Textron Ezgo RXV-E Troubleshooting Manual Download

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Customer Care

Resistor Temp Sensor Test

Unplug the resistor temperature sensor from the harness.

Place one meter probe in one terminal and the remaining probe

in the other terminal. 0.0 – 0.2 should be observed. If not,

replace the sensor.

Page 3

Summary of Contents for Ezgo RXV-E

Page 1: ...Customer Care RXV E Advanced Trouble Shooting Guide 610873...

Page 2: ...cted 15 16 12833 DC Bus Low 17 19 16912 Motor temp High 20 17168 Heat Sink Temp High 21 20753 15V Supply Low Voltage 22 20755 5V Supply Low or High Voltage 23 25 21008 Current Sensor Offset Calibratio...

Page 3: ...brake Reverse alarm check Controller sounds the alarm for 100ms Charger inhibit check Controller checks the charge receptacle for connection to the charger Throttle switch check Throttle switch must...

Page 4: ...tective equipment Wrap battery wrenches to prevent accidental connection Use a 2X4X12 to spread the load between the jack pad and the composite bumper Always properly lift the vehicle and chock the wh...

Page 5: ...luminate The 1 5 arrows control upward and downward movement of the cursor The 4 button breaks down each menu item to a sub menu The 5 button returns the user to the previous screen The 3 button is us...

Page 6: ...shooting procedures 1 Handheld diagnostic tool PN 606215 2 Digital volt ohm meter DVOM 3 Wire insulation piercing tools 3A Grainger PN 1RK18 or 3B Radio Shack PN 270 334B or equivalent 4 Alligator ad...

Page 7: ...lt 36 56 is 0 throttle 5 4 1v is acceleration range 4 1 4 8 is 100 throttle 4 8v is a fault Pin 10 48v ground output from controller for the reverse buzzer active in reverse and during start up only P...

Page 8: ...SOLENOID COIL TEMP SENSOR MOTOR SENSOR B BATTERY BRK BRK BRAKE BRAKE LIGHTS REVERSE BUZZER TOW SWITCH CHARGER RECEPTACLE SOC METER THROTTLE SWITCH B SOLENOID THROTTLE SENSOR BRAKE SENSOR KEY SWITCH IN...

Page 9: ...Customer Care RXV E Wiring Diagram Page 6...

Page 10: ...ailed motor bearing See pages 33 34 No park brake disengage even in tow position Verify power to the park brake solenoid tow switch or the brake coil driver See pages 17 18 33 34 Roll freely in the ru...

Page 11: ...e may not be observed on either screen Error codes can be accessed using the diagnostic hand held tool Scroll down to the error code screen then press the 4 key to view sub menu codes Error status wil...

Page 12: ...to remaining steps 2 Disconnect all three motor wires Contact the V wire lug to the pos meter terminal A Contact the U lug to the negative terminal B Meter ohm resistance should be 0 0 0 2 If not repl...

Page 13: ...o the negative terminal Meter ohm resistance should be 0 0 0 2 If not replace motor 3 Contact the V wire lug to the pos meter terminal Contact the W lug to the negative terminal Meter ohm resistance s...

Page 14: ...set If not replace battery to solenoid wire 3 Turn key switch to the on position The solenoid should click Place pos meter probe A on bottom solenoid post Place neg meter probe B on 48V battery termi...

Page 15: ...eplace 48V battery wire to B If voltage is still not the same verify steps 2 4 6 Disconnect resistor control module black wire from B on the controller If error status changes replace the resistor mod...

Page 16: ...een large posts replace the solenoid between 1 2v controller has disconnected solenoid If voltage is good go to step 4 A A A B B B 12817 DC Bus High Software Detected Caused by Battery pack voltage is...

Page 17: ...is good go to step 7 12817 DC Bus High Software Detected Continued A B 5 Disconnect resistor control module black wire from B on the controller If error status changes replace the resistor module If e...

Page 18: ...is less than 1V different between large posts replace the solenoid If voltage is 1 2v difference controller has disconnected solenoid due to error or warning Voltage is good go to step 4 A A A B B B 1...

Page 19: ...step 7 A B 5 Disconnect resistor control module black wire from B on the controller If error status changes replace the resistor module If error continues see step 6 7 Try a known good controller if...

Page 20: ...oltage by performing a discharge test Check for 12V accessory taps and verify accessory usage 2 Check all battery terminal connections Torque to 95 105 in lbs 3 Check for less than 0 1 ohms resistance...

