Needing Help with DCS EzGO 1995

[JayJacobs77]

I need help. I have a 1995 EzGo DCS, controller was bad, so replaced and still wouldn't run. So found red wire from charger receptacle and it was bad, so replaced, and now it runs to 0 to 1/3 throttle. Once you exceed that it quits. If you reset the key switch and the F and R switch it will perform again. I have replaced the solenoid, have tested the inductive throttle sensors, tested the resistor assembly that mounts to the solenoid, and the total vehicle voltage is 38 volts. Anyone have any ideas to what might be the actual issue with my cart. I have talked to two professionals and have not gotten anywhere with this.

[cgtech]

Did the ITS testing as described in this site?

[JayJacobs77]

yes I used the test procedure from this site and it checked good even when the cart quits running it still tests fine. then I cycle the key and the F&R switch then it runs again. I have also removed the motor tested between the four posts and the posts and case. then reinstalled and performed a 12v test to the motor all tests showed good. thanks for any help

[scottyb]

Reconditioned (= repaired) control bad?

[JohnnieB]

Does the solenoid click when the cart won't run?

If not, check for full pack voltage on Pins 5, 6, 9 & 10. (Pedal pushed)
If there is pack voltage on Pin-7 also, the solenoid coil in intact, so the controller is bad.

[JayJacobs77]

there has never been a solenoid click even when it runs at 1/4 throttle I've even jumped the solenoid with pedal down with no positive results. I did the pin volt test with good results when i first installed the controller. but I just did it a second time and its showing bad and the cart will no longer run at 1/4 speed. so I shorted something myself or the remanufactured controller had a very short life. thanks again I'm going to get ahold of another controller and give that a try. if not the cart may have to learn how to swim.

[JohnnieB]

The cart won't move at all, or at least not more than a few feet, unless the solenoid contacts are closed.

The DCS controller is a high failure item and was only installed in carts for about five years before being replace with the PDS drive system, so stop wasting your money on new, used or rebuilt DCS controllers.

Install an Alltrax XCT or DCX. The DCX was designed as a Plug-n-Play replacement for the DCS controller and while installing a XCT take more work, it is 15 year newer technology.

[scottyb]

Odd he said cart ran without solenoid click. Either you didn't hear it or it was latched closed from the git-go.

[JayJacobs77]

just installed a new alltrax controller and the cart works fine. the rebuilt controller was intermitted and I was counting on in being fine. so I was running in circles testing every part multiple times. thanks

[gornoman]

Rebuilt controllers - Pfffftttttt!