ITS/Controller

[eadavis]

Hello I have a 99 ezgo DCS cart that I have been fighting for some time now. It randomly works fine but not very often. It is very slow or won't go when it is acting up. I have a new D &D motor with correct mapping per D &D which problem was same before. Alltrax 400amp controller and white roger heavy duty solenoid with 2 gauge wiring everywhere. Cart ran great like this with current setup minus upgraded motor for years. 48 volt pack. I have replaced a couple years ago the ITS and recently while troubleshooting eliminated the molex connector for the ITS and replaced ITS switch and even tried new wiring from controller to ITS system with no luck. I get the 10.5 volts to ITS and runs smoothly down to 5.8 volts and when I am watching the throttle percentage on the Alltrax software it only goes up to 12% that is when it is acting up other times it goes higher. I am at a loss and need help I am tired of throwing money at it. It seems to me to either be the ITS coil or the controller but I am perplexed because the voltage from the ITS coil is correct but does not match the % of throttle. I have made sure the connector o the controller is making good contact with the pins also. I have jumpered out the Solenoid contacts, made sure pack voltage was good everything I know to do. Please help!!!!!!!!!!!

[JohnnieB]

Is it an Alltrax DCX400 or an XCT48400-DCS?

In either case, measure the voltage on the backsides of Pins 1 and 2 (White and Black wires) while the 10-pin plug is plugged into controller with pedal up and pedal down. Should be 10V up and 6V down, or close to it. (10.5V Up and 5.8V Down are probably okay)

If you get that while cart is misbehaving, contact Alltrax.

If it is a DCX, it is time to upgrade to an XCT.

[eadavis]

It is a DCX. That is what I was afraid of that it was going to be the most expensive part. I will see if I can do as you recommended and try to contact Alltrax.

[JohnnieB]

The DCX was designed to be a Plug-n-Play replacement for the stock DCS controller (Curtis 1206SX), which was only used from 1995 through 1999, so the DXC design is a quarter century old. The XCT is pretty much state of the art.

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I forgot the plug on the DCS wiring harness is difficult to probe with a test lead. Unplug it and wrap two or three turns of hookup wire around the individual pins 1 & 2 on the DCX, then plug the connector back in place and measure voltage from the free ends of the hookup wires.

[eadavis]

Here was the response I received from Alltrax.

"

Sent: Thursday, June 11, 2020 11:28 AM
To: helpdesk
Subject: Re: [EXTERNAL] RE: DCX 400


________________________________________
From: helpdesk <helpdesk@alltraxinc.com>
Sent: Thursday, June 11, 2020 9:29 AM
To: Davis, Eric
Subject: [EXTERNAL] RE: DCX 400

You may have already done this but the next time it acts up and is going slow or not moving, check B- to M- of the controller, give the cart full throttle and see how low the voltage goes. If you’re going slow the voltage shouldn’t drop very much, so if it goes all the way to zero and you’re hardly moving there’s a problem in the forward/reverse or motor. If the voltage barely drops then it has to be the controller because you already confirmed the throttle is operating correctly so voltage would be the only other reason for slow speeds aside from a controller.

Thank you. B- to M on controller read 54V no pedal and 50V full Pedal. Does this mean that I will have to replace the controller?

Eric

Yes, if you got that voltage, the cart moved nowhere and we know we have good readings on the throttle then it has to be a bad controller.

DCX was discontinued about 5 years ago and replaced with the XCT so the new part number is XCT48400DCS
"

[JohnnieB]

You'll love the XCT.

Thanks for the feedback.