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Old 08-21-2018, 09:37 AM   #1
Dobbelaar15
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Default 1995 DCS EZGO wiring troubleshooting

Hey guys wondering if someone could send me the info for testing the wiring and motor on a 1995 DCS EZGO 36v.

I cannot seem to get the Solenoid to click without jumping the negative battery terminal to the blue wire from controller.

I have removed motor and confirmed it was a DCS motor and tested the ITS and switch.

Looking for info for testing the armature on the motor
and what each pin on the harness should test and when?

Currently I have 36v on both sides of solenoid without click? is that correct?
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Old 08-21-2018, 10:37 AM   #2
JohnnieB
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Default Re: 1995 DCS EZGO wiring troubleshooting

Which type F/R switch does your cart have? Attachment-1 is early 95 and Attachment-2 is later 95 to 99.

In either case, with Run/Tow switch in Run, F/r in either F or R and Keyswitch ON, you should have battery pack voltage (38.2V for fully charged) on Pins 6, 7, 9 and 10.

When you push the pedal, you should get battery pack voltage on Pin-5 and Pin-7 ought to drop to 0V (B-), energizing solenoid.
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File Type: jpg Early DCS F-R with diode-.jpg (195.2 KB, 0 views)
File Type: jpg Later model DCS F & R.JPG (121.2 KB, 0 views)
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Old 08-21-2018, 02:05 PM   #3
Dobbelaar15
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Default Re: 1995 DCS EZGO wiring troubleshooting

Its is an early 95 style.

I do not have pin seven dropping to 0V when the pedal is pushed.

I have tested switch in pedal control and it does not allow 38v with pedal not pressed and allows 38v with pedal depressed.

I will check all voltage when i get home and let you know.
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Old 08-21-2018, 07:28 PM   #4
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Default Re: 1995 DCS EZGO wiring troubleshooting

IF it turns out to be a bad controller, do not install another stock controller.

The Curtis 1206SX (stock DCS controller) was EZGO's first attempt at a sepex drive system and the controller was flawed design and fails often. Replace it with an Alltrax XCT48400-DCS (or larger), which is user programmable.

------------
When the blue wire on the solenoid is jumpered to B-, getting the solenoid to click, will the cart run?

---------
Here is a schematic for your cart's drive system.
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File Type: jpg DCS Schematic - with diode.jpg (221.9 KB, 0 views)
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Old 08-22-2018, 10:52 AM   #5
Dobbelaar15
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Default Re: 1995 DCS EZGO wiring troubleshooting

When I put negative directly to blue wire, cart will run in forward ( sometimes) but not in reverse

you can hear it trying but it does not spin all the time in forward.
I have to switch the FR switch a few times for it to spin full out.

Also unfortunately I purchased a refurbished controller already and am having the same issue.

I was told if the blue wire doesn't pull a ground, then the controller is bad.
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Old 08-23-2018, 11:54 AM   #6
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Default Re: 1995 DCS EZGO wiring troubleshooting

All of the Voltage checks out ok as per what you sent me Ö except pin 7 does not drop to zero
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Old 08-23-2018, 12:28 PM   #7
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Default Re: 1995 DCS EZGO wiring troubleshooting

If you have pack voltage on Pins 6,9 & 10 and Pin-7 does no go low when Pin-5 goes high, the controller is bad.
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Old 08-23-2018, 04:05 PM   #8
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Default Re: 1995 DCS EZGO wiring troubleshooting

Well that solves that lol ... thanks ! I appreciate all the help!

Also do you know what direction this is installed on soleboid?
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Old 08-23-2018, 07:49 PM   #9
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Default Re: 1995 DCS EZGO wiring troubleshooting

I bought a 500a Alltrax controller and the solenoid to go with it and am really happy with it (I have a 1995 dcs also). But I have 2 of the Curtis controllers you are welcome to. I honestly have no idea if either of them work though. I never even tried them. I know the harness was melted on one of them. Not sure where you live, but Iím in Louisiana and youíre welcome to them if you would like them. Just thought I would offer.
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Old 08-24-2018, 11:58 AM   #10
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Default Re: 1995 DCS EZGO wiring troubleshooting

I sent you a pm

anyone have an idea of how that resistor and diode set goes on solenoid? or does direction not matter?
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