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Old 09-26-2017, 11:59 AM   #1
Pbennison
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Default Powerdrive Plus Controller Diagnosis

Hi Everyone,

Club Car DS - SN A0005-866770
Controller - GE Catalog # IC3645SH4D27202
Serial # SH4D0121447P
48V-270AMP


Have never posted before but have done a lot of researching on the site. My family has a 2000 Club Car DS with a PowerDrive Plus 48 controller. The machine is about an hour away from me and I plan to get it and bring it home to work on over the winter soon.

Here is some background.

Worked one day then not the next, worked again for a day then not. Looked around for loose connections/ground and don't see any obvious issues. This is not used for anything other than up and down a paved road. I can hear the solenoid click, but no power to the drive unit. I had the charging unit checked and checked the batteries and fuse which are all OK.

I have found a troubleshooting manual (1998/1999 PowerDrive System 48 Vehicle Maintenance and Service Supplement) for a similar machine. I am having trouble following the test procedures because the controller is different. I have searched internet and this forum and have found some close but nothing that I can use to determine if in fact this is a controller. Given that a replacement is around $600 I am hesitant to just take a guess. So, I guess I have a few questions for someone that may have been down this road before.

1) Is there a definitive way to determine if the controller is bad?
2) Is there anything I can do to try and fix it?
3) Is there a way to bypass this controller? I did see a very lengthy post by Dr. Bob from 2009. However, I did not really get the gist of whether or not it is possible/practical to bypass. I also saw the post (Bypassing Club Car IQ/Excel OBC) but again I could not really get a feel for whether or not this will work in my case.

I have done just about anything with a car, transmission, starter, brakes, etc. so I am confident I can do it, if I have a well documented procedure. I just have not been able to find that. If I cannot I guess I will just have to pony up the $800-$1000 it would cost to have it done. I had someone at a local shop do a diagnosis on it and they said it was the Power Drive System Controller. I would not have it done until spring and figured I could try to do this on my own over the winter.

Any advice/wisdom would be very much appreciated.....Pat
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Old 09-26-2017, 01:24 PM   #2
NoleFan4Ever
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Default Re: Powerdrive Plus Controller Diagnosis

Get out your DVM and start testing. Check the pack voltage at the solenoid, then see if the solenoid closes in and comes up to full pack voltage after you press the Go Pedal. If not, start back tracking as you could have lost the 48v (-) at the solenoid or the (+). In either case, I would start there and report back what you find.

In regards to the controller, there is probably nothing you can do as a DIY to repair it if it has failed. And an XCT-48300 is only $415 from site sponsor if needed.
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Old 09-26-2017, 06:38 PM   #3
Pbennison
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Default Re: Powerdrive Plus Controller Diagnosis

Thank you. I will report back once I get the cart.
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Old 09-27-2017, 08:59 AM   #4
twilliams81
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Default Re: Powerdrive Plus Controller Diagnosis

FYI also that year DS (99-01 1/2 I believe) was a transition period for Club Car (from what I've heard) and there were about 3 or 4 different systems they had in those carts and some had ALOT of issues. I have an 01 that I've replaced just about everything on and still I can't get it to do anything; which sucks because it's a great looking cart and right now it's a heap just sitting mocking me! lol I hope you figure it out but I would consider going the Alltrax controller route with all the compatible components (which is what I'm considering doing with mine) and maybe even replace that main harness as well due to the all the sonic weld issues I've heard they have. Good luck!
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Old 09-28-2017, 02:22 PM   #5
Pbennison
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Default Re: Powerdrive Plus Controller Diagnosis

Thanks for the replies. I am hoping to get it down here next week to start working on it. Is the Alltrax XCT-48300 a direct replacement or do I have to buy adapters, etc.?
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Old 09-28-2017, 02:32 PM   #6
NoleFan4Ever
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Default Re: Powerdrive Plus Controller Diagnosis

It is a replacement for it. Yours is 4th one down. Check with Revolution Golf Cars and Carts Unlimited from Site Sponsors link above for best cost and service.

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Old 09-28-2017, 02:35 PM   #7
Sergio
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Default Re: Powerdrive Plus Controller Diagnosis

If this is the PD+ (aka: Regen 2), Alltrax never made a XCT production Controller for it, it was only available on the old DCX model.
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Old 11-07-2017, 02:25 PM   #8
Pbennison
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Default Re: Powerdrive Plus Controller Diagnosis

I finally got the golf cart home. I hooked up positive to the large post that has the positive cable from the battery (plus one small wire). I get 48V at each of the posts on the solenoid. Does not matter if key is in off or on position.
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Old 11-07-2017, 04:35 PM   #9
Pbennison
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Default Re: Powerdrive Plus Controller Diagnosis

I took the solenoid out and bench tested and it works fine. Now I am confused.
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Old 11-07-2017, 07:03 PM   #10
Tom47
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Default Re: Powerdrive Plus Controller Diagnosis

Quote:
Originally Posted by Sergio View Post
If this is the PD+ (aka: Regen 2), Alltrax never made a XCT production Controller for it, it was only available on the old DCX model.
Yes, I found this out the hard way and had to go the IQ harness conversion route.

As a master electrician and HVAC tech, I still had a tough time of it. The harness is nowhere near a direct replacement on the Regen 2 models. It needs a lot of rewiring to work properly. Hardly any of the wire colors are correct. There is no connection for the R/T switch and one had to be improvised.

If you have to do this, start at the controller IQ plug and work your way along to each component. Be aware of all the internal slices which can throw you off. I removed all of the loom on the wiring to be able to see where I was going.

When I finally finished 2 days later, I realized I could have kept the original Regen 2 harness and simply replace the controller plug with an IQ plug to fit the XCT controller.
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