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Unread 04-22-2008, 07:09 AM   #1
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Default 96 DCS, no buzzer, no solenoid click

Hi all, newbie here. Just started fixin up a cart for grandma, not having much luck. I have spent much time reviewing posts here, lots of great info. I hope you can help.

1996 DCS (run/tow switch, padel F/R at knee, only the 10 pin connector on controller).

Nothing happens when key on/forward/pedal down. Started to follow the troubleshooting steps and hit snag several steps into it...

I have ref.volt at solenoid bat side, ref -2.5v at solenoid controller side (only if in TOW, not RUN). Have 36 volt on left small solenoid stud (which has a red and yellow wire - NOT 2 reds like all drawings here and manual says!!). I have a BLUE wire from controller on the other solenoid energizer post.

I can get solenoid to fire if I jump from right post (the one with the BLue) to the B- on top of controller. Fires off when I hit Forward or Reverse - pedal has NO effect.

Manual says "replace small black wire from solenoid to B-", I don't have this wire - only a BLUE to controller pins. (page 52 step




I have tested the micro switches for F/R individually, OHmed out fine. Same with pedal switch. Don't know how to test the "ITC" speed thing yet but that may not be an issue yet. Have tried spare solenoid - no change.

Question: Should I be in Run or Tow during these tests? Sounds like dumb question, but not a SINGLE repair manual mentions this.

Question: Shouldn't the blue wire to the solenoid from controller provide the negative to fire the solenoid? Is this why I get it to fire with temp. jumper to B-?

Question: I found a great PDF slideshow on a post here that goes through wiring tests, complete with red highlighted test point... I get to step 5 and that is as far as I get - but it doesn't tell me what this failure means?!

Question: How do I rule out the "reed switch" in charging harness?

Thanks in advance, sorry for such long first post but I can tell you people are into details.

Rob.
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Unread 04-22-2008, 12:21 PM   #2
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Default Re: 96 DCS, no buzzer, no solenoid click

More info: I did find one of the "troubleshooting" manuals that specifies when to have Tow/Run switch moved... but this is in a manual for PDS carts.

The diagrams of wiring DCS controller and solenoid DO show the wiring as I have, its is just the the text troubleshooting flowchart reference other wires... confusing.

Anyone point me to the "DCS troubleshooting " manual. I have looked at the ones from the manufacturer and they also mixing the two types.... hmmm, I can't be the only person to run into this, I must be cross eyed :-)
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Unread 04-23-2008, 08:38 PM   #3
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Default Re: 96 DCS, no buzzer, no solenoid click

Did this cart run when you got it? Have you checked the microswitch in the throttle box? Its under the floormat.
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Unread 04-23-2008, 11:22 PM   #4
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Default Re: 96 DCS, no buzzer, no solenoid click

Thanks for taking a minute...

I have not seen unit run, but it is in fine overall shape - 96 year old owner needed to get it out of garage! Not a single splice in the entire unit.... that being said - do not know any more history.

I have checked each microswitch (1 pedal, 2 directional) by disconnecting and ohming them as well as hooking them up and checking at the far end of each connection.... all seem fine. I bypassed the reed switch in the charger plug: no change.

Last night I went and sequentially checked continuity on EVERY wire run... no problems found.

I am suspecting the controller - I can't ever get it to throw a negative to the solenoid (blue wire from 9pin to right-hand small post). But even if I jumper the solenoid and fire it off, I still get no buzzer or motor action.

Any ideas?
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Unread 04-24-2008, 06:28 AM   #5
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Default Re: 96 DCS, no buzzer, no solenoid click

Sounds like you are having a controller issue. Alltrax make a High amp controller that works awesome. I would make sure all other avenues have been checked before deciding to purchase/replace the controller.
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Unread 04-28-2008, 07:52 PM   #6
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Default Re: 96 DCS, no buzzer, no solenoid click

Went ahead and ordered the DCX 300 controller. Any tricks on the programming?
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Unread 04-28-2008, 08:15 PM   #7
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Default Re: 96 DCS, no buzzer, no solenoid click

Just get the cable and the software and run it....its pretty self explanitory. Radio shack has a USB-Serial cable for around $30 so it can be used on newer laptops.
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Unread 05-02-2008, 10:40 AM   #8
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Default Re: 96 DCS, no buzzer, no solenoid click

Update: Installed controller, WE HAVE MOVEMENT.

Working good, batter time is now the issue... One thing at a time.

Thanks for all advice.

Last edited by yourflorida; 05-02-2008 at 10:40 AM.. Reason: spelling
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