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Unread 10-02-2011, 10:08 AM   #1
Not Yet Wild
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Default 1996 48v Regen Module Issue

Hello All - Looking for opinions if my cart is worth repairing. The local dealer is telling me this module cost more than the cart is worth. We then proceeded to buy another cart. So now I sit with the old cart still. Should I part this out or try to fix it? Based on previous post, it looks like this is a Regen circuit since I have a rocker switch for directions.
The failure mode started to be intermittent. Now it doesn't work at all.
Please help with some inputs. I'm new to this site. Thanks :)
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Unread 10-02-2011, 11:27 AM   #2
The Last Moja Morani
 
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Default Re: 1996 48v Regen Module Issue

welcome to BGW......what does the cart do? anything? does solenoid click when you press pedal? 1st you need to get good charged batteries in it and than see if the solenoid is even engaging when you try and drive........the more history the better................................
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Unread 10-02-2011, 11:49 AM   #3
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Default Re: 1996 48v Regen Module Issue

Thanks for the quick reply. The cart would work one day and not the next. Almost seemed like a bad connection, but got to the point where NOTHING would work. We then took in for service to a local dealer. He claims the module is bad. He also stated they only had this module for one year. 1996 We then bought another Club Car. They swapped out the batteries from the 1996 since they were almost new and put them in the 1999. The 99' has been running good for the last 2 years. I then know I had a good charge. I don't recall hearing any clicking from a relay.
I'm to the point of working on this again. I might swap back the batteries and see what it does after sitting for 2 years.
Is this thing worth anything to someone? It is in EXCELLENT shape!
Thanks again for the input. Tim
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Unread 10-02-2011, 11:56 AM   #4
The Last Moja Morani
 
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Default Re: 1996 48v Regen Module Issue

if its the cart i,m thinking of they only made it 2 years and it can be a real pain.........the module i take it they meant controller......if its that cart yes very expensive......but you have to start somewhere to find out just whats wrong with it.............it could have been as simple as a solenoid going bad when they told you controller but you need to start somewhere.....................
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Unread 10-02-2011, 05:00 PM   #5
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Default Re: 1996 48v Regen Module Issue

If the cart is in good shape you could convert it to a series and have a better cart!
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Unread 10-02-2011, 09:03 PM   #6
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Default Re: 1996 48v Regen Module Issue

Pais54,... I had the exact same cart, which I upgraded the controller to an ATX 500 and once I fixed all the wiring and the main solenoid the cart would run at 21-23 mph. In fact it was just a little too fast. It turns out the ATX controller has adjustable current ramps so I was able to control it. You may be in luck since I still have the original STOCK controller and I have all of the wiring diagrams. As you have found out the Regen model is a beast by itself but I will tell you it was a great cart. When I bought my new 2008 CC Precedent I traded in the 1996 Club car. I still have the controller module. I think I can help you with the wiring. My cart had 6- 8volt trojan batteries so it is a 48 Volts system. Everyone will tell you that 48 volts is the best. By the time I had converterd my cart over to the high current controller, new solenoid, new cables, new contoller, I was out $750. I decided I had over done it. Yes it ran Very Fast, but it also eat up the batteries. If I were you i would just get the cart back to stock function and see what you could get for it. If in fact it was only the controller you are lucky you found me.
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Unread 10-02-2011, 10:03 PM   #7
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Default Re: 1996 48v Regen Module Issue

Thanks Trigger...This is some GREAT information. I have not torn into this yet. Is the controller mounted under the rear cover above the rear axle? Do you think your controller will be a drop-in to what I have? I could maybe look at what I have and see if there is some numbers I can show you. What do you need to get for your controller?
I see some of the other members on this site have posted the current wiring diagram. Not real easy to read!!
It's interesting about the ATX 500 unit. That is really fast! Did it destroy the batteries or just run them down quicker?
Thanks again for all your help.... Tim
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Unread 10-02-2011, 11:49 PM   #8
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Default Re: 1996 48v Regen Module Issue

pais54,... Don't tell me you were born in 1954,...Christ,...you are just a baby.

At the rear of your Regen, just under the basket, there is a cover to access the controller. I know mine was in good condition because it was working before I switched it out. I had to convert the total wiring of my cart to get it into a compatibility mode for any of the ATX high current controllers. If you are not an Electrical Engineer, such as myself, I don't recommment trying to change it. If you can confirm that you problem was the controller, the replacement will be very simple. Unbolt the old one and put in the new one. No wires, cables, solenoids, splices, etc. Now you have an original cart that runs again. Of course you have to get some batteries,..but maybe you can find someone that is going for new batteries and use their old ones,

Tomorrow I will take a picture of the controller and post it,... that is if I can get done with golf soon enough.
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Unread 10-03-2011, 11:22 AM   #9
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Default Re: 1996 48v Regen Module Issue

Thanks for the info... '54' was my favorite year for a truck several years ago. I'm actually younger.... This does sound like a simple fix if that indeed is the problem. The batteries on my 1999 are getting a little weak. I'm thinking of getting new ones. Maybe I swap those over to the 1996 to see if it works. Any idea what you want for your controller?? It would be GREAT to get this machine going again. Thanks again for the great information. It seems like I can read for hours on this forum. Tim
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Unread 10-03-2011, 01:18 PM   #10
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Default Re: 1996 48v Regen Module Issue

Pais54,...OK,..here are a couple of pictures. This is the Standard Club Car 1996 48 Volt -220AMP controller. It is know good. I've searched the net looking for prices and I think that $150 plus shipping is competitive. Seems you live in WI, so I would have to find out what the cost is to ship from my place. The Controller weighs 5.5 pounds.



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