need new 96 club car 48 volt controller

a4x4tripping

need me a controller or the upgraded kit one for 1996 club car 48 volt ds power drive....yes I know I will be paying over 500$...thank you..

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joesam

It would be good if you purchased from a Site Sponsor. What you are asking about is described as:

Club Car Regen 1 300A GE Controller. It includes a plug adapter.

There is also a 500A version available which (with 4 ga. wires) won't go faster, but it will climb hills far more promptly.

Not 100% plug and play (you do need to remove/bypass the OEM dynamic braking solenoid and coil) but effectively the easiest (DIY) replacement available.

a4x4tripping

ok thank you.. I emailed a couple...

a4x4tripping

Ok got new controller hooked up worked great...unhooked batteries to secure and put loom on harness etc..hooked batteries back up and recharged completely and have nothing ..no solenoid click anything..? Every part on this cart is new down to the low battery light ...any ideas ??

joesam

Well now it's gonna be tricky, since you now have a "cross-over" cart. Since you removed the batteries it's safe to assume there were no sparks/arcs during install...correct?

If you don't have one, I can provide a link to the Regen-1 manual (with full troubleshooting steps in Sec 21-B). Of course with the "new" controller some of the circuitry has been bypassed/modified so not all steps will yield the expected result. If your replacement controller is an FSIP product, you might try to give them a call for some troubleshooting tips, also.

Do you need that link to the full '95/'96 Regen 1 manual?

a4x4tripping

Yeah fsip 300 amp one..i didnt arx anything just unhooked batteries and tied off wires and slipped plastic loom over the ones underneath..but it did work 100 % after i installed new controller..link would be great if one available..

joesam

Double check your solenoid connections and key switch. make sure you see 48v on the small terminals on your solenoid when you turn the key. There's one wire on my main solenoid (red as I recall) that's short and easy to drop/forget. It's gotta be something pretty basic if it worked before looming (did you need to disconnect any "small wires" prior to looming?). Also check the little F&R spade connectors on the rocker switch - just give them a push/wiggle. I had a marginal connection on one that made me think the controller was cooked a couple years ago. Also plug/unplug the controller/adapter connectors to ensure they are firmly connected.

Here's the LINK

a4x4tripping

Yeah i wiggled harness solenoid came on everything worked ..turned key off and on ..now nothing again..

joesam

Look inside your plugs/connectors in case a pin got pushed back and is making marginal connection. Spray each with isopropyl alcohol or a contact cleaner and re-insert (let dry before trying). Also check your "small wire" ring connectors for corrosion at the joints. Give each one a firm pull/wiggle. You know you've got a marginal connection somewhere...so now it's a matter of finding it!

It could even be your key switch - try a small jumper to eliminate that possibility.

a4x4tripping

Well found that when i connect old pin connector to new pin adaptor the solenoid will click on occasion while wiggling it..did test old pin connection is good but adatpor had a failed voltage test..waiting on i.t from fsip to get back to me