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Unread 08-08-2015, 10:29 PM   #1
Not Yet Wild
 
Join Date: Aug 2015
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Default Calling all Regen 1 experts

I have a 96 Club Car with the Powerdrive Plus Regen system and it has died. It started as an intermittent problem and now doesn't run at all. I turn on the key and can hear the solenoid click. It clicks again when the accelerator is pressed but not much happens. The motor makes a humming/whining sound and I can feel it trying to do something with my hand but thats about it. In another post this afternoon someone walked me through testing the solenoid and the motor, both of which appear to be ok. About all that is left is the controller. I am open to most anything at this point, fire away. Thanks. Terry
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Unread 08-09-2015, 09:37 AM   #2
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Default Re: Calling all Regen 1 experts

If you turn the key, do you still hear a click - and without touching anything hear another click about 10 - 30 seconds later? If so - your controller is powering up and the OBC lockout is not the problem. Also does your reverse buzzer still sound with the rocker switch in "R" (key off or on....doesn't matter)?

Please provide a full description of:
Quote:
It started as an intermittent problem and now doesn't run at all.
Your detailed answer to this question might point in an obvious direction. Controller problems don't typically come & go with this model - it either works...or doesn't.

In your first post you said you did the OBC bypass - but you only bypassed the charging function - not the OBC lockout function. There is more to do if the OBC lockout is preventing the cart from moving. Take the time to download and save the manual (its in thread link at bottom). Starting in section 21A of the manual is a complete troubleshooting sequence which will absolutely determine what is failing. You will need a good Digital Voltmeter.

BUT - Here is a maintenance step you should perform - no matter what:

Disconnect the main battery negative post and secure it to one side. The connectors on Regen 1 are "less industrial" than in later years. Buy a bottle of isopropyl alcohol at the drug store and put it in a small spray bottle. Squirt alcohol into the female/socket connectors and plug them in and out a few times. Then assemble them wet. The alcohol will evaporate within an hour or so leaving clean metal to metal connections. Do this with all small connectors (eg. spade connectors on rocker switch; plugs between accelerator & controller etc) basically ensure all small wire connectors are clean & making good contact.

Then get to work on the BIG cables (between batteries and leading down to the motor) Make sure all big cable connectors are clean and tight.

Reconnect the battery pack about an hour after all the connectors & wires have been "serviced". This process has helped more than a few Regen 1 owners solve what they thought were more serious problems.

Also - here's a link to a recent Regen 1 owner's troubleshooting issues plus a link the the manual for that cart
Regen Thread
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Unread 08-09-2015, 12:31 PM   #3
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Default Re: Calling all Regen 1 experts

Yes it clicks when the key is turned on and again about two seconds later if nothing is done. From what I read this is how it is supposed to work. As far as the intermittent thing it happened to me once. My daughter claimed it happened to her a few times also although I cannot confirm or deny this. She said that simply by rocking it with the accelerator pushed the cart would take off and go. Not the case when it happened to me. When I started farting with it a couple weeks ago it would work intermittently on the jack stands, now it will do nothing. Going to start the trouble chart now...hopefully it gets me somewhere.
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Unread 08-09-2015, 08:03 PM   #4
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Default Re: Calling all Regen 1 experts

That does sound more like an intermittent connection (wires & connectors) rather than controller. Suspect items are socket connector & wires to controller, failing rocker switch or a failing potentiometer (accelerator pedal). You didn't say whether reverse buzzer still works properly.
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Unread 08-09-2015, 09:43 PM   #5
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Default Re: Calling all Regen 1 experts

Yes the reverse buzzer works. I went through the troubleshooting chart and it led me straight to the controller. Kind of had to assume the potentiometer was good as I didn't have the special tool to hook up to it. Took the controller off this afternoon and something rattles around inside it, kind of doubt that is supposed to be the case. I guess I am going with the potentiometer is good because the motor makes noise when the accelerator pedal is pushed, as if it is trying to do something but I had no real measurable voltage to the motor from the controller.
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Unread 08-10-2015, 12:50 AM   #6
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Default Re: Calling all Regen 1 experts

If you followed the tests (plus it rattles) looks like it is the controller. There are Regen-1 replacement controllers available assuming your plan is to restore standard operation. They have an adaptor cable compatible with your original wire harness. If you planned a speed upgrade, the task list is quite a bit more complex and costly.
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Unread 08-10-2015, 08:11 AM   #7
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Default Re: Calling all Regen 1 experts

She said that simply by rocking it with the accelerator pushed the cart would take off and go.

That sounds like motor brushes or commutator. Broken spring maybe ??

Test Procedure 2 - Armature Circuit Open
1. Place Tow/Run switch in the TOW position and disconnect the batteries (Figure 15-1, Page 15-2).
2. Using two wrenches to prevent post from turning, disconnect wires from the A1 and A2 terminals on the
motor. Using a multimeter set to 200 ohms (), place the red (+) probe on the A1 terminal and black (–) probe
on the A2 terminal (Figure 15-1, Page 15-2). The multimeter should indicate continuity. If the reading is
incorrect, a possible open or poor contact in a brush assembly and/or open armature windings may be the
cause. .


since it's disconnected , I would check the armature A1 to A2 ohms while turning the wheel , rear end raised on stands.
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Unread 08-10-2015, 11:55 AM   #8
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Default Re: Calling all Regen 1 experts

It does sound strange for a controller to "fail-slowly", but I guess its possible? In this PRIOR POST - he apparently performed a motor test.

The only thing that sounds a bit weird is that his solenoid clicks on - then off with the key in two seconds. THAT'S FAST - s/b more like 10 seconds (or even longer) in my experience.
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Unread 08-10-2015, 12:26 PM   #9
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Default Re: Calling all Regen 1 experts

Quote:
Originally Posted by joesam View Post
It does sound strange for a controller to "fail-slowly", but I guess its possible? In this PRIOR POST - he apparently performed a motor test.

The only thing that sounds a bit weird is that his solenoid clicks on - then off with the key in two seconds. THAT'S FAST - s/b more like 10 seconds (or even longer) in my experience.

When the key switch is turned to the ON position, the solenoid is activated and there should be an audible
click. If the accelerator pedal is not depressed within 2 seconds (20 seconds on some early models) to activate
the controller, the controller will shut off the main solenoid. The controller disables the solenoid by turning
off the transistor at the Z4 position.
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Unread 08-10-2015, 12:47 PM   #10
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Default Re: Calling all Regen 1 experts

Hmmmm - 2 seconds...who knew? Back in the day there were 3 privately owned Regen-1's among my golf buddies. Not surprisingly, they've been sold or traded (except mine). Must all have been early ones!
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