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Unread 09-12-2011, 03:03 PM   #1
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Default 1994 DS Series Troublesooting Chart

I am a new member here and new to the world of carts. I have a fairly extensive background in Mechanics, Electrics and Some Electronics which apparently means little in the cartworld according to some posts Ive read here .

I have a 1994 DS Series Electronic Controller ( HA Serial#) cart in my shop that I have put new batteries in and cleaned all of the connections. I am reading 38.1 volts at the 2 battery cables. The keyswitch was hooped for starters as were the old batteries. The PO ran the cart extensivley with the dying batteries which is a no no I understand.

Someone before me changed the solenoid and I have tried to read the wiring diagram to make sure it is wired right but the low resolution one I have from here makes it difficult. The diode might be polarity reversed but all else looks right.

There was a click from the MSw on the pedal before I wired the keyswitch across now it does not click anymore. The solenoid does not make a sound and there is power on the motor/controller terminals as well as the other terminals. I suspect the controller is fried but thats just a guess.

I bought a manual online for download but it turned out to be stuff mostly ripped from this site and is not model specific

Apart from a proper service manual where can I find a troubleshooting flowchart that would point me in the right direction as to locating/eliminating the faulty components??

I have fixed several bad and broken connections\wires and the outside microswitch on the F/R sw with a broken tab but I can force a connection but visually all else looks good. The backup buzzer is not hooked up. Is that essential??

Sorry for the long post but i tried to give as much info as possible. Thanks
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Unread 09-13-2011, 10:09 AM   #2
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Default Re: 1994 DS Series Troublesooting Chart

Contact me about service manual at
donaldwscott@att.net
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Unread 09-13-2011, 10:46 AM   #3
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Default Re: 1994 DS Series Troublesooting Chart

Since you have established good batteries and cable connections. concentrate your trouble shooting on the solenoid activation circuit.
You probably already know a solenoid needs a 36v pos+ & a neg- at the small posts to create a magnetic field and draw the contact bar up against the two large terminal connection lugs. This closes the solenoid switch bringing power to the controller at B+.
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Unread 09-13-2011, 11:49 AM   #4
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Default Re: 1994 DS Series Troublesooting Chart

Quote:
Originally Posted by scottyb View Post
Since you have established good batteries and cable connections. concentrate your trouble shooting on the solenoid activation circuit.
You probably already know a solenoid needs a 36v pos+ & a neg- at the small posts to create a magnetic field and draw the contact bar up against the two large terminal connection lugs. This closes the solenoid switch bringing power to the controller at B+.
Ok, I will start there and check voltages.
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Unread 09-13-2011, 07:16 PM   #5
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Default Re: 1994 DS Series Troublesooting Chart

Quote:
Originally Posted by scottyb View Post
Since you have established good batteries and cable connections. concentrate your trouble shooting on the solenoid activation circuit.
You probably already know a solenoid needs a 36v pos+ & a neg- at the small posts to create a magnetic field and draw the contact bar up against the two large terminal connection lugs. This closes the solenoid switch bringing power to the controller at B+.
This is surprising to me but remember I am a complete novice in cartworld and hope to change that.

I have power at all solenoid contacts with the neg cable disconnected so essentially the batteries are not supplying power to anything.

The reference to B+ above leads me to believe that there are capacitors in the controller upping the voltage or storing it. Correct??

I fix and mod guitar amps for a hobby so I am aware of the lethal voltages in that environment. Is this something to be cautious of ??

Obviously I need to drain the caps if they are in there before poking around as I want to see if the solenoid is the correct one and use an ohmmeter on it before putting it back in the circuit. The PO replaced it but I don't know if it is the right one or not.

Ok Batt voltage at 38V. engagement lugs at 36.9V both and large controller wires at 38V both testing at solenoid.

Last edited by farmboy101; 09-13-2011 at 07:23 PM.. Reason: added content
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Unread 09-13-2011, 08:10 PM   #6
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Default Re: 1994 DS Series Troublesooting Chart

I removed the solenoid. It is the correct 36V rated. I tested it using batt voltage and it engages and closes the contacts. I removed the diode and resistor for the test and will test them separately. So I gather that the engagement circuit is where I need to go.
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Unread 09-13-2011, 08:28 PM   #7
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Default Re: 1994 DS Series Troublesooting Chart

Quote:
Originally Posted by farmboy101 View Post
I removed the solenoid. It is the correct 36V rated. I tested it using batt voltage and it engages and closes the contacts. I removed the diode and resistor for the test and will test them separately. So I gather that the engagement circuit is where I need to go.
The resistor shows 255 ohms. The diode shows continuity both ways so it is pooched. I will ohm the micro switch near the wiper for continuity as I cannot hear it clicking anymore.
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Unread 09-13-2011, 08:40 PM   #8
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Default Re: 1994 DS Series Troublesooting Chart

Sometimes when a diode goes it will take a micro switch with it. Sounds like you are on the right path
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Unread 09-13-2011, 09:01 PM   #9
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Default Re: 1994 DS Series Troublesooting Chart

Quote:
Originally Posted by scottyb View Post
Sometimes when a diode goes it will take a micro switch with it. Sounds like you are on the right path
The micro switch in the speed control is pooched. Looks like its off to the cart store tomorrow to get some parts.
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Unread 09-13-2011, 09:37 PM   #10
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Default Re: 1994 DS Series Troublesooting Chart

The inside micro switch on the F/R switch is no good. The outside micro on the F/R had a broken tab so it needs replacing also. So far 1 diode,1 key switch,3 micros. All of this looks to control the solenoid circuit as far as I can tell from the wiring diagram.

Heres hoping that is all I need.
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