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Unread 10-01-2010, 10:44 PM   #1
Not Yet Wild
 
Join Date: Feb 2010
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Default Regen2 Cart no go

This is my first thread and I hate having to post it. I am usally pretty good a figuring out issues on any cart and if I can't figure it out I can usally find an answer by looking thru the many informative post here on BGW. I however have a cart that is literly whipping my b-hind.

I working on a 98 Club Car DS Power Drive with the Regen2 General Electric Controller. When I got the cart it would not move so the first steps i completed were to verify that the batteries were good. I did this by performing a load, hydrometer, and a voltage test of the entire pack. The batteries tested good so i proceded to test the components. As i went thru each test i found that I was not getting varible voltage (usally 3.5v to .5v as you push the accelerator) thru pin 7 of the controllers wire harness. This immediately let me to believe that i needed a new potentiometer. Put one on order and replaced. After replacement i was getting the correct voltage thru pin 7 but still was not getting any movement thru the motor. I then went on to test the output between A1 and A2 of the controller. Its been my experience that as you pust the accelerator that your voltage increases between these two terminals the further you push down the accelerator. This was not happening and all i was getting was 48v thru each A1 and A2 to ground no mater how far the accelerator was pushed down. As i never really tinkered with a Regen 2 cart before, I thought this was odd and sent the controller out to be rebuilt.

I got the controller back and reinstalled in the cart. FSIP informed me that indeed i had a burnt controller. So I feel confident that this is going to work, but it didn't. At this point there is only one other thing left in this equation. I performed an contunituity test between A1 and A2 and also between F1 and F2. I found that i had no contunitunity between the two fields F1 and F2. Pulled the motor and found that someone had twisted the teriminal on the F2 post and broke the wire inside the motor. I took the motor to my local electrical motor repair shop and got it fixed. Reinstalled the motor and was feeling confident that i would be running again. Still nothing.

Now if you are still awake after reading my long story about this cart the one thing that keeps puzzling me is that i am still getting the same readings out of the controller as i was before i sent it for repair. I get 48v between A1 and ground and 48v between A2 and ground but nothing between the two. Its almost like there is a collision of voltage taking place in the motor. I have to feel like my controller is good because i did get it rebuilt.

Can anyone share any wisdom on what is wrong and what else i may be overlooking? Thanks
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Unread 10-02-2010, 10:33 AM   #2
The Last Moja Morani
 
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Default Re: Regen2 Cart no go

what year? did you check soleniod, OBC ? did you try jumping soleniod to see if cart would run? and is the charger working ok ? shutting off when done..............................
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Unread 10-02-2010, 06:45 PM   #3
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Default Re: Regen2 Cart no go

99 Regen2 Club Car. Tried jumping the soleniod after reading another post of someone that had the same problem. The soleniod appears to be functioning correctly. Tow/Run in run and key on you can hear it click and can measure 48v on the post with the yellow wire to ground. The cart does charge and turns itself off. I accually even took another OBC i had on the shelf and installed to see if that would help, with no luck. I got to think it is the controller even though i had it rebuilt. I know on Ezgos when you check the voltage between A1 and A2 it goes from 0v to 36v the further you push the accelerator. Although i am not to familiar with the Regen 2 Club Cars, I would think it would do close to the same. I just want to know why Club Car has to make things so difficult. Too many checks and balances to get that cart to move. If one thing is out of sink, no go.

I guess that i will just have to go out and purchase another CC service manual that will collect dust after this fix. Any more ideas before i warm this credit card up?
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Unread 10-03-2010, 10:43 AM   #4
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Default Re: Regen2 Cart no go

A bad motor will fry a controller quick,that goes for any golfcar.Fsip is a good co.to deal with as I use them myself.You could send that contrller back and have them do a test and advise to find out if the motor might have fried the controller again.Dont feel bad as I hate those gen2 cars myself.
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Unread 10-04-2010, 06:51 PM   #5
Dawg Gone Wild
 
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Default Re: Regen2 Cart no go

Agree with Golfcarfixer... a bad motor can destroy a controller quick. I hope that's not what happened.. You should hear a slight hum from the controller when you push the accelerator.. Do you? It should change pitch as you fluctuate the pedal. These cars are such a headache but I'm leaning to a bad controller as well.
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Unread 10-04-2010, 08:44 PM   #6
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Default Re: Regen2 Cart no go

I took the motor back to my local electric motor repair shop today to have it checked. They hooked it to the dyno and applyed 32v to it. The motor turned as it should. Thus confirming that the motor is ok. Controller is going back to FSIP tomorrow.
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Unread 10-04-2010, 10:03 PM   #7
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Default Re: Regen2 Cart no go

Sorry for the inconviencence as these cars are good when they are running.
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Unread 10-04-2010, 10:36 PM   #8
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Default Re: Regen2 Cart no go

No inconvience. Just more experience. I take every challenge as a lesson learned. If every repair was easy, this job wouldn't always be interesting.
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Unread 10-06-2010, 01:35 PM   #9
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Default Re: Regen2 Cart no go

Yet again, another golf cart shop's first post to receive free technical support. Try the donate button.
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Unread 10-06-2010, 04:08 PM   #10
Dawg Gone Wild
 
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Default Re: Regen2 Cart no go

Hey we've all been there.
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