2000 Club Car DS controller issue?

48knees · 09-01-2019, 08:20 AM

Good morning, our 2000 DS 48 volt series cart is making me crazy. All of a sudden when I pressed the throttle and nothing until about 1/2 pedal and full power. F&R. Then it was fine a few trips around the hood, then nothing, no movement, then fine. Next was at 1/2 pedal it would bump F or R .
Currently its on blocks and will turn wheels under power very intermittent and for a moment.
My mechanic ability is good my electronic ability is limited but determined lol. I'I've been reading and testing everything I can.
Batteries are 1 year old, tested with hydrometer all good. Charges fine.
Cleaned every contact point in the cart.
Dissasembled the Potentiometer, cleaned and shimmed the contact arm.Tested the unit before install and after, tests good.
Solenoid clicks and best as I can it test good.
I've jumped the OBC and no difference disconnected and jumped or connected.
The Controller is a bare aluminum Curtis. 3 bolt lugs 3 small terminals. I've tested this best as I understand but am lost.
Sorry for the long winded post but I'm ready to push it into the Bay, smash into it with my truck or put on some heavy metal and start smashing it to bits.

Fairtax4me · 09-01-2019, 09:55 AM

Kinda sounds like you have a failed resistor or poor connection in the v-glide. Remove the v-glide assembly and remove the rear cover and you’ll see them all. Check each one for resistance and/or broken wires.

powerandglory · 09-01-2019, 12:05 PM

Quote:

Originally Posted by 48knees

Good morning, our 2000 DS 48 volt series cart is making me crazy. All of a sudden when I pressed the throttle and nothing until about 1/2 pedal and full power. F&R. Then it was fine a few trips around the hood, then nothing, no movement, then fine. Next was at 1/2 pedal it would bump F or R .

Currently its on blocks and will turn wheels under power very intermittent and for a moment.

My mechanic ability is good my electronic ability is limited but determined lol. I'I've been reading and testing everything I can.

Batteries are 1 year old, tested with hydrometer all good. Charges fine.

Cleaned every contact point in the cart.

Dissasembled the Potentiometer, cleaned and shimmed the contact arm.Tested the unit before install and after, tests good.

Solenoid clicks and best as I can it test good.

I've jumped the OBC and no difference disconnected and jumped or connected.

The Controller is a bare aluminum Curtis. 3 bolt lugs 3 small terminals. I've tested this best as I understand but am lost.

Sorry for the long winded post but I'm ready to push it into the Bay, smash into it with my truck or put on some heavy metal and start smashing it to bits.

I own a 97 DS that originally had the v-glide, but since upgraded to the MCOR4. In the past I’ve had similar issues with the v-glide. I would start with doing resistance checks on each wiper contact as you push down on the accelerator pedal. Should get down as close to 0 ohms as possible. If you find an area in the wipers that reads high resistance than contacts will need to be cleaned. Electrical contact cleaners will do. Spray the heck on em. It won’t hurt. I would also do end to end resistance checks on all wires coming in and going out of your v-glide. These are common problems I’ve had in the past.

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48knees · 09-03-2019, 07:00 PM

Thanks for the advice. The high and low diodes test bad. I will look for replacements an let you know

48knees · 09-07-2019, 08:12 PM

You guys are brilliant, Thank you. After seeing CC wants 100.00 for the set of resistors I went to our local electronic shop. He matched the resistors and a couple bucks and a sort time later our hoopdy is cruisin.
Now we are going to add some style.

Mooncarter · 09-07-2019, 08:21 PM

Quote:

Originally Posted by 48knees

You guys are brilliant, Thank you. After seeing CC wants 100.00 for the set of resistors I went to our local electronic shop. He matched the resistors and a couple bucks and a sort time later our hoopdy is cruisin.
Now we are going to add some style.

Sounds like a plan!

powerandglory · 09-09-2019, 08:45 PM

Quote:

Originally Posted by 48knees

Thanks for the advice. The high and low diodes test bad. I will look for replacements an let you know

Nice work! Troubleshooting is the fun part

Sent from my iPad using Tapatalk

billyvray · 03-26-2023, 09:00 AM

Can you tell me how you troubleshot this?

