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Old 04-30-2021, 07:12 PM   #1
Predataber
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Default 2002 Club Car Villager (DS) Will Not drive

Alls it needs are batteries!

I Picked up this really clean cart that came with this persons house purchase. Was driving fine up until last year and this year they believe it to need batteries as it won't budge.
I take it to a battery place, replace the 2011 Trojans with 2021 Trojans and it still doest move. When we push it, the alarm does go off and the guy at the shop says its not the speed sensor (because of that) He believes it to be the motor. I find a local guy selling the exact motor and he gives it to me in a PlumbQuick box (he just upgraded but had no issues with original from what he says.)

The motor I took out looks crap with debris and rust (mostly lower exterior)-

New batteries, Newish Motor, still nothing.
The reverse buzzer does go on, the onboard charging seems to work. I have the controller exposed for some trouble shooting (its looks absolutely brand new like its never seen the light of day) but I'm not sure where to go with what. I hear a click I'm pretty sure and I don't believe its a series cart.

Thanks for any help moving forward.
Just a random pic of my controller in there as its all I have at the moment.
Heading over there now to mess with it.

Thanks again in advance!
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Old 04-30-2021, 07:15 PM   #2
Predataber
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Default Re: 2002 Club Car Villager (DS) Will Not drive

48Volt, btw. In case I missed that.
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Old 04-30-2021, 08:23 PM   #3
R&TBabich
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Default Re: 2002 Club Car Villager (DS) Will Not drive

Quote:
Originally Posted by Predataber View Post
.... I hear a click I'm pretty sure and I don't believe its a series cart. ....
Our 2003 IQ sepex DS had the same OEM controller in it.
There should be a circuit diagram in the Stickies section at the beginning of the forum.
You should hear the solenoid click when depressing the Foot Switch
There is an ON-OFF switch in the MCOR that closes when the Foot Switch is depressed (Controller Pin #6 - Green - Foot switch - pedal depressed).
It is the last interlock the controller needs after:
Pin #5 - Light Blue - Charge Interlock (OBC) - (not charging = B+)
Pin # 9 - Gray - Tow/Run switch - Run
Pin #10 - Tan - Key switch - On
Pin #16 - Blue - Forward/Reverse switch - Reverse
or
Pin #8 - Brown - Forward/Reverse switch – Forward
(All inputs are B+)

What is the pack voltage a couple of hours after charging?
Check that all connections are tight and corrosion free.
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Old 05-02-2021, 01:31 PM   #4
Predataber
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Default Re: 2002 Club Car Villager (DS) Will Not drive

Whats the bet way to start troubleshooting everything? Im much more familiar with gas carts. Ive replaced parts and upgraded electric carts but not much in the war of troubleshooting issues.
How do I determine a bad controller?
I Have a voltage meter I was going to start Troubleshooting today. A cart shop installed the batteries and they appear to take a charge though the onboard charger as one would expect. Ill get the pack voltage today.

Thanks so much for the help!
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Old 05-02-2021, 07:07 PM   #5
Fairtax4me
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Default Re: 2002 Club Car Villager (DS) Will Not drive

You say it has an on-board charger?
Which charger is in it?

It may be stuck in charge lockout due to bad wiring, or a dead OBC (on board charge computer)
The OBC was used on all 48v electric club cars up until 2014 whether they had an onboard or external charger. It's common for the OBC to fail, and it can cause the controller to say in charge lockout, which will mean it won't move.
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Old 05-03-2021, 07:31 AM   #6
Noonan
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Default Re: 2002 Club Car Villager (DS) Will Not drive

I second the OBC idea. You could try to bypass it and see if that works.
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Old 05-05-2021, 10:19 AM   #7
Predataber
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Default Re: 2002 Club Car Villager (DS) Will Not drive

Great, so I will try to bypass the "On Board Charge Computer." The wiring I believe is good as its never been toyed with AFAIK (until I get in there now, of course). The charging system does look to be a factory installation from what I hear but you'd know better than I after some more pics and does currently function. I will look up how to do this bypass and update you both this afternoon. Thanks guys!
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Old 06-12-2021, 02:49 PM   #8
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Default Re: 2002 Club Car Villager (DS) Will Not drive

So the batteries still charge. Will that happen if the controller is in charger lockout or not? Once I cut the grey and rerout the black to final negative, will that release the controller from Charger lockout? Thanks again!
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Old 07-01-2022, 07:24 AM   #9
mfffri
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Question Re: 2002 Club Car Villager (DS) Will Not drive

Predataber, Did you ever figure out what the issue is? I have an 02 villager 6 and I’m in the same boat
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