EZGO PDS/ Alltrax DCX 500 no reverse

[wmacree0807]

EZGO PDS with Alltrax DCX 500 controller

Controller will not power on in reverse

Solenoid is not being fed B+ or B- to small posts in reverse

Motor readings:

In Fwd: A1 A2 - Pack Voltage on each / S1 S2: 13.7 v on each

In Reverse A1 A2 - Pack Voltage / S1 S2: 1.7 v on each

Here are the voltages I am getting to controller on the DCX 10 pin harness.

Reverse
Pin 1: .7
Pin 2: 0
Pin 3: 0
Pin 4: 50.2
Pin 5: 0
Pin 6: 0
Pin 7: 0
Pin 8: No wire
Pin 9: 50.2
Pin 10 50.2


Forward
Pin 1: 10.2
Pin 2:0
Pin 3: 0
Pin 4: 0
Pin 5: 50.2
Pin 6: 50.2
Pin 7: 50.2
Pin 8: no wire
Pin 9: 50.2
Pin 10: 50.2

I took this controller/wiring harness out and put on a different pds cart, it worked perfectly.
I took the readings on the 10 Pin DCX wiring harness just to compare

Reverse
Pin 1: 10.7
Pin 2: 0
Pin 3: 0
Pin 4: Pack Voltage 50.2
Pin 5: 0
Pin 6: Pack Voltage 50.2
Pin 7: Pack Voltage 50.2
Pin 8: No wire
Pin 9: Pack Voltage 50.2
Pin 10: Pack Voltage 50.2

Forward
Pin 1: 10.2
Pin 2:0
Pin 3: 0
Pin 4: 0
Pin 5: 50.2
Pin 6: 50.2
Pin 7: 50.2
Pin 8: no wire
Pin 9: 50.2
Pin 10: 50.2

Differences:

Pin 1: .7 vs 10.7
Pin 6: 0 vs 50.2
Pin 7: 0 vs 50.2

I’m losing power to these pins and I don’t know where. Any help would be appreciated.

[JohnnieB]

The controller has to power up first, then the solenoid has to click when the pedal is pushed.

To get controller to power up (LED turning on), you need battery pack voltage on pins 6, 9 and 10. Pins 9 & 10 are good in both F and R, so pin-6 is the issue.

Here are drawings of a DCX in a PDS using the adapter kludge, with the voltage path to pin-6 highlighted. Attch-1 is in F and attch-2 is in R.

I also attached a clean copy of the full DCX in a PDS schematic.

The PDS to DCX adapter works in a different cart, so I suspect there is an issue with pin-2 on the J1 plug that is part of the cart's wiring harness.

[wmacree0807]

Originally Posted by JohnnieB

The controller has to power up first, then the solenoid has to click when the pedal is pushed.

To get controller to power up (LED turning on), you need battery pack voltage on pins 6, 9 and 10. Pins 9 & 10 are good in both F and R, so pin-6 is the issue.

Here are drawings of a DCX in a PDS using the adapter kludge, with the voltage path to pin-6 highlighted. Attch-1 is in F and attch-2 is in R.

I also attached a clean copy of the full DCX in a PDS schematic.

The PDS to DCX adapter works in a different cart, so I suspect there is an issue with pin-2 on the J1 plug that is part of the cart's wiring harness.

Thanks JohnnieB. When I get back to the house I will try and troubleshoot and let you know.

[kgsc]

Starting another thread usually isn’t a good idea but go for it

[scottyb]

Two of the most common causes of a single direction loss in PDS is
1. Controller failure > Swap F1 and F2 at the control if the problem changes direction the controller may have failed.
2. F&R toggle switch failure > Usually caused by corrosion on the terminals on the back of the switch. Clean or replace

[wmacree0807]

Originally Posted by kgsc

Starting another thread usually isn’t a good idea but go for it

Well unfortunately I have no other carts to work on so I have been spending every bit of time trying to figure this out. I always lean on these threads when I have these problems and y’all always come through. I appreciate the help, and I’m sure you have plenty of other things taking up your time but I was needed timely assistance as I’m trying to get this cart back to someone. Also Alltrax is closed for the holidays so my options are limited. Is there a way I can reach out off of the same thread to try and get other people? Because it was up for a couple days and only you were replying. If starting a new thread is frowned upon I get it but I figured a few more heads working together is never a bad idea.

[wmacree0807]

Originally Posted by scottyb

Two of the most common causes of a single direction loss in PDS is
1. Controller failure > Swap F1 and F2 at the control if the problem changes direction the controller may have failed.
2. F&R toggle switch failure > Usually caused by corrosion on the terminals on the back of the switch. Clean or replace

Thanks ScottyB for the suggestion. I finally figured it out. After all the digging it always seems to be something simple. Someone had the wires switched around on the PDS harness that goes to the key switch and FNR. Working as it should now.

[wmacree0807]

[QUOTE=JohnnieB;1868506]The controller has to power up first, then the solenoid has to click when the pedal is pushed.

To get controller to power up (LED turning on), you need battery pack voltage on pins 6, 9 and 10. Pins 9 & 10 are good in both F and R, so pin-6 is the issue.

Here are drawings of a DCX in a PDS using the adapter kludge, with the voltage path to pin-6 highlighted. Attch-1 is in F and attch-2 is in R.

I also attached a clean copy of the full DCX in a PDS schematic.

The PDS to DCX adapter works in a different cart, so I suspect there is an issue with pin-2 on the J1 plug that is part of the cart's wiring harness.[/

Thanks JohnnieB for the help. I finally figured it out. After all the digging it always seems to be something simple. Someone had the wires switched around on the PDS harness that goes to the key switch and FNR. Working as it should now.

[JohnnieB]