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Unread 09-05-2014, 03:40 PM   #1
Not Yet Wild
 
Join Date: Oct 2013
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Question 1996 Club car

I have a 1996 Club car , It wont move ,I believe its a regen cart, It has a speed sensor and 14 pin connector coming from controller, but no run /tow switch. The solenoid clicks when the key is on, that's it , what are my options?with this cart? its in great shape . I want to fix it! thanks Jeff
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Unread 09-05-2014, 05:44 PM   #2
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Default Re: 1996 Club car Help

Jeff - If you are certain its a '96 - and you have a rocker switch for F & R - then its a Regen 1. In fact - with no run/tow switch and a rocker switch for F & R, then its almost certainly Regen 1.

Many of them ended up with an upgraded controller, though. So your next step is to check if it has a BLACK colored controller or a SILVER (upgraded) one.
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Unread 09-05-2014, 06:24 PM   #3
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Question Re: 1996 Club car Help

How do I test the controller and motor ? Can I test the motor by
jumping A-1 and S-2 / A-2 and S-1 then putting it up on jack stands and applying 12 v to them ? Thanks jeff
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Unread 09-05-2014, 10:10 PM   #4
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Default Re: 1996 Club car Help

First some basics - what color is your controller (this sounds lame but it does matter)? The black colored controller is a complex beast and controls and affects many things. Its not easy to troubleshoot - but lets start.

1) Does the cart make a "audible click" when you turn on the key?
2) If it does, after 10 to 30 seconds of just sitting - does it click again by itself?
3) With the key on - when you depress the go pedal - do you hear a very faint but audible (with the seat off) soft whine from the controller?
4) When you plug in the charger - does it charge?
5) What is the total voltage of your battery pack (measured 12 hours AFTER a full charge).

It may seem important, but its very rare for the motor to have failed - it can happen with abuse or for some other obscure reason - but its rare.
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Unread 09-05-2014, 10:34 PM   #5
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Default Re: 1996 Club car Help

1) Does the cart make a "audible click" when you turn on the key? Yes

1.5) the controoer is silver!

2) If it does, after 10 to 30 seconds of just sitting - does it click again by itself? No


3) With the key on - when you depress the go pedal - do you hear a very faint but audible (with the seat off) soft whine from the controller? None


4) When you plug in the charger - does it charge? Yes


5) What is the total voltage of your battery pack (measured 12 hours AFTER a full charge). i will see.

Why is regen 1 such a nightmare ??
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Unread 09-05-2014, 11:36 PM   #6
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Default Re: 1996 Club car Help

O.M.G - your reply said the controller is silver - so I won't be much help.

If you have a silver controller and a rocker F & R but you have no run/tow switch - you have a "Frankencart" Regen 1.5 (it may not have a regen solenoid and coil)....I won't be of much help to you - maybe someone else who is familiar with an upgraded Regen 1 can help. Look in the stickies for a circuit diagram for Regen 1 - I suspect yours is different in subtle ways.

If possible, find the model number on your silver controller. Maybe the mfr. can help with troubleshooting.
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Unread 09-06-2014, 12:31 AM   #7
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Default Re: 1996 Club car Help

Great !!! To see if the motor is shot how can I check?
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Unread 09-06-2014, 12:34 AM   #8
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Default Re: 1996 Club car Help

[QUOTE=Jefd;1072599]How do I test the controller and motor ? Can I test the motor by
jumping A-1 and f-2 / A-2 and f-1 then putting it up on jack stands and applying 12 v to them ? Thanks J
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Unread 09-06-2014, 01:23 AM   #9
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Default Re: 1996 Club car Help

Just to be thorough - there is a motor test process (per Stevegrmich) as follows:

Quote:
To test run a Sep-Ex (regen) motor with wheels off of ground, of course, and in TOW mode - (in your case with Regen 1.5 - be extra safe and disconnect the main pos & neg cables from the battery pack and set them aside).

USE TWO Wrenches to disconnect the motor cables - holding the lower nut firm on each terminal and spinning the top nut (you DO NOT want the terminal posts to spin while removing the cables otherwise internal motor connections/damage will occur). Remove all cables from the motor; connect a jumper from A1 to F1 and a jumper from A2 to F2. Connect 12 to 24 volts, positive @ A1/F1 and negative @ A2/F2. Swap F1 and F2 to change rotation direction.

DO NOT RUN MOTOR longer than it takes to see if it will spin tires to prevent damaging motor

BUT HONESTLY - I think your motor is fine - if I were guessing - its either:

1) A failed controller - afraid I have no real idea how a silver non-OEM Regen 1 controller might be tested.

2) The OBC on/off control circuit has failed and has disabled your controller. I'm sure you can bypass it....but again...the silver controller - so I have no idea which wires/connection to bypass or jumper.

3) The PotBox/accelerator system has a connection fault or has failed (relatively easy to test)

I will PM you a link to my OEM Regen 1 manual - it will be good for testing many things - maybe even how to test your controller if the pin-outs on the controller are identical.
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Unread 09-06-2014, 05:26 PM   #10
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Default Re: 1996 Club car Help

Looks like I have the beloved silver Ge controller#ic 3645sh4d222c2 now what?
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