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Electric Club Car Electric DS, and Precedent golf cars |
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04-30-2021, 07:12 PM | #1 |
Not Yet Wild
Join Date: Oct 2016
Location: Myrtle Beach
Posts: 44
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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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04-30-2021, 07:15 PM | #2 |
Not Yet Wild
Join Date: Oct 2016
Location: Myrtle Beach
Posts: 44
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Re: 2002 Club Car Villager (DS) Will Not drive
48Volt, btw. In case I missed that.
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04-30-2021, 08:23 PM | #3 | |
Gone Wild
Join Date: Apr 2020
Location: 1000 Oaks, SOCAL
Posts: 424
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Re: 2002 Club Car Villager (DS) Will Not drive
Quote:
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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05-02-2021, 01:31 PM | #4 |
Not Yet Wild
Join Date: Oct 2016
Location: Myrtle Beach
Posts: 44
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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! |
05-02-2021, 07:07 PM | #5 |
Bonafide Nincompoop
Join Date: Dec 2015
Location: Charlottesburg Va
Posts: 8,987
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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. |
05-03-2021, 07:31 AM | #6 |
Gone Wild
Join Date: Jul 2017
Location: Cape Coral FL
Posts: 243
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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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05-05-2021, 10:19 AM | #7 |
Not Yet Wild
Join Date: Oct 2016
Location: Myrtle Beach
Posts: 44
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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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06-12-2021, 02:49 PM | #8 |
Not Yet Wild
Join Date: Oct 2016
Location: Myrtle Beach
Posts: 44
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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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07-01-2022, 07:24 AM | #9 |
Not Yet Wild
Join Date: Jun 2022
Posts: 1
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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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