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Old 04-14-2014, 06:15 AM   #1
caokgafamily
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Default DCS No Reverse Limo Cart

Hey EZ GO Guys good morning,

A friend of mine owns a DCS EZGO Limo cart. Everything is stock except for a 400 Alltrax and 3" lift with some 20" tires. His cart has ran well this last year and I finnaly convinced him to replace his wires a month ago. He is happy with the wire replacement and the added performance. He called me up the other day and told me he has no reverse. Long story short, either S2 or S1 has come loose and shorted out with A1 or A2. I know its S1 or S2 because its the stud thats in the brush cap. I told him to pull the motor and bring it over. He couldn't tighten the jam nut. I opened the motor and the S1 or s2 is loose, the wire looks a little hot and it may have come in contact with the spring that pushes the magnet in. The cart runs forward just fine but when you put in reverse no go and Alltrax blinks red.

Any thoughts what I should do to fix. No pics yet..
Thanks,
Steve
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Old 04-14-2014, 08:36 AM   #2
JohnnieB
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Default Re: DCS No Reverse Limo Cart

Typically, if a sepex drive cart like a DCS goes in one direction but not the other, either the controller bad the F/R switch isn't telling the controller to change the direction of current flow through the field windings.

All the cables and components used in reverse are also used in forward, so having the LED on the controller blinking Red only in reverse is odd.

How many times does it blink Red?
The error codes are listed on page-3 of the attached.

Also check for worn through insulation on the F1 & F2 cables where they are routed around the battery box.

FWIW: The A1 & A2 studs are located on the end cap while the S1 & S2 (aka F1 & F2) studs are on the motor case.
Attached Images
File Type: jpg Worn field wire insulation.jpg (593.6 KB, 0 views)
Attached Files
File Type: pdf Doc100-005-B_OP-DCX-Operators-Manual.pdf (97.2 KB, 0 views)
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Old 04-14-2014, 08:44 AM   #3
caokgafamily
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Default Re: DCS No Reverse Limo Cart

Johnnie,

Thank you!

Steve
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Old 04-14-2014, 09:06 AM   #4
scottyb
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Default Re: DCS No Reverse Limo Cart

Likely the controller is fried.
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Old 04-14-2014, 09:35 AM   #5
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Default Re: DCS No Reverse Limo Cart

Scotty,

But the cart runs fwd just fine, so how can the controller be fried?

Steve
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Old 04-14-2014, 11:57 AM   #6
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Default Re: DCS No Reverse Limo Cart

Quote:
Originally Posted by caokgafamily View Post
Scotty,

But the cart runs fwd just fine, so how can the controller be fried?

Steve
I'm not Scotty, but I know the answer to your question.
A Sepex (SEParately EXcited) controller is two controllers in one box.
The higher ampacity of the two, feeds the Armature windings and the lower ampacity one (about 1/10 the ampacity), feeds the Field (aka Stator) windings.

The smaller controller that feeds the Field is the also the one that sends the current through the winding it feeds in the opposite direction to make the motor rotate CCW instead of CW (or CW instead of CCW).

Since both controllers are in the same box, if either is bad, the whole box is bad.

------------
The controller is generating an error code (Flashing Red LED), which tells us what the controller thinks the problem is. Following up on that error code will tell us if something external to the controller is causing a problem.

---------
If the motor has a loose wire in it and it has shorted the Field windings to the Armature winding, there is a very good chance that the controller was taken out when that happened.

Also, if the battery cables were disconnected or were connected (or any other wiring) while the Run/Tow switch was in Run, the controller may have been damaged and subsequently failed.
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Old 04-14-2014, 12:02 PM   #7
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Default Re: DCS No Reverse Limo Cart

Johnnie,

Thanks for answer, I will have him count the flashes once I clean up his motor and get it back to him for reinstall.

Thanks again.
Steve
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Old 04-14-2014, 12:42 PM   #8
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Default Re: DCS No Reverse Limo Cart

Well I called my buddy and he did count the blinks. 5 Red..
5 red = Open field circuit. Check field connections and motor’s field resistance.

Your thoughts.

Thanks,

Steve
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Old 04-14-2014, 01:06 PM   #9
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Default Re: DCS No Reverse Limo Cart

Quote:
Originally Posted by caokgafamily View Post
Well I called my buddy and he did count the blinks. 5 Red..
5 red = Open field circuit. Check field connections and motor’s field resistance.

Your thoughts.

Thanks,

Steve
Since the cart runs forward, I suspect the MOSFETs that feed the field windings in reverse are blown.
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Old 04-14-2014, 01:08 PM   #10
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Default Re: DCS No Reverse Limo Cart

Thank you very much

The answer was in the original post.
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