2002 Club Car DS bad OBC or Controller?

Ferger · 07-01-2022, 08:04 PM

I have a 2002 club car ds 48 volt that won’t move. Solenoid clicks when hitting the accelerator pedal and you hear a electrical whine type noise but won’t move in forward or reverse. F&R switch tested good. MCOR checked out okay. I suspected the controller was bad because all of the inputs checked out okay but on the output side at full throttle it only puts out about 13 volts. So I sent the controller out to a guy in Florida and he “bench tested” it and he said everything was working correctly.
If I’m correct the OBC only supplies the ground to the solenoid so if the OBC was bad the solenoid wouldn’t click correct?
Not sure where to go from here. Also has brand new batteries and battery cables. I’ve installed a new solenoid and did the MCOR conversion just to try and neither made any difference.

Tom47 · 07-01-2022, 08:17 PM

Is this a series or regen cart? Does it have a run/tow switch?

Volt_Ampere · 07-01-2022, 08:29 PM

Find the source of the "Whine" noise. Is the motor possibly spinning and not turning the wheels? (Stripped hub?)

sthreatt · 07-01-2022, 09:35 PM

Sounds like stripped hub. Jack the rear end up off the floor and see if it will spin the wheels in the air.

CP241 · 07-01-2022, 09:41 PM

Or stripped motor splines, maybe stripped or broken input shaft.

I’ve never heard of stripped hubs in club cars, very common in ezgo. But club car the axles are splined at the differential. Not saying you *couldn't* but I’ve never seen one strip. I have seen one break near the splines but that cart was used under some very, very harsh conditions

Ferger · 07-01-2022, 10:45 PM

It’s a series cart. The whine noise is the same type of noise when you disconnect batteries and place F&R switch to reverse and hit the accelerator pedal to discharge the controller (high pitched whine like a mosquito). Checked hubs all okay. Motor does not turn. I’ve checked continuity’s across all motor terminals and all checked okay. I even removed the motor and checked brushes, etc. motor appears to be in very good shape.

Fairtax4me · 07-02-2022, 11:37 AM

The whine is the motor getting power, but not enough power.
Cable issues, possibly a bad solenoid, or a bad connection in the FnR switch (corrosion or burned contacts inside).
Verify all of those first.
Also check the throttle signal going to the controller. This cart could have had the Pie wedge Multi-step pot, or could have had an MCOR. Testing will be slightly different depending which throttle type it has.

Ferger · 07-08-2022, 01:22 AM

Installed new MCOR 4 conversion and no change. I'm suspecting the problem is in the FNR switch because it looks questionable. I figured now would be a good time to install a "Heavy Duty" FNR switch. Is this recommended and if so what kind/brand should I get?
Thank you for your help!

simicrintz · 07-08-2022, 07:45 AM

Give a Site Sponsor a call; they will point you in the right direction!

07-01-2022, 08:04 PM	#1
Ferger Not Yet Wild Join Date: May 2022 Location: IN Posts: 12	2002 Club Car DS bad OBC or Controller? I have a 2002 club car ds 48 volt that won’t move. Solenoid clicks when hitting the accelerator pedal and you hear a electrical whine type noise but won’t move in forward or reverse. F&R switch tested good. MCOR checked out okay. I suspected the controller was bad because all of the inputs checked out okay but on the output side at full throttle it only puts out about 13 volts. So I sent the controller out to a guy in Florida and he “bench tested” it and he said everything was working correctly. If I’m correct the OBC only supplies the ground to the solenoid so if the OBC was bad the solenoid wouldn’t click correct? Not sure where to go from here. Also has brand new batteries and battery cables. I’ve installed a new solenoid and did the MCOR conversion just to try and neither made any difference.

07-01-2022, 08:17 PM	#2
Tom47 Gone Wild Join Date: Dec 2016 Location: Kingsland, Georgia Posts: 1,825	Re: 2002 Club Car DS bad OBC or Controller? Is this a series or regen cart? Does it have a run/tow switch?

07-01-2022, 08:29 PM	#3
Volt_Ampere Gone Wild Join Date: May 2012 Location: Rio Verde, Az Posts: 7,686	Re: 2002 Club Car DS bad OBC or Controller? Find the source of the "Whine" noise. Is the motor possibly spinning and not turning the wheels? (Stripped hub?)

07-01-2022, 09:35 PM	#4
sthreatt Gone Wild Join Date: Jul 2015 Location: Central South Carolina Posts: 1,002	Re: 2002 Club Car DS bad OBC or Controller? Sounds like stripped hub. Jack the rear end up off the floor and see if it will spin the wheels in the air.

07-01-2022, 09:41 PM	#5
CP241 Nincompoop village idiot Join Date: Apr 2018 Location: Michigan Posts: 9,837	Re: 2002 Club Car DS bad OBC or Controller? Or stripped motor splines, maybe stripped or broken input shaft. I’ve never heard of stripped hubs in club cars, very common in ezgo. But club car the axles are splined at the differential. Not saying you couldn't but I’ve never seen one strip. I have seen one break near the splines but that cart was used under some very, very harsh conditions

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07-01-2022, 10:45 PM	#6
Ferger Not Yet Wild Join Date: May 2022 Location: IN Posts: 12	Re: 2002 Club Car DS bad OBC or Controller? It’s a series cart. The whine noise is the same type of noise when you disconnect batteries and place F&R switch to reverse and hit the accelerator pedal to discharge the controller (high pitched whine like a mosquito). Checked hubs all okay. Motor does not turn. I’ve checked continuity’s across all motor terminals and all checked okay. I even removed the motor and checked brushes, etc. motor appears to be in very good shape.

07-02-2022, 11:37 AM	#7
Fairtax4me Bonafide Nincompoop Join Date: Dec 2015 Location: Charlottesburg Va Posts: 8,987	Re: 2002 Club Car DS bad OBC or Controller? The whine is the motor getting power, but not enough power. Cable issues, possibly a bad solenoid, or a bad connection in the FnR switch (corrosion or burned contacts inside). Verify all of those first. Also check the throttle signal going to the controller. This cart could have had the Pie wedge Multi-step pot, or could have had an MCOR. Testing will be slightly different depending which throttle type it has.

07-08-2022, 01:22 AM	#8
Ferger Not Yet Wild Join Date: May 2022 Location: IN Posts: 12	Re: 2002 Club Car DS bad OBC or Controller? Installed new MCOR 4 conversion and no change. I'm suspecting the problem is in the FNR switch because it looks questionable. I figured now would be a good time to install a "Heavy Duty" FNR switch. Is this recommended and if so what kind/brand should I get? Thank you for your help!

07-08-2022, 07:45 AM	#9
simicrintz Gone Wild Join Date: Apr 2020 Location: Hurricane, Utah Posts: 3,174	Re: 2002 Club Car DS bad OBC or Controller? Give a Site Sponsor a call; they will point you in the right direction!

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