include an innovative engineering center, upgrades to the existing facility, new high-speed assembly equipment, and new injection molds.

The project will result in a capital investment of $6 million and the creation of 64 jobs.

“It is a core value we have at Flow-Rite to remain a ‘Made in the USA’ manufacture,” says Robert Burnetter, Chief Executive Officer for Flow-Rite. “We are continuously reinvesting in our facility, products and people here in West Michigan. With the help of The Right Place and this advantageous incentive program, we can reinvest quicker in our company and community.”

The Right Place, a regional non-profit economic development organization, worked with Flow-Rite to help attain the grant from the Michigan Strategic Fund under the Michigan Business Development Program.

“Flow-Rite is the definition of what advanced manufacturing looks like today in West Michigan,” said Birgit Klohs, President and CEO, The Right Place, Inc. “It is imperative that we retain and expand growing companies like Flow-Rite in our region; companies that take pride in the ‘Made in the USA’ labels on their products.” Visit www.flow-rite.com for more details.

U.S. BATTERY’S 8-VOLT DEEP CYCLE BATTERIES INCREASE GOLF CAR PERFORMANCE AND RELIABILITY

With higher initial capacity and longer service life, U.S. Battery Manufacturing’s 8-volt Deep Cycle batteries improve golf car performance and reliability. The company’s exclusive XC2™ formulation and Diamond Plate Technology® are combined to create the industry’s most efficient battery design, providing the highest initial capacity and highest rated capacity through the life of the battery. This plate technology also allows U.S. Battery’s products to reach peak capacity in fewer cycles, provide higher total energy delivery, extend service life, and be compatible with a wider range of battery chargers.

“Golf car owners and fleet managers used to have to choose between a battery that provided either higher peak power or longer service life,” says Don Wallace, U.S. Battery CMO/Executive Vice President. “We set out to build a better battery that provides our customers with both higher initial capacity and longer service life by improving the plate structure and composition. A better, longer lasting battery won’t need to be replaced as often and, when properly maintained will save our customers money in the long run.”

Available in three configurations, US8VGCE (121 amp-hrs. @20 hrs), US8VGC (170 amp-hrs.@20 hrs.), and U8VGCHC (183 amp-hrs.@20 hrs.), the batteries feature extra heavy-duty connector lugs, a tough polypropylene exterior case, and the company’s positive locking SpeedCap® venting system for easy maintenance.

U.S. Battery also manufactures 6 and 12volt deep-cycle batteries for a variety of applications. U.S. battery products are manufactured in the U.S.A. and distributed worldwide. For more information, visit www.usbattery.com.

FLOW-RITE PROMOTES TODD HART TO EXECUTIVE VICE PRESIDENT

“As our company continues to grow, it’s essential to not only continue providing the best products in the market place, but to also champion innovation and a superior customer experience,” said Robert Burnetter, Chief Executive Officer for Flow-Rite. “Todd Hart genuinely personifies this drive to improve, serve and succeed.”

As the Executive Vice President, Hart will direct all operations of Flow-Rite, lead the executive team in formulating and executing the business strategic plan, and organize each department to optimize performance. He will maintain Flow-Rite’s history of consistent growth with emphasis on sales of proprietary products, while continuously improving efficiency.

Hart was a business development consultant for Flow-Rite before being hired for the role of Sales Director in September 2012. He oversaw all Flow-Rite sales efforts, including both our battery watering and marine businesses. Hart was involved with developing new markets and industries, as well as working closely with the marketing and customer service departments on various projects. Under his leadership as Sales Director, sales have grown 20% each year.

Hart brings with him nearly two decades of experience in various industries and roles. Prior to Flow-Rite, Hart worked for B & J Rocket, where he was the General Manager for over eight years.

“We have complete confidence in Todd’s abilities,” says Burnetter, “and are looking forward to him leading our team forward.” Visit www.flow-rite.com for more details.

