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Old 11-13-2015, 04:08 PM   #1
devybob
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Default Replaced controller

I replaced my dcx400 controller with a known good one from another cart. {Borrowed} I still can't get the solenoid operating so the cart will not run. I checked the solenoid and I have full pack voltage on both small terminals. Went to check pins #5, 6, 9 and 10 and found full pack voltage on #5 but nothing on pin#6,9 or 10. Where do I go from here?
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Old 11-13-2015, 04:19 PM   #2
scottyb
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Default Re: Replaced controller

Check run tow switch power source and operation
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Old 11-13-2015, 05:02 PM   #3
devybob
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Default Re: Replaced controller

Checked all 4 terminals on run tow switch and all 4 terminals have full pack voltage.
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Old 11-13-2015, 07:51 PM   #4
scottyb
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Default Re: Replaced controller

Okay well what kind of cart are you asking about? And do you have the wiring diagram?
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Old 11-13-2015, 09:16 PM   #5
devybob
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Default Re: Replaced controller

I have a 2005 western golf cart,42 volt, alltrax dcx400 controller,HD solenoid,4 gauge battery cables and only have a ezgo wiring diagram.
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Old 11-14-2015, 10:07 AM   #6
devybob
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Default Re: Replaced controller

I also have the DCX to EZGO PDS wiring diagram.
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Old 11-14-2015, 10:14 AM   #7
JohnnieB
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Default Re: Replaced controller

A 2005 Western with a SepEx motor is probably based on a EZGO PDS cart, so is there a PDS to DCX adapter between the cart's wiring harness and the DCX controller? (See attached picture)

Or does a plug from the cart's wiring harness plug directly onto the 10-pin connector on top of the DCX controller? (That would mean it is based on a EZGO DCS Cart)

Once we figure out whether it is based on a PDS or a DCS drive system, I can help you troubleshoot it.
Attached Images
File Type: jpg 015_15-s.jpg (8.5 KB, 0 views)
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Old 11-14-2015, 10:36 AM   #8
devybob
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Default Re: Replaced controller

I have the adapter plug installed.
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Old 11-14-2015, 11:49 AM   #9
JohnnieB
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Default Re: Replaced controller

Okay, it is PDS based.

Attached are five schematics for a DCX installed in a PDS system.

The first is an unmarked schematic.
The second has the voltage path to Pin-6 highlighted.
The third has the voltage path to Pin-9 highlighted.
The fourth has the voltage path to Pin-10 highlighted.
The fifth has the voltage path to Pin-5 highlighted.

You said you had voltage on pin-5, but not on 6, 9 and 10. That is strange since the voltage on pin-5 comes from the pedal switch, which is fed by the voltage that goes to pin-6


I'd start with Pin-10. The voltage source is the battery side large terminal on the solenoid.

Then Pin-9. Voltage source is the reed switch.
Attached Images
File Type: jpg DCX In PDS- Full.jpg (261.0 KB, 0 views)
File Type: jpg DCX in PDS - In Forward - Pin-6 traced.jpg (327.8 KB, 0 views)
File Type: jpg DCX in PDS - Pin-9 traced.jpg (322.7 KB, 0 views)
File Type: jpg DCX in PDS - Pin-10 traced.jpg (321.7 KB, 0 views)
File Type: jpg DCX in PDS - Pedal Switch traced.jpg (330.1 KB, 0 views)
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Old 11-14-2015, 01:40 PM   #10
devybob
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Default Re: Replaced controller

I'm getting very confused about the wire colors,I'm using the same PDS adapter that worked for me for the 3 years I have been using the alltrax DCX 400 controller, but the wires don't seem to be in the same place on the plugs as shown in your photos.DSCN0066.jpg
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