1999 DCS Controller Dead???

[tcascario]

I have a 1999 EZGO DCS Limo converted to 48v 8-6v batteries and alltrax dcx400 controller. My wife was driving cart up a hill at normal speed when it just stopped. Now it wont move at all not even a small jerk. Batteries are full at 51.2v and each individual battery reads 6.4v all connections are tight.

The controller is always in a state of on even if key is off. When tow/run is flipped back to run controller flashes 4 times and then stays solid green even with the key off.

Alltrax troubleshooting says to remove B+ and M- and connect dvm to see if it powers up when tow/run is switched or when key is turned. Mine powers up with tow/run switch. The troubleshooting says I need a new controller. I just want to make sure others on here feel the same before I drop money on a new one. Thanks.

[scottyb]

Key on, select forward, test leads on M- and B-. When the solenoid clicks you should have pack voltage(50v) this reading should decrease to 0 as the peddle is pushed down.

[tcascario]

ok scotty Checked that and I get 28.3 volts not 50. With pedal depressed volts drop to 0. I also forgot to mention that when I turn the key and place it in forward or reverse the solenoid clicks on and never clicks off until direction put in neutral.

[scottyb]

Can you put a battery cable jumper on the solenoid big terminals and try it?

[tcascario]

I will have to get a battery cable. I do have 51v on battery side of solenoid at all times. The controller side has 50.8v at all times whether the solenoid has clicked or not.

[scottyb]

Originally Posted by tcascario

I will have to get a battery cable. I do have 51v on battery side of solenoid at all times. The controller side has 50.8v at all times whether the solenoid has clicked or not.

You are reading the precharge resistor. Grab a cable and lets eliminate the solenoid from the equation. I have a customer with a PDS cart getting the same 50% reading at B- and M- ... I'm sort of confused by this if the solenoid is good.

[tcascario]

Ok jumped the solenoid with a battery cable and get the same result no movement at all.

[scottyb]

I think your controller has failed.

[tcascario]

Thats what I was afraid of. Thanks for your help.

[tcascario]

OK so I got my new alltrax dcx 400 controller installed today and still have the same problem. Its always on even with key off I only have 28.8v across m- and b- and my cart won't move. My solenoid comes on when key is on and direction is forward or reverse but it never shuts off.