Page 21: ...good go to step 6 6 Place pos meter probe A on controller terminal B Place neg meter probe B on controller B Voltage should be the same as the battery set If not replace 48V battery wire to B If volt...

Page 22: ...nty controller Error remains reinstall controller and contact Customer Care Tech Tip Always verify accessories and usage Warranty requires a 48 12v DC to DC converter for all accessories The converter...

Page 23: ...hermo coupler resistance Place pos meter probe A on the pink wire terminal Place neg meter probe on the green black wire terminal Resistance should be 400 ohms and 1300 ohms If faulty replace the moto...

Page 24: ...us or higher 1 Verify controller heat sink surface temperature The temperature should be 80 Celsius 176 Fahrenheit Take temperature here 2 Reduce payload or loading 3 Try a known good controller if er...

Page 25: ...eg probe on the purple wire terminal Depress brake pedal Should observe 12 15 VDC If good replace relay If bad go to step 4 4 Check continuity between the 86 terminal on the harness and pin 22 Purple...

Page 26: ...wire at the 3 position on the controller plug Place neg probe B on the black wire at the 4 position on the controller 23 pin connector 5V should be observed If bad check all 5V components first then t...

Page 27: ...V If good go to step 7 If bad replace sensor 7 Place the pos probe A on the small red wire of the encoder harness Place the neg probe on the small black wire of the encoder harness 5V should be observ...

Page 28: ...be A on the red wire terminal Place neg meter probe B on the black wire terminal 48V should be observed with the key on If bad replace the harness If good go to step 12 12 Check 5V circuit Place pos m...

Page 29: ...0 0 0 2 If not replace motor 2 Contact the V wire lug to the pos meter terminal A Contact the W lug to the negative terminal B Meter ohm resistance should be 0 0 0 2 If not replace motor 3 Contact th...

Page 30: ...tage should be the same as the top solenoid post If voltage is less than 1V different between large posts replace the solenoid Voltage should bleed down slowly when the key is turned off If not replac...

Page 31: ...terminal on the harness and pin 22 Purple wire of the controller23 pin connector 1st Check continuity between 85 terminal of harness and pin 1 Red wire of the controller 23 pin connector 2nd If contin...

Page 32: ...s not return got to step 2 2 Check connection to hand held tool Verify hand held tool function with a known good unit 3 Check wire connections to the CAN plug be removing the cup holder and inspecting...

Page 33: ...e B on the C pin Full continuity should be observed on the multi meter Go to step 2 2 Now place the neg meter probe B on the D pin of the switch The meter should now read full continuity with the key...

Page 34: ...dily increase from 5v to between 4 5V and 4 8V Above 4 8v is a fault If good go to step 4 If bad replace sensor 1 Verify the pedal stop bumper is in the correct position If not correct and secure in p...

Page 35: ...pin 10 and 13 Value should be 0 01 ohms If out of range replace the harness or the alarm 2 Place the pos meter probe A on the red wire of the buzzer harness Place the neg probe B on the black wire 48V...

Page 36: ...eg meter probe B on the remaining terminal Resistance should be 27 ohms 3 ohms If out of range replace the coil driver If good go to step 3 3 Verify friction disk alignment Remove the park brake and i...

Page 37: ...e coil driver by placing the pos meter probe A on the gray wire Place the neg meter probe B on the black wire 12 18V should be observed in the tow position with the key on If good go back to step 1 If...

Page 38: ...f good go to step 3 3 Place pos meter probe A on the green wire of the brake position sensor and place neg meter probe B on the black wire of the brake position sensor Leave harness connected to the s...

Page 39: ...e lower right terminal Battery voltage should be observed If not check loaded battery pack voltage then replace the charge receptacle 2 Place the pos meter probe A on the lower left terminal of the ch...

Page 40: ...eleased Full continuity should be observed with the pedal depressed If continuity is wrong replace the accelerator switch 2 Brake switch is normally closed Disconnect the brake switch harness Place th...

Page 41: ...r Temp Sensor Test 1 Unplug the resistor temperature sensor from the harness Place one meter probe in one terminal and the remaining probe in the other terminal 0 0 0 2 should be observed If not repla...

Page 42: ...his replace the controller 11 Power Reduction This warning occurs in conjunction with motor and heat sink temp warnings This warning indicates that max torque current reduction is in affect 12 Cur Mea...

Page 43: ...__________________________________________ ______________________________________________________________________ ______________________________________________________________________ _______________...

Page 44: ...l may not be reproduced in whole or in part without the express permission of E Z GO Division of Textron Inc Technical Communications Department E Z GO Division of Textron Inc 1451 Marvin Griffin Road...

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