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Old 09-09-2017, 09:04 PM   #1
FullSpool
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Default 97 club car 48v basket case project

So I picked up a project , no batteries , wiper switch broken , wires missing etc .

I got the wiper switch rebuilt and working however looking at this diagram it appears I need a resistor board for these 2 green wires coming off the solonoid.

http://www.buggiesgonewild.com/attac...s_-regen1-.jpg


However this car has a 300 amp FSIP controller upgrade so can I disregard this resistor board or does it need it ?

controller diagram attached
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Old 09-09-2017, 09:07 PM   #2
FullSpool
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Default Re: 97 club car 48v basket case project

files below
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File Type: pdf doc43281320170908095007.pdf (368.2 KB, 0 views)
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Old 09-09-2017, 10:02 PM   #3
joesam
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Default Re: 97 club car 48v basket case project

I havent installed one, but reading others who have, suggests that second solenoid, resistor (and those green cables) are removed and unnecessary when installing the FSIP controller upgrade. Its original use was for a regen 1&2 "feature" called dynamic braking.
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Old 09-09-2017, 10:13 PM   #4
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Default Re: 97 club car 48v basket case project

yep you don't need it
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Old 09-09-2017, 10:51 PM   #5
FullSpool
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Default Re: 97 club car 48v basket case project

okay great , well I got everything wired up per the diagram.
just need to find some batteries to test it.
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Old 09-10-2017, 09:25 PM   #6
TexTurbo
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Default Re: 97 club car 48v basket case project

My "go to" for testing is 4 12v trolling motor batteries.

I bought enough battery cable to chain them together for
a 48v pack.
It will not run it for long, but it will provide enough power for a
a few trip around the block for drive system, and braking system
checks....

hope it helps !
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Old 09-11-2017, 08:33 PM   #7
FullSpool
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Default Re: 97 club car 48v basket case project

Well I put 48v to it and nothing happened , all fuses are good. Any ideas ?
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Old 09-11-2017, 09:35 PM   #8
joesam
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Default Re: 97 club car 48v basket case project

Lots to check when you've rewired

1) Does the main solenoid click when you turn the key, or apply go-pedal?
2) Can you measure the ohms coming from the "wiper switch" plug (actually called multi-step potentiometer). Measure ohms at it's plug (while unplugged). s/b 5K ohms at zero pedal and 0 ohms at full pedal.
3) Does your OBC work? (eg. can your charger see / start-a-charge on those batteries when charger is plugged in?). A failed OBC can lock-out your controller (if it is not working)
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Old 09-12-2017, 07:21 AM   #9
FullSpool
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Default Re: 97 club car 48v basket case project

I will check those items this evening. However I did not hear any clicking of the solenoid. You do however hear the buzzer going off in the forward and reverse position. Its much louder in 1 position than the other though.
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Old 09-12-2017, 08:51 AM   #10
joesam
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Default Re: 97 club car 48v basket case project

There should be absolutely no buzzer in the "F" position - only "R". I suspect something in the wiring is amiss! Recheck everything to do with the rocker switch and trace those wires back to their terminating points. Also - just a generic question - the drawing you provided is for Regen-1 which means on the replacement controller there s/b a short plug conversion pigtail on the controller - which converts the GE "Z" type Regen-1 plug to a FSIP plug. Do you have that?
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