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Old 09-23-2019, 03:53 PM   #1
meimk
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Default 97 DS 48 volt, early regen conversion to ?

Working on a 97 Club Car DS. It's had a different controller & some kind of conversion harness done some years ago. The cart doesn't move, no solenoid click, no grounding signal to the solenoid. Of course this doesn't match any wiring diagram I've been able to find. The controller was replaced with a GE but it's got some small off white to yellow box along the conversion harness that seems to come between the controller and the OBC. The second solenoid and resistor coil I would expect on an early regen cart are gone. Anybody got any hints just what I've got here? Trying to find the source path for the ground signal to the solenoid. Pictures below of the controller ID, and a couple shots of the yellow "box".
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Old 09-23-2019, 05:21 PM   #2
The Big Weezy
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Default Re: 97 DS 48 volt, early regen conversion to ?

That is a picture of the OBC. That controls battery charging and are known to fail. I converted my 97 DS from a regen 1 cart to a series cart. The regen 1 cart didn't last long in production (something like a year or so) and shares little electronics with other generations. I removed all stock electronics and replaced with Alltrax, Admiral motor, high current solenoid, heavy duty FnR and a DPI smart charger. I'm happy with this setup.

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Old 09-23-2019, 05:22 PM   #3
The Big Weezy
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Default Re: 97 DS 48 volt, early regen conversion to ?

Your controller is different than what I had though.

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Old 09-23-2019, 07:32 PM   #4
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Default Re: 97 DS 48 volt, early regen conversion to ?

Quote:
Originally Posted by The Big Weezy View Post
That is a picture of the OBC. That controls battery charging and are known to fail. I converted my 97 DS from a regen 1 cart to a series cart. The regen 1 cart didn't last long in production (something like a year or so) and shares little electronics with other generations. I removed all stock electronics and replaced with Alltrax, Admiral motor, high current solenoid, heavy duty FnR and a DPI smart charger. I'm happy with this setup.

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No, it's got a conventional OBC. Whatever that box is it's wired between the controller and the OBC. The blue with white tracer wire that is connected to the ground side of the small, control circuit side of the solenoid comes from that yellowish box.
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Old 09-23-2019, 08:36 PM   #5
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Default Re: 97 DS 48 volt, early regen conversion to ?

Your cart was originally a Regen 1, but it's been converted to the Regen 2 with a factory conversion kit. That's the adapter you're seeing. The "Conversion" version of the Regen 2 controller is slightly different than the OEM version of the Regen 2 controllers that came on these cars. I'm not sure of the exact differences, but the engineers at Club Car told me they're different. For long term reliability of this cart, I recommend putting a new IQ wire harness in the car, updating to MCOR, with a new OBC or Smart charger, and putting an Alltrax XCT controller on it.
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Old 09-23-2019, 09:53 PM   #6
LukeL
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Default Re: 97 DS 48 volt, early regen conversion to ?

Isn’t there a Regen 2 controller replacement available now from Allrrax?
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Old 09-23-2019, 10:45 PM   #7
Fairtax4me
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Default Re: 97 DS 48 volt, early regen conversion to ?

There is but I doubt it would work correctly with the conversion done on this cart. It probably still has a regen 1 harness.

Did you check the resistance of the solenoid coil?
Does the cart have a Tow/Run switch?
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Old 09-24-2019, 05:16 AM   #8
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Default Re: 97 DS 48 volt, early regen conversion to ?

Quote:
Originally Posted by The Big Weezy View Post
That is a picture of the OBC. That controls battery charging and are known to fail. I converted my 97 DS from a regen 1 cart to a series cart. The regen 1 cart didn't last long in production (something like a year or so) and shares little electronics with other generations. I removed all stock electronics and replaced with Alltrax, Admiral motor, high current solenoid, heavy duty FnR and a DPI smart charger. I'm happy with this setup.

Sent from my LG-H910 using Tapatalk

Would you be willing to share part numbers? I have a 97 CC DS that still has resistor coils. The OBC has been removed and I have a reconditioned Plum Quick motor. I’m looking at pulling the coils and vglide to swap in: 1. Controller, 2. upgraded solenoid, 3. new FnR, 4. New “gas” pedal. Can you tell me if I have missed anything?
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Old 09-24-2019, 05:24 AM   #9
meimk
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Default Re: 97 DS 48 volt, early regen conversion to ?

Quote:
Originally Posted by Fairtax4me View Post
There is but I doubt it would work correctly with the conversion done on this cart. It probably still has a regen 1 harness.

Did you check the resistance of the solenoid coil?
Does the cart have a Tow/Run switch?
I've worked with the regen 1 to IQ conversion, that's not what this is. I could buy this being a regen 1 to regen 2 conversion, maybe. Sepex motor, no tow/run switch. The solenoid that was in there when it came to me was bad. This is one of the 48 volt carts that used a 36 volt solenoid, been working that way for years. I did put another solenoid on it, but still wouldn't run. Finding 50 volts (key on) at the + side of the solenoid control circuit (measured against pack -), but only a 12.6 volt drop to the - side small terminal (key on, in gear, pedal down). Not enough to switch that 36 volt solenoid. The wiring doesn't match anything I've found for regen1, regen 2 or IQ. That little yellow box is between the controller and the solenoid, and between the controller and the OBC. If I jump the big posts of the solenoid the cart will run. If I jump - signal to the solenoid it will switch the solenoid & run. Being a 36 volt solenoid I've used the aprox 42 volts from one battery in from pack -. I've got a suspicion that the yellow box I can't ID (no labels of course) is what's failing. These are little old folks from out at the lake. I don't really want to tell them it needs the majority of the drive system replaced.
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Old 09-24-2019, 07:08 AM   #10
Sergio
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Default Re: 97 DS 48 volt, early regen conversion to ?

Without having an exact diagram of how that conversion modified the original wiring it will be difficult to trouble shoot.

By the way, I don't think Club Car has ever used a 36v Solenoid on a 48v system.

The OBCs used for Regen I and Regen II worked very differently from each other and the OBC they have installed is not compatible with either version.

Measure the voltage on the Solenoid positive activation coil as You press the pedal to make sure it is not dropping.

If the voltage stays steady, disconnect the negative wire from the solenoid activation and measure the voltage from that wire to pack positive as You press the pedal to see if You get 48v.
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