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Unread 11-17-2014, 02:38 AM   #1
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Default '95 DS with no reverse

I just bought a 95 DS Club Car with the 48v system at a farm auction. It wasn't working, but I got it cheap. After checking it out, I was surprised to find the batteries in good shape. I replaced all the battery cables, and had to buy a new speed controller. The cart moves forward nicely, but wont move in reverse at all. The solenoid clicks, but no movement. When I checked the resistance at the speed controller terminals in reverse, I have 10k resistance, and when I depress the pedal completely it goes down to 5k. In forward the resistance goes from 5k ohms down to a few hundred. I assume I am missing something simple here. I know there is a 5.1k resister in the reverse half-speed limit switch, but I don't understand how it can work like this, when its a 5k-0 ohms input required for the speed controller. Any help would be appreciated here.
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Unread 11-17-2014, 07:29 AM   #2
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Default Re: '95 DS with no reverse

Check the wires in the FNR switch, you most likely have 2 of them in the wrong position.

The 3 wire throttle works in a voltage divider mode, so the additional resistor introduced by the reverse microswitch reduces the maximum voltage as seen by pin #3 in the controller.
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Unread 11-17-2014, 03:29 PM   #3
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Default Re: '95 DS with no reverse

Thanks for the reply Sergio

All wires seem correct and connections clean and tight. I replaced the original speed controller (Curtis 1204-410) with a new one (Curtis 1204M-5301). The new controller just uses 2 wire 5k-0 ohms for input control. If I understand you, the old controller didn't use that for input and instead used voltage? If that is the case, could I not just replace the 5.1k ohm resister at the microswitch with a 2.5k resister to get half speed in reverse?

Thx again,

Cam
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Unread 11-17-2014, 04:02 PM   #4
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Default Re: '95 DS with no reverse

IF Your controller now is setup for a 2 wire 5k-0Ω rheostat, You are correct about the half-speed resistor value being too high.

I would go with a 2kΩ resistor 1/4watt, but You can just jump the green wire with the white wire on micro switch #3 for now to see if it runs in reverse (full speed).

You also need to disconnect the purple wire (and tape it) coming from your Multi-Step or variable potentiometer at the controller B-.

Edit: Wiring the 1/2 speed this way (with a resistor in series) will give you half the pedal travel with no movement and then 0-1/2 speed on the 2nd half of the pedal travel. I would just leave it a full speed reverse.
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Unread 11-17-2014, 07:35 PM   #5
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Thumbs up Re: '95 DS with no reverse

I switched the wires on the microswitch, and it ran fine in reverse. I have removed the purple wire completely from the wiring harness (I hate having extra wires that aren't hooked to anything). I will make a little jumper wire to go from the green wire to the white wire, and bypass the microswitch completely.

Thanks for clearing things up for me Sergio
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