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Old 10-19-2014, 09:41 PM   #1
gunnardog
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Default Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....help?

Bought a 2007 Ezgo PDS that was running but not well. It wouldn't reverse consistently, batteries were bad, lots of surface rust. I ended up completely disassembling the cart down to the bare bones, repainting the frame and all the pieces and reassembling. Everything mechanical is back to tip top shape, new shocks, new seals in rear end, new tie rod ends, brakes etc, etc.

I am converting the cart to 48V so I order an Altrax DCX400 for PDS, 400 amp solenoid (w/ correct diode and resistor)(I realize now that this solenoid is probably too big but shouldn't hurt right?), new 4 ga. cables Fast forward to today I finally wire everything up and I think I have it perfect, turn the key and the controller doesn't blink, solenoid doesn't click, the system doesn't do anything. I search around and see that I reversed my wires and my diode on the small posts on my solenoid and figure that is the problem. I then install the yellow wire on the positive side of the solenoid and reverse the diode so the banded side is facing the positive side as well. Turn the key and nothing. I have 49.8V at the battery terminals and 49.8V across the small posts on the solenoid.

I never figured out what was causing the unit to back up intermittently before I ripped it apart but I have since ordered a new F/R switch and ignition switch just to be sure that the electrical system is problem free in the future.

There is probably something really obvious that I am missing, please help me if you can think of anything. I am ready to stop working on and start riding on my new cart!!
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Old 10-19-2014, 09:45 PM   #2
cgtech
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Default Re: Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....h

You do have it in forward or reverse?
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Old 10-19-2014, 10:00 PM   #3
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Default Re: Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....h

You have a little over 70% on batteries, charge them up and check voltage again and see where it stops. Check any fuses etc that could be bad. Good luck and keep us posted.
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Old 10-19-2014, 10:54 PM   #4
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Default Re: Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....h

When that diode was backward, you may have fried the reed switch in the charge port, or the microswitch at the gas pedal.
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Old 10-20-2014, 06:37 AM   #5
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Default Re: Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....h

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Originally Posted by cgtech View Post
When that diode was backward, you may have fried the reed switch in the charge port, or the microswitch at the gas pedal.
I was worried about that. Since the controller LED never blinked I was thinking that maybe it never energized. How can I check the switch? Can I check continuity through the throttle plug or do I need to open up the box by the pedal and pull the microswitch.

I don't have the charge port hooked up yet so I hope thats not a problem.

I tried it in both forward and reverse.
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Old 10-20-2014, 08:34 AM   #6
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Default Re: Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....h

The controller will power-up on 49.8V, but you are killing your new batteries by letting then sit in a partially discharged state. Get them fully charged and then break them in properly to obtain maximum storage capacity.

The first task is to get the LED on the controller to come on. (Blinks Green four times if it is set for an ITS throttle type and then stays on steady green.)

Controller should power up when Run/Tow is in RUN, Keyswitch is ON and F/R switch is in either F or R.

That will (should) give you full pack voltage on Pins 6, 9 and 10 on the DCX controller plug and the LED should come on.

When you push the throttle pedal, pack voltage should be applied to Pin-5 and the solenoid should click.

Here's a schematic showing a DCX in a PDS.

------------
Mounting the controller upside down is going to make troubleshooting difficult. The second attachment is how I mounted mine.
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Old 10-20-2014, 11:32 AM   #7
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Default Re: Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....h

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Originally Posted by JohnnieB View Post
The controller will power-up on 49.8V, but you are killing your new batteries by letting then sit in a partially discharged state. Get them fully charged and then break them in properly to obtain maximum storage capacity.

The first task is to get the LED on the controller to come on. (Blinks Green four times if it is set for an ITS throttle type and then stays on steady green.)

Controller should power up when Run/Tow is in RUN, Keyswitch is ON and F/R switch is in either F or R.

That will (should) give you full pack voltage on Pins 6, 9 and 10 on the DCX controller plug and the LED should come on.

When you push the throttle pedal, pack voltage should be applied to Pin-5 and the solenoid should click.

Here's a schematic showing a DCX in a PDS.

------------
Mounting the controller upside down is going to make troubleshooting difficult. The second attachment is how I mounted mine.
Good point. I am impatiently awaiting the arrival of my new charger. I just went down and picked up the batteries so they haven't had any load or anything on them so hopefully they will be ok.

I have no idea why I didn't turn my controller around like yours. I think I am going to flip mine around like that today. So much easier to see what is going on.

My new F/R switch and ignition will be arriving with the same order so hopefully that eliminates some of the potential failure modes.
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Old 10-20-2014, 12:06 PM   #8
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Default Re: Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....h

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Originally Posted by gunnardog View Post
1. Good point. I am impatiently awaiting the arrival of my new charger. I just went down and picked up the batteries so they haven't had any load or anything on them so hopefully they will be ok.

2. I have no idea why I didn't turn my controller around like yours. I think I am going to flip mine around like that today. So much easier to see what is going on.

3. My new F/R switch and ignition will be arriving with the same order so hopefully that eliminates some of the potential failure modes.
1. You want to fully charge new batteries prior to their first use, but using them for troubleshooting and maybe moving the cart a few feet in both directions to make sure it works probably won't hurt them.

As low as they are (76% SoC), the initial charge will take a long time, so don't be surprised if the charger runs for 12 hours or more. Most chargers have a backup timer and it may time out on the first charge, so if it does, just restart the charge and let the charger shut off automatically.

2. I ran the high current cables behind the heatsink to get them out of the way and used the stock solenoid mounting bracket mounted with the bottom set of bolts so the access panel to the serial port wasn't covered. The stock solenoid mounting bracket took a little "Adjusting" with a file and some spacers to get everything to fit right. (See attached)

3. Hopefully, but not to worry. The schematic with the PDS to DCX adapter on it looks like a plate of spaghetti, but I've got it figured out pretty well and can walk you through it.
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Old 10-20-2014, 06:36 PM   #9
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Default Re: Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....h

Quote:
Originally Posted by gunnardog View Post
I was worried about that. Since the controller LED never blinked I was thinking that maybe it never energized. How can I check the switch? Can I check continuity through the throttle plug or do I need to open up the box by the pedal and pull the microswitch.

I don't have the charge port hooked up yet so I hope thats not a problem.

I tried it in both forward and reverse.
Might be an issue-- ? johnnieB ? is this possible problem?
small Red wire on charger harness?
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Old 10-20-2014, 06:58 PM   #10
cgtech
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Default Re: Brand New Alltrax DCX400 controller, solenoid, batteries, cables and nothing....h

Yep, thats a problem, if your reed switch is still part of the system.
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