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Old 05-13-2017, 08:06 AM   #1
a4x4tripping
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Default 96 regen 1 controller and potentometer question

What is reading for potentometer? And how to check controller.I've replaced everything but those two .
Meter seems to be ok it it reads 5.8 at full pedal
Is there a way to check controller or bypass for a quick test as i already have atleast a grand into this cart and dont want to dump another few hundred until im sure .i am only getting one click when key turned on...thanks
1996 club car power drive plus
# a9635 i belive.
48 volt motor.
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Old 05-13-2017, 08:10 AM   #2
scottyb
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Default Re: 96 regen 1 controller and potentometer question

Correct me if I'm wrong but a cart with a 1996 serial # should have a 5k-0 pot, seems you have a more common 0-5k installed. Maybe somebody changed it. If yes your reading would be 0-5k and you need either a 5k-0 pot or a 0-5k controller so these two can communicate.
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Old 05-13-2017, 11:28 AM   #3
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Default Re: 96 regen 1 controller and potentometer question

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Originally Posted by scottyb View Post
Correct me if I'm wrong but a cart with a 1996 serial # should have a 5k-0 pot, seems you have a more common 0-5k installed. Maybe somebody changed it. If yes your reading would be 0-5k and you need either a 5k-0 pot or a 0-5k controller so these two can communicate.
Yeah I'll have to double check monday..im certian i had a low reading then as i pushed pedal it went to 5.8 ..i belive i tested on the purple and yellow wires..
The micro switch has been replaced...
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Old 05-13-2017, 11:46 AM   #4
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Default Re: 96 regen 1 controller and potentometer question

If that's the case - get all the numbers off the controller and identify if it is compatible with the pot you have.
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Old 05-13-2017, 01:07 PM   #5
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Default Re: 96 regen 1 controller and potentometer question

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Originally Posted by scottyb View Post
If that's the case - get all the numbers off the controller and identify if it is compatible with the pot you have.
Well i am pretty certian they are original...and those are the only things i have not replaced..i replaced obc because wasnt charging..now it charges.
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Old 05-14-2017, 12:41 PM   #6
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Default Re: 96 regen 1 controller and potentometer question

If you had to replace the OBC it sounds like the batteries could have been hooked up wrong at some point and could have blown the controller as well.

Check all the connections at the solenoid, controller, and motor first.
Get the service manual for your year cart and test the controller. Also disconnect the motor and look up how to jump it with a 12v battery to see if the motor works. I had one a while back that the brushes in the motor were toast. Tested the motor in the cart and it wouldn't spin so took it out and pulled the end off with the brushes and they were worn down to nubs.
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Old 05-15-2017, 02:19 PM   #7
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Default Re: 96 regen 1 controller and potentometer question

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Originally Posted by Fairtax4me View Post
If you had to replace the OBC it sounds like the batteries could have been hooked up wrong at some point and could have blown the controller as well.

Check all the connections at the solenoid, controller, and motor first.
Get the service manual for your year cart and test the controller. Also disconnect the motor and look up how to jump it with a 12v battery to see if the motor works. I had one a while back that the brushes in the motor were toast. Tested the motor in the cart and it wouldn't spin so took it out and pulled the end off with the brushes and they were worn down to nubs.
Wasn't charging so replaced obc and now charges..(bypassed obc to check ) ..solenoid are new plus replaced all bad wires with proper guage ones...
Cleaned all connections and plugs with electric alcohol type cleaner...still only one click when key turned on....I'll check controller and brushes..
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Old 05-17-2017, 07:48 AM   #8
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Default Re: 96 regen 1 controller and potentometer question

I get a 1.1 on pot and when pedal fully pressed it hits 5.7 ....is that normal ?
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Old 05-17-2017, 09:02 AM   #9
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Default Re: 96 regen 1 controller and potentometer question

Quote:
Originally Posted by a4x4tripping View Post
I get a 1.1 on pot and when pedal fully pressed it hits 5.7 ....is that normal ?
That can be normal. Higher than I like a but typical CC reading for 0-5k
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Old 05-17-2017, 09:32 AM   #10
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Default Re: 96 regen 1 controller and potentometer question

The Regen 1 has a Continuously Variable potentiometer, so it is neither 0-5kΩ nor 5k-0Ω.

If You measure from purple to yellow, it will be 0-5kΩ

If you measure from white/black to yellow, it will be 5k-0Ω

If you measure from white/black to purple, it will be a fixed 5kΩ

Make sure You get all of the above resistance readings.

Here is the wiring diagram:
http://www.buggiesgonewild.com/attac...s_-regen1-.jpg
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