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Old 06-29-2015, 12:09 PM   #1
Mcvd02
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Default 2001 EZGO DCX400PDS AND HD SOLENOID Issues

I purchased the a Alltrax DCX400PDS controller with HD solenoid kit from Scottyb on June 20, 2015. Just installed and it ran awesome for about 10 minutes. Then at first stop it would not go, cart lunges momentarily after I depress pedal. I depress the pedal to go forward and solenoid picks up then drops out. Nothing in reverse other than beeper. What do I need to troubleshoot? Is there any programming in controller that I need to look at?
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Old 06-29-2015, 12:17 PM   #2
jjance
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Default Re: 2001 EZGO DCX400PDS AND HD SOLENOID Issues

I'd start with the connections on the controller. Make sure nothing came loose.
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Old 06-29-2015, 12:39 PM   #3
kgsc
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Default Re: 2001 EZGO DCX400PDS AND HD SOLENOID Issues

Is the controller showing any blinking codes ?
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Old 06-29-2015, 05:56 PM   #4
JohnnieB
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Default Re: 2001 EZGO DCX400PDS AND HD SOLENOID Issues

Lets find out if the controller is being powered up.

Preconditions:
Charger disconnect from cart
Run/Tow in Run
Keyswitch ON
F/R switch in F

When those four preconditions are met, the LED should blink Green four times (Meaning it is programmed for an ITS type throttle) and the stay a steady Green.

If the LED isn't coming on, check for FULL pack voltage on Pins 6, 9 and 10 in the 10 pin connector on top of the DCX controller. You'll have to lift the connector slightly to get to the pins.

If one or more voltage is missing, I have schematics with the voltage paths to those pins highlighted.
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Old 06-29-2015, 08:32 PM   #5
Mcvd02
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Default Re: 2001 EZGO DCX400PDS AND HD SOLENOID Issues

Just got home guys, I hope to get out and troubleshoot after I take care of getting kiddos feed, etc.. Forgot to mention that I also purchased a brand new set of batteries too. Appreciate the suggestions and help!
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Old 06-29-2015, 09:12 PM   #6
Mcvd02
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Default Re: 2001 EZGO DCX400PDS AND HD SOLENOID Issues

Quote:
Originally Posted by JohnnieB View Post
Lets find out if the controller is being powered up.

Preconditions:
Charger disconnect from cart
Run/Tow in Run
Keyswitch ON
F/R switch in F

When those four preconditions are met, the LED should blink Green four times (Meaning it is programmed for an ITS type throttle) and the stay a steady Green.

If the LED isn't coming on, check for FULL pack voltage on Pins 6, 9 and 10 in the 10 pin connector on top of the DCX controller. You'll have to lift the connector slightly to get to the pins.

If one or more voltage is missing, I have schematics with the voltage paths to those pins highlighted.
Okay guys here is a quick led status on controller.

Solid green until I depress pedel. Once depressed I get 7 red blinks. Which indicates a Battery Over Voltage according to the Alltrax manual. I checked battery voltage and it is 38.29 VDC.
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Old 06-29-2015, 09:41 PM   #7
cgtech
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Default Re: 2001 EZGO DCX400PDS AND HD SOLENOID Issues

Ok, does main positive lead from main source to F&R come from solenoid terminal, or controller B+ terminal. I have been seeing this on SPM controller, needs to be from main B+ terminal on controller on SPM. May not be relevant, but it is something i learned the hard way. Not too sure why it makes a difference, but it fixed my problem instantly, so im not gonna argue. Same "code", overvoltage.
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Old 06-30-2015, 01:58 AM   #8
JohnnieB
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Default Re: 2001 EZGO DCX400PDS AND HD SOLENOID Issues

Quote:
Originally Posted by Mcvd02 View Post
Okay guys here is a quick led status on controller.

Solid green until I depress pedel. Once depressed I get 7 red blinks. Which indicates a Battery Over Voltage according to the Alltrax manual. I checked battery voltage and it is 38.29 VDC.
What is the over voltage slider set to in the programming?


What is the voltage on Pins 9 and 10?
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Old 06-30-2015, 09:01 PM   #9
Mcvd02
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Default Re: 2001 EZGO DCX400PDS AND HD SOLENOID Issues

Quote:
Originally Posted by JohnnieB View Post
What is the over voltage slider set to in the programming?


What is the voltage on Pins 9 and 10?
Actually an under voltage guys when I depress the pedal. I miscounted last night. Controller is fine until I depress pedal, cart lunges then I get 6 red lights. I check voltage at packs when i depressed pedal and it dropped to 37.6, and the same voltage across solenoid. Where do I need to start troubleshooting?
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Old 06-30-2015, 10:39 PM   #10
Mcvd02
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Default Re: 2001 EZGO DCX400PDS AND HD SOLENOID Issues

Found the issue guys: I used one of the stickies to find a faulty solenoid. This was a brand new HD solenoid too. Luckily I saved the stock for a spare. Here is the stick I used to troubleshoot.

Testing of the EZGO ELECTRONIC SPEED CONTROL - SERIES & PDS (NON DCS)
ALWAYS DISCONNECT THE NEGATIVE BATTERY CABLE BEFORE REMOVING CONTROLLER COVER. RE-CONNECT CABLE AFTER COVER IS REMOVED.
These test are to be conducted after making sure all wires and connections are clean and tight.
PLACE THE REAR OF THE CART SECURELY ON BLOCKS OR JACK STANDS FOR SAFETY
Connect (-) probe of meter on Battery Pack Negative (-) post. (This probe will on the post for the rest of the testing procedures) Connect (+) probe to the Battery Pack Positive (+) battery post. (This reading is the Battery Voltage and the amount of POWER TO THE CONTROLLER -
NOW, Key switch ON, gear selector in FORWARD, Place the (+) probe on the battery side of the solenoid's large post (If the reading is below battery voltage, check all wiring and terminals).
Place the (+) probe to the controller side of the solenoid's large post. The reading should be 0.1 to 3 volts less than battery voltage. If the reading is more than 3 volts less the battery voltage, the resistor is faulty. If the voltage is the same as the battery voltage, replace the solenoid.
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