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Old 01-27-2015, 08:38 PM   #1
railrider
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Default Ez go dcs problem

Guys I have a 97 ezgo 36 volt dcs , i had a problem with it not moving so I ordered new controller and solonoid and replaced microswitches on F n R switch. The cart will move only about 10 ft then just stop but the solonoid never clicks in either direction . I ran the troubleshooter and all checks out but the blue wire, no voltage. Any suggestions ?
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Old 01-27-2015, 08:41 PM   #2
jakesnake27
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Default Re: Ez go dcs problem

Possibly a solenoid problem. Here is the wiring diagram:
http://www.buggiesgonewild.com/elect...eshooting.html
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Old 01-27-2015, 09:41 PM   #3
railrider
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Default Re: Ez go dcs problem

Yea I have triple checked wiring and still scratching my head. Does that resistor diode combo have to be installed for it to work ?
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Old 01-28-2015, 01:13 AM   #4
scottyb
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Default Re: Ez go dcs problem

Quote:
Originally Posted by railrider View Post
Yea I have triple checked wiring and still scratching my head. Does that resistor diode combo have to be installed for it to work ?
no - but the solenoid has to click. Check the solenoid activation circuit for a bad switch or connection.
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Old 01-28-2015, 08:06 AM   #5
JohnnieB
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Default Re: Ez go dcs problem

Quote:
Originally Posted by railrider View Post
Guys I have a 97 ezgo 36 volt dcs , i had a problem with it not moving so I ordered new controller and solonoid and replaced microswitches on F n R switch. The cart will move only about 10 ft then just stop but the solonoid never clicks in either direction . I ran the troubleshooter and all checks out but the blue wire, no voltage. Any suggestions ?
The cart only moves a few feet because the solenoid contacts are not closing.
What is happening is that the resistor across the solenoid's contacts charges up the filter capacitors in the controller and when the pedal is pushed, the controller sends that stored energy to the motor, so cart moves, but only until the energy stored in the filter capacitors is depleted. If you left your foot on the pedal, the resistor would get mighty hot.

The controller is working, or at least parts of it are.
The pedal switch is working, or the cart would not move when the pedal is pushed.
That means pack voltage is being applied to the small solenoid terminal with three wires on it, since that is the voltage source for the pedal switch.

Measure the voltage on the solenoid's small terminal with the single (blue) wire connected to it.
With the pedal up, you should measure pack voltage.
If not, the solenoid coil is open.

If you do measure pack voltage there, measure the voltage at the other end of the blue wire, which is Pin-7 on the controller.
If you don't get pack voltage on Pin-7, the blue wire is bad.
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Old 01-29-2015, 11:47 AM   #6
tcascario
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Default Re: Ez go dcs problem

Im not saying this is your problem. The guys on here will help you get to the bottom of this. I have a 99 dcs and had the same issue with solenoid not closing and would move a short distance from the resistor. I tried 2 new controllers from Alltrax and tested solenoid several times to find out it was the 10 pin connector that attaches to the controller was not letting voltage pass through the blue wire. Changed the connector and worked immediately. Just a thought for later!!!
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Old 01-29-2015, 12:10 PM   #7
scottyb
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Default Re: Ez go dcs problem

Quote:
Originally Posted by tcascario View Post
Im not saying this is your problem. The guys on here will help you get to the bottom of this. I have a 99 dcs and had the same issue with solenoid not closing and would move a short distance from the resistor. I tried 2 new controllers from Alltrax and tested solenoid several times to find out it was the 10 pin connector that attaches to the controller was not letting voltage pass through the blue wire. Changed the connector and worked immediately. Just a thought for later!!!
The solenoid activation circuit test should show either the (+) or the (-) missing on the small posts if the 10 pin connector is failed.
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Old 01-29-2015, 02:21 PM   #8
JohnnieB
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Default Re: Ez go dcs problem

When the voltage at the back side of the molex connector on the controller is good, but the controller isn't responding to it, lift the connecter slightly and use a miniature hook type test lead to get onto the pin itself. (See attached picture)

The nutty thing is that the act of unplugging the molex connector slightly often solves this type of problem.

----------
If a bad connection is suspected, disconnect and clean it. If that solves the problem, disconnect it again and apply a dielectric grease (IE: Sanchem NO-OX-ID A-Special Electrical Contact Grease) and reconnect.

In fact, it is a good idea to treat all the cart's electrical connectors and connections with dielectric grease before any of them acquire enough corrosion to cause problems. (They all will eventually - it is inevitable.)
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File Type: jpg Miniature Hook Test Leads.jpg (95.5 KB, 0 views)
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Old 01-30-2015, 05:38 PM   #9
vagabond
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Default Re: Ez go dcs problem

Quote:
Originally Posted by tcascario View Post
Im not saying this is your problem. The guys on here will help you get to the bottom of this. I have a 99 dcs and had the same issue with solenoid not closing and would move a short distance from the resistor. I tried 2 new controllers from Alltrax and tested solenoid several times to find out it was the 10 pin connector that attaches to the controller was not letting voltage pass through the blue wire. Changed the connector and worked immediately. Just a thought for later!!!
where did you find a 10 pin connector I have a friend here in the park that could use a replacement
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Old 02-03-2015, 09:51 PM   #10
tcascario
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Default Re: Ez go dcs problem

Sorry hadn't checked this thread in a while. Here is the link where I got it.
http://www.evdrives.com/product_p/acc-adap-pds.htm
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