CLUB CAR WELCOMES THE VILLAGES GOLF CARS TO ITS DEALER NETWORK

Nation’s Largest Retail Golf Car Dealership “Joins the Club”

Club Car recently extended its dealer network when The Villages Golf Cars, the nation’s largest retail golf car dealership, became an Authorized Club Car Dealer. The dealership operates four locations with more than 30,000 square feet of retail showroom space within The Villages, a sprawling retirement community in central Florida. The Villages is home to 95,000 residents, making it the largest age-restricted community in the world. Ninety-nine percent of its residents drive golf cars for local transportation.

“We are pleased to have such a prominent dealership join our network,” says Mary A. Sicard, Club Car’s consumer marketing manager. “They share our dedication to customer service and finding innovative solutions for golf car owners.”

A Customer-driven Decision

“We approached Club Car because our customers want the very best products on the market and were requesting Club Car vehicles,” says Lori Resmondo, the dealership’s retail operations manager. “We were aware of the outstanding quality of Club Car’s electric Precedent® golf cars, and were pleased to learn that new gasoline Precedent golf cars will feature powerful Subaru EFI engines. Now, our customers can purchase those products and bring their Club Car vehicles in for service without leaving.”

The Villages

The Villages Golf Cars’ service technicians have already completed Club Car technician certification training, and all four locations carry Club Car products. Those products include Precedent golf cars and commercial/industrial utility vehicles.Club Car now has two Authorized Club Car Dealers serving The Villages and the surrounding area. Cart World Golf Cars, at 133 Hermosa St. in Lady Lake, Fla., is the area’s longest-serving Authorized Club Car Dealer and has serviced The Villages and the central Florida area for almost 30 years.

Club Car vehicles are sold through Authorized Club Car Dealers. www.clubcar.com.

CS (NovDec14) - Yamaha

YAMAHA GOLF CAR AND LEE TREVINO DRIVE THROUGH 2015

Yamaha Extends Trevino’s Brand Ambassador Role, While Featuring Him in a New Advertising Campaign Running on Golf Channel Coverage of the Ryder Cup

After an initial test drive that began last January, Yamaha Golf-Car Company and Lee Trevino have agreed to extend the former Ryder Cup Captain’s role as Yamaha’s international brand ambassador and company spokesman through 2015.

The timing of the announcement coincides with the launch of a broad-reaching new marketing campaign that features Trevino in a series of print, broadcast and web-based advertisements showcasing Yamaha’s proprietary Electronic Fuel Injection technology (EFI) in its gas-powered cars.

The Yamaha Golf Car campaign has commenced on Golf Channel and will run during its coverage of the 2014 Ryder Cup matches at Gleneagles, Scotland. Trevino is 4th on the all-time list of “Most Ryder Cup Matches Won,” tied with Jack Nicklaus at 17 wins.

The announcement of the extended partnership was made by Kevin Norcross, director of sales and marketing for Yamaha Golf-Car Company. Said Norcross, “Lee’s passion for our brand began 22 years ago with his first Yamaha golf car. Today, he embodies the commitment to golf, dependability and camaraderie on which Yamaha has built its reputation.”

As an industry first, Electronic Fuel Injection for the Yamaha gas golf cars offers many benefits over traditional carbureted fuel delivery systems, including:

• The greenest gasoline-powered golf car available, and with the industry’s smallest carbon footprint.

No choke required, meaning smoother, more responsive acceleration.

• Best gas mileage of any golf car.

Lowest cost of ownership in the industry.

Over two years ago we were excited to be the first golf car manufacturer to offer Electronic Fuel Injection to our customers” added Norcross. “We were able to draw from the technology gained in manufacturing other reliable Yamaha products such as Wave Runners, outboard motors, motorcycles and ATV’s that also have Fuel Injection. The benefits of EFI will save fleet operators thousands of dollars in fuel costs.”

In referring to the benefits of EFI in one of the YGC television commercials, Trevino cleverly coined the phrase “No Choke, No Smoke.”

For more information about Yamaha Golf-Car Company, visit online at www.yamahagolfcar.com.

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