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Old 08-14-2018, 11:26 AM   #1
Johnv 410
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Default EZGO DCS no activation at the solinoid

Where would you recommend I go from here? -
I got a 96 DCS cart and was told the previous owner could not get it running. So I started with replacing the batteries, solenoid and the controller (Stock Curtis) because one of the spade terminals was very loose. After taking different voltage readings -
37.6 volts at battery pack. 37.6 volts at battery side of the Solenoid, 35.1 volts on controller side. I replaced the micro switch in at the ITS in the floor to make sure it was good.
I am getting 0 volts at both small post on the Solenoid so it will not activate. I measured voltage on the pins at the controller (5,6 8,9) with no voltage there. I was told to check the wiring harness by the first battery as when you get inside there is a splice from the factory and make sure that its still a good connection. Any advice as to where to go from here is appreciated.
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Old 08-14-2018, 12:45 PM   #2
JohnnieB
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Default Re: EZGO DCS no activation at the solinoid

Unless the Run/Tow is in the Tow position, you ought to have battery pack voltage on Pins 9 and 10.

Pin-10's voltage source is the solenoid's battery side large terminal, so it ought to have pack voltage om it whenever Run/Tow is in Run.

Pin-9's voltage source is the Reed Switch, so it ought to have pack voltage on it whenever the Run/Tow is in Run and no charger is plugged into cart.

Get the pack voltage on Pins 9 and 10 and we'll go from there.

Attached is a schematic with the solenoid activation circuit highlighted in red.
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File Type: jpg Wiring Diagram - DCS - No Reverse Diode -KSI Traced.JPG (94.7 KB, 0 views)
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Old 08-14-2018, 03:56 PM   #3
Johnv 410
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Default Re: EZGO DCS no activation at the solinoid

Thanks for the reply JohnnieB. Pin 10 I did have pack voltage(Only pin with it)
Pin 9 had 9 volts. I did bypass the Reed Switch but not 100% sure it is correct. I got ride of the white wire and put a ring terminal on the Red/with white stripe and attached to the screw on the larger white wire that goes to the battery. The other end had a plug that went to the main wiring harness by the F/R Switch? I ran these readings after the Reed switch was eliminated. I am at a total loss.
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Old 08-14-2018, 05:47 PM   #4
Johnv 410
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Default Re: EZGO DCS no activation at the solinoid

This is correct. I have pack voltage at pin 10. Pin 9 only had 8/9 volts. Please let me know your thoughts as to where to go from here. Thanks again.
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Old 08-14-2018, 08:12 PM   #5
JohnnieB
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Default Re: EZGO DCS no activation at the solinoid

There is a bad wire or connector someplace between your bypassed reed switch and Pin-9.

Here is schematic with the path to Pin-9 highlighted.
I'd check the voltage in and out of the Run/Tow switch and if that is good, I would check the voltage at the "Forward" switch. (It is actually the run switch since it is closed in both F and R.) It is the microswitch on the driver's side of the F/R assembly.

Unfortunately, I don't have a true wiring diagram (a schematic only shows electrical connections, not necessarily the actual physical locations for them.) so I don't know where the Red (To Pin-9) and Org/Red (From Run/tow switch) wires are connected physically.
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Old 08-15-2018, 10:10 AM   #6
Johnv 410
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Default Re: EZGO DCS no activation at the solinoid

Thanks for the info. That was my guess also. I was thinking the issue was between the key switch to the solenoid. Either the F/R Switch, ITS Micro switch or the Run/Tow Switch. I am not sure how to check the volts at the F/R Switch because I thought you had to unplug the connection at the switch. Please advise. I did check and have continuity on the Run/Tow and the F/R when unplugged at the switch itself. What's the best way to test voltage at these points you suggested?
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Old 08-15-2018, 10:14 AM   #7
Johnv 410
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Default Re: EZGO DCS no activation at the solinoid

I also had continuity at the Reed switch plug at the harness back to the 4 wire plug (Tow switch) I believe.
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Old 08-15-2018, 11:43 AM   #8
JohnnieB
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Default Re: EZGO DCS no activation at the solinoid

Unless otherwise stated, all voltage measurements are made with DVM's negative test lead connected to the battery pack's main negative terminal.

Measuring voltage on the Run/Tow switch is fairly easy, it has exposed connections. All four of them ought to have battery pack voltage on them when in Run position.

Measuring voltage at the F/R microswitch isn't so straightforward. Unplug the driver's side microswitch and and measure the voltage on the pins in the plug connected to the cart's wiring harness. One of the ought to have pack voltage.

Then measure the continuity between the pins in the plug connected to the microswitch. Should have continuity when either F or R is selected.

The next place to measure is Pin-9 on controller. Lift the connector slightly to access the pin on controller.

We are trying to get voltage to Pin-9 at this point and neither the keyswitch or pedal switch need to be looked at yet since they are not in the reed switch to Pin-9 circuit.
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Old 08-15-2018, 12:02 PM   #9
Johnv 410
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Default Re: EZGO DCS no activation at the solinoid

OK Thank you again. I will try these readings. I took the controller out to have it tested so once I get it back I will be all over it.
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Old 08-16-2018, 06:23 PM   #10
Johnv 410
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Default Re: EZGO DCS no activation at the solinoid

JohnnieB, I believe I found what we was looking for.
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