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Electric Club Car Electric DS, and Precedent golf cars |
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09-23-2019, 03:53 PM | #1 |
Gone Wild
Join Date: Jun 2011
Location: Northern Indiana
Posts: 2,823
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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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09-23-2019, 05:21 PM | #2 |
Getting Wild
Join Date: Aug 2016
Location: Illinois
Posts: 104
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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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09-23-2019, 05:22 PM | #3 |
Getting Wild
Join Date: Aug 2016
Location: Illinois
Posts: 104
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Re: 97 DS 48 volt, early regen conversion to ?
Your controller is different than what I had though.
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09-23-2019, 07:32 PM | #4 | |
Gone Wild
Join Date: Jun 2011
Location: Northern Indiana
Posts: 2,823
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Re: 97 DS 48 volt, early regen conversion to ?
Quote:
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09-23-2019, 08:36 PM | #5 |
revolutiongolfcars.com
Join Date: Mar 2010
Location: Golf Car Capital of The World... Augusta, Georgia
Posts: 10,224
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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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09-23-2019, 09:53 PM | #6 |
Gone Wild
Join Date: Jun 2017
Location: Savannah, GA
Posts: 6,539
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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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09-23-2019, 10:45 PM | #7 |
Bonafide Nincompoop
Join Date: Dec 2015
Location: Charlottesburg Va
Posts: 8,987
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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? |
09-24-2019, 05:16 AM | #8 | |
Not Yet Wild
Join Date: Aug 2019
Posts: 70
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Re: 97 DS 48 volt, early regen conversion to ?
Quote:
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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09-24-2019, 05:24 AM | #9 |
Gone Wild
Join Date: Jun 2011
Location: Northern Indiana
Posts: 2,823
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Re: 97 DS 48 volt, early regen conversion to ?
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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09-24-2019, 07:08 AM | #10 |
Gone Wild
Join Date: Sep 2012
Location: Charlotte, NC
Posts: 9,329
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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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