Quote:

Originally Posted by 48knees

You guys are brilliant, Thank you. After seeing CC wants 100.00 for the set of resistors I went to our local electronic shop. He matched the resistors and a couple bucks and a sort time later our hoopdy is cruisin.
Now we are going to add some style.

Csimpler · 03-28-2023, 12:04 PM

Had the same issue. Remove the green and yellow small wires from the controller. Should read 0-5k ohms with a black controller or 5k-0 ohms with a silver controller. 5k at rest, 0 at full throttle. Mine was intermittent until it just quit. Resistors looked OK till I touched one with my VOM leads and one fell apart. Let me know if you need resistors I bought three packs of 6 and only used 2 each 1.1k, 910, 750 ohms.

09-01-2019, 08:20 AM	#1
48knees Not Yet Wild Join Date: Aug 2019 Posts: 6	2000 Club Car DS controller issue? Good morning, our 2000 DS 48 volt series cart is making me crazy. All of a sudden when I pressed the throttle and nothing until about 1/2 pedal and full power. F&R. Then it was fine a few trips around the hood, then nothing, no movement, then fine. Next was at 1/2 pedal it would bump F or R . Currently its on blocks and will turn wheels under power very intermittent and for a moment. My mechanic ability is good my electronic ability is limited but determined lol. I'I've been reading and testing everything I can. Batteries are 1 year old, tested with hydrometer all good. Charges fine. Cleaned every contact point in the cart. Dissasembled the Potentiometer, cleaned and shimmed the contact arm.Tested the unit before install and after, tests good. Solenoid clicks and best as I can it test good. I've jumped the OBC and no difference disconnected and jumped or connected. The Controller is a bare aluminum Curtis. 3 bolt lugs 3 small terminals. I've tested this best as I understand but am lost. Sorry for the long winded post but I'm ready to push it into the Bay, smash into it with my truck or put on some heavy metal and start smashing it to bits.
48knees Not Yet Wild Join Date: Aug 2019 Posts: 6

09-01-2019, 09:55 AM	#2
Fairtax4me Bonafide Nincompoop Join Date: Dec 2015 Location: Charlottesburg Va Posts: 8,987	Re: 2000 Club Car DS controller issue? Kinda sounds like you have a failed resistor or poor connection in the v-glide. Remove the v-glide assembly and remove the rear cover and you’ll see them all. Check each one for resistance and/or broken wires.

09-03-2019, 07:00 PM	#4
48knees Not Yet Wild Join Date: Aug 2019 Posts: 6	Re: 2000 Club Car DS controller issue? Thanks for the advice. The high and low diodes test bad. I will look for replacements an let you know
48knees Not Yet Wild Join Date: Aug 2019 Posts: 6

09-07-2019, 08:12 PM	#5
48knees Not Yet Wild Join Date: Aug 2019 Posts: 6	Re: 2000 Club Car DS controller issue? You guys are brilliant, Thank you. After seeing CC wants 100.00 for the set of resistors I went to our local electronic shop. He matched the resistors and a couple bucks and a sort time later our hoopdy is cruisin. Now we are going to add some style.
48knees Not Yet Wild Join Date: Aug 2019 Posts: 6

03-28-2023, 12:04 PM	#9
Csimpler Not Yet Wild Join Date: Aug 2013 Posts: 69	Re: 2000 Club Car DS controller issue? Had the same issue. Remove the green and yellow small wires from the controller. Should read 0-5k ohms with a black controller or 5k-0 ohms with a silver controller. 5k at rest, 0 at full throttle. Mine was intermittent until it just quit. Resistors looked OK till I touched one with my VOM leads and one fell apart. Let me know if you need resistors I bought three packs of 6 and only used 2 each 1.1k, 910, 750 ohms.
Csimpler Not Yet Wild Join Date: Aug 2013 Posts: 69

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