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Old 01-01-2017, 02:26 PM   #1
Hi-man38
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Default Intermittent loss of reverse

I have a 2007 EZGO with a Alltrax DCX400 motor controller. Forward always works fine but the reverse function comes and goes. I noticed that when the reverse fails the solenoid fails to click when switched to reverse. I confirmed the problem in not the rev/forward switch. Typically after many attempts of selecting reverse the solenoid will click and start working again for a period of time. I pulled the environment cover and checked all connections. No problems. When changing direction the small green light consistantly flashing 4 times and stay on the 5th in each direction. It just fails to power the solenoid at times for reverse.

Bad motor sontoller? If so can it be repaired?
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Old 01-01-2017, 03:53 PM   #2
JohnnieB
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Default Re: Intermittent loss of reverse

When not working in reverse, what are the voltages on Pins 4, 5, 6, 7, 9 & 10 on top of the DCX with the pedal pushed?

With a fully charged 36V battery pack, all the pins mentioned above, except Pin-7, should measure 38.2V or whatever the battery pack voltage is at the time.

You may have to lift the 10 pin plug on top of the DCX slightly to access the pins.

-------
The DCX controller is resin filled and not repairable.

Last edited by JohnnieB; 01-01-2017 at 03:54 PM.. Reason: added comments
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Old 01-01-2017, 05:23 PM   #3
Hi-man38
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Default Re: Intermittent loss of reverse

Assuming 8 is the missing pin on the connector. Battery pack = 36.5v

Reverse not working pedal fully pressed
4= 5.80v
5= 5.07v
6= 4.98v
7= .162v
9= 36.5v
10= 36.5v

Forward working pedal fully pressed
4= .03v
5= 33.5v
6= 33.6v
7= .83
9=34.8
10= 34.8v
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Old 01-01-2017, 06:03 PM   #4
JohnnieB
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Default Re: Intermittent loss of reverse

Quote:
Originally Posted by Hi-man38 View Post
Assuming 8 is the missing pin on the connector. Battery pack = 36.5v

Reverse not working pedal fully pressed
4= 5.80v
5= 5.07v
6= 4.98v
7= .162v
9= 36.5v
10= 36.5v

Forward working pedal fully pressed
4= .03v
5= 33.5v
6= 33.6v
7= .83
9=34.8
10= 34.8v
You are not getting full battery pack voltage from the F/R switch when in Reverse.

Pin-4 comes straight from the F/R switch's Reverse contacts through only four connections. Attached schematic has path with F/R in reverse highlighted.

Swap the Orange and Green wires on the F/R and it'll probably run fine in reverse, but not all the time in forward.
Attached Images
File Type: jpg DCX in PDS - In Reverse - Pin-6 traced.jpg (328.7 KB, 0 views)
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Old 01-02-2017, 12:41 PM   #5
Hi-man38
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Default Re: Intermittent loss of reverse

Absolutely correct. When swapped no forward yet reverse worked. In the process of trying this its started working again. I now have 36v on#4 now. What are my options to correct the problem? Thanks
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Old 01-02-2017, 01:16 PM   #6
JohnnieB
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Default Re: Intermittent loss of reverse

Replace the F/R switch.

https://shop.ezgo.com/products/PDS-F...se-Switch.html
You can find them for less on-line.

You can also use most any SPDT/Center-Off switch.

Also, it might have been just a dirty/loose connection between the wire and the tab on the switch.
I'd run it as is and replace switch if it fails again.

Last edited by JohnnieB; 01-02-2017 at 01:18 PM.. Reason: added comments
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Old 01-02-2017, 06:43 PM   #7
Hi-man38
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Default Re: Intermittent loss of reverse

Thanks, you have been awsome help.
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