DCX 300 Amp Controller No LED

[gunnardog]

My friend has a 2001 EZGO TXT PDS with an Alltrax DCX 300 controller on it.

They were driving it and it lost power. We pulled it into the garage and started testing a few things.

When the key is turned on the solenoid doesn't energize and click nor does the Controller LED blink to show any error code.

We checked each battery voltage and all batteries are holding good charge with 38 plus volts for the pack. Cables are all good and 4 ga.

We checked the reed switch and no problem there.

It was towed with the T/R switch in tow mode.

Any help would be greatly appreciated!

[usgicollector]

Originally Posted by gunnardog

My friend has a 2001 EZGO TXT PDS with an Alltrax DCX 300 controller on it.

They were driving it and it lost power. We pulled it into the garage and started testing a few things.

When the key is turned on the solenoid doesn't energize and click nor does the Controller LED blink to show any error code.

We checked each battery voltage and all batteries are holding good charge with 38 plus volts for the pack. Cables are all good and 4 ga.

We checked the reed switch and no problem there.

It was towed with the T/R switch in tow mode.

Any help would be greatly appreciated!

1. Solenoid doesn't click till the pedal is pushed.

[scottyb]

PDS solenoid will initially click in and drop out when the ignition is turn on. Don't ask why they just do.

Try tracing the rest of the solenoid activation circuit shown in red here... For the alltrax application you will need power (+) at pins #5,6,9,10 to run. Get the solenoid to click and the cart should run again. This could be a supply problem or a control problem.
Is there power at pins 9,10 ?

[JohnnieB]

Here is a schematic of a DCX in a PDS showing the voltages needed to get the solenoid to click traced through the adapter.

Does the LED blink green four times and then go to steady green?

[gunnardog]

Originally Posted by scottyb

PDS solenoid will initially click in and drop out when the ignition is turn on. Don't ask why they just do.

Try tracing the rest of the solenoid activation circuit shown in red here... For the alltrax application you will need power (+) at pins #5,6,9,10 to run. Get the solenoid to click and the cart should run again. This could be a supply problem or a control problem.
Is there power at pins 9,10 ?

ScottyB thanks. That is the click I was referring to is when you energize the controller and the solenoid cycles once.

Ok I will get to testing voltages and let you know what happens. Thanks!

[gunnardog]

Originally Posted by JohnnieB

Here is a schematic of a DCX in a PDS showing the voltages needed to get the solenoid to click traced through the adapter.

Does the LED blink green four times and then go to steady green?

JohnnieB, thanks for the schematic. I will be using that in about 5 mins!

Muchas Gracias!!

[scottyb]

Da Nada

[gunnardog]

Originally Posted by scottyb

PDS solenoid will initially click in and drop out when the ignition is turn on. Don't ask why they just do.

Try tracing the rest of the solenoid activation circuit shown in red here... For the alltrax application you will need power (+) at pins #5,6,9,10 to run. Get the solenoid to click and the cart should run again. This could be a supply problem or a control problem.
Is there power at pins 9,10 ?

Key off, 9 & 10 are pack voltage
Key on, 6,7,9 & 10 are pack voltage
No voltage on pins 1-5 in either case

Does this mean dead controller?

[gunnardog]

Originally Posted by JohnnieB

Here is a schematic of a DCX in a PDS showing the voltages needed to get the solenoid to click traced through the adapter.

Does the LED blink green four times and then go to steady green?

JohnnieB there is no LED light action at all. Not 4 blinks for the PDS programming and no solid green LED. The LED has not illuminated since the problem started.

[JohnnieB]

Originally Posted by gunnardog

Key off, 9 & 10 are pack voltage
Key on, 6,7,9 & 10 are pack voltage
No voltage on pins 1-5 in either case

Does this mean dead controller?

Originally Posted by gunnardog

JohnnieB there is no LED light action at all. Not 4 blinks for the PDS programming and no solid green LED. The LED has not illuminated since the problem started.

Voltage to Pins 9 & 10 comes from the Run/Tow switch.
Voltage to Pin-6 comes from the keyswitch, via the F/R switch.
With voltage on Pins 6, 9 & 10, the LED should blink a number of times (Indicating what the throttle type setting is. 4 blinks = ITS) and then stay on steady green.

At this point, the controller is powered up and applying pack voltage to Pin-5 (Pressing the pedal) will tell the controller to connect Pin-7 to B-, which energizes the solenoid.

The voltages needed to power-up the controller (Green LED on) appear to be there, but the controller is not turning on. This points to the controller being bad, but I'd do some more checking before declaring it bad.

Instead of connecting the DVM's negative test lead to the main negative terminal on the battery pack, connect it to the B- terminal on the controller and recheck the voltages on Pins 6, 9 & 10. If they still have pack voltage on them, the controller is not powering up when it is being told to do so.

I suspect the reason no voltage was measured on Pin-5 is because the pedal was not pushed at the time. However, Pin-5 is not needed to turn the controller on, it just tells it to activate the solenoid after the controller is turned on.

Also, when measuring the voltages, slightly lift the 10-pin connector on top of the DCX and measure on the actual pins themselves.