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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Unread 11-09-2016, 06:18 AM   #1
Not Yet Wild
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Location: South East UK
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Default RXV fault and rebuild

Hi to all,
I am a new owner in the UK of a non running 2011 Ezgo RXV 48v buggy.
I am seeking advise as to which route to go on the diagnosis of the fault/s on the electrics. I put my hands up as I have not had much exposure to a multi meter and where to start? I have a sneaky feeling that the controller is duff? That is just a guess from all the info I have tried to absorb on the type of failure I have?
What I am asking is is there a really easy (Dummies) procedure to track down if it is a soleniod or controller fault,or both? (As a matter of course I am going to check and clean up every connector and terminal before getting stuck into the fault finding process).
In the meantime I have stripped down the buggy to the frame although have left wiring as undisturbed as possible. The batteries/on board charger appear good and I have 12.5 volts reading out of each of them after charging before the strip down.
If for instance ,I find it is the controller would it be wiser to go for a new unit (ie not oem) or as I see some companies will take your core and test / repair?
Any thoughts and advise would be really appreciated.

Many thanks.

Mcalan
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Unread 11-09-2016, 06:49 AM   #2
Gone Wild
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Default Re: RXV fault and rebuild

Quote:
Originally Posted by mcalan View Post
Hi to all,
I am a new owner in the UK of a non running 2011 Ezgo RXV 48v buggy.
I am seeking advise as to which route to go on the diagnosis of the fault/s on the electrics. I put my hands up as I have not had much exposure to a multi meter and where to start? I have a sneaky feeling that the controller is duff? That is just a guess from all the info I have tried to absorb on the type of failure I have?
What I am asking is is there a really easy (Dummies) procedure to track down if it is a soleniod or controller fault,or both? (As a matter of course I am going to check and clean up every connector and terminal before getting stuck into the fault finding process).
In the meantime I have stripped down the buggy to the frame although have left wiring as undisturbed as possible. The batteries/on board charger appear good and I have 12.5 volts reading out of each of them after charging before the strip down.
If for instance ,I find it is the controller would it be wiser to go for a new unit (ie not oem) or as I see some companies will take your core and test / repair?
Any thoughts and advise would be really appreciated.

Many thanks.

Mcalan
If you can find someone with a handheld RXV diagnostic tool in your region, it would help to locate any issues. They are very expensive to buy. The RXV is the most complex modern golf cart from E-Z-GO. It is essentially a 3 Phase AC microchip controlled drive-by-wire system and differs greatly from Series and PDS type drive systems. This complexity makes it difficult to troubleshoot without the proper tools and knowledge.

There are no aftermarket controllers that are plug and play for the RXV. You can buy a brand new 2016 Curtis RXV controller for $275 USD + shipping from a seller on eBay. I've bought several because it is the most logical option for replacement of a defective controller. A 2011 RXV has the Danaher controller, while an RXV mafufactured on Feb 23 2012 or later would have the Curtis controller. The Danaher version wiring harness can be changed out with a new Curtis one from E-Z-GO, the part number is listed in an earlier thread by me on this subject. If you have good electrical skills, you can buy the 35 pin Curtis connector and convert the harness. If you search earlier threads by me, I give all of the details and wiring diagrams to make this conversion possible.

The most common failure mode on the RXV is EM motor brake failures. Next is connection and/or corrosion issues in the wiring harness or its connectors. Then there is other component failure, such as solenoid or key switch. Your first test would be to remove the plastic cover over the controller location and check the fuse(s) underneath the cap(s). Earlier RXVs only have one fuse, later models have 2. The caps have 2 leads, 2 yellow wires on the one and 2 red wires on the added one. These fuses are inline with the power to the controller logic section (yellow) and the switched power (red) circuits.

Bob
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Unread 11-09-2016, 07:12 AM   #3
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Default Re: RXV fault and rebuild

Thanks for that info Bob. I do have the Danaher type controller as you say.
Interesting that you mention the EM motor brake feature as a possible fault. I will start there perhaps?
As far as I can tell of the "top of my head" the soleniod "clicked" but the brake feature had to released by plugging connector 1 into 3 to get the cart to move when it was delivered.
I will look through your previous postings for guidance.

In the meantime thanks very much

Mcalan
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Unread 11-09-2016, 09:08 AM   #4
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Default Re: RXV fault and rebuild

also check cgtech and HiTechRedNeck

(Shameless plug)
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Unread 11-10-2016, 05:41 AM   #5
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Default Re: RXV fault and rebuild

Hi again, and Thanks to Bob and Cg for your input.

I take on board the how complex the rxv series is. On hind site I would have left alone apart from the fact it was dirt cheap and in overall good shape.
I am trying to get my head round the expense of having to get a $8/900 dollar hand held before I even begin.
I would hazard a guess we don't have anything like the following and numbers here in the UK for anything Buggies?

That said I am trying to find a tech guy with diag and more knowledge on these than I, to help out as I write .
I was wondering if it would be possible to dump the existing system and replace motor/ controller and all the other electrics and upgrade so to speak with kit that can be more easily maintained?
If I have to spend out I would rather do so and get an up graded system . Would that be possible? Perhaps you guys can laugh me out of the park with that idea but I was just thinking???
Failing that I will go back to plan A and poke up with going the curtis and conversion route. I am of the mind to deffo dump the Danaher unit and start over.
Many thanks again for your help and input.
Mcalan
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Unread 11-10-2016, 08:15 AM   #6
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Default Re: RXV fault and rebuild

I have done what you describe. I think its more of a pain than you are wanting to do. I had to weld brackets to the axle for installing brakes & buy a "gas rxv" brake pedal & cables. Have a look under the back, there are no brakes. I suggest you download the "danaher rxv troubleshooting guide" for you to study. It is intended to help you "decode the codes provided by the programmer", but it has alot for you to learn about how a rxv is supposed to work & lots of electrical tests. Better brush up on those voltmeter skills. The conversion I was speaking of was to a system not intended for RXV, not the update to the curtis system for rxv. I dont think you should jump ship to the curtis system yet, that job makes the programmer look cheap, and the danaher programmer wont work with the curtis system (keep that in mind when considering buying handheld).
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Unread 11-10-2016, 09:03 AM   #7
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Default Re: RXV fault and rebuild

Thanks for that CG,
I will now go and ponder? I am in no rush,(winter project etc) and will do some studying on the type.
This site is brilliant and thank you again.
Mcalan
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Unread 12-06-2016, 04:06 AM   #8
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Default Re: RXV fault and rebuild

Hi again Bob ,CG and all.

Now having stripped and cleaned up everything on my RXV, I have thrown it all back together.
In the meantime I took in some of the advise kindly given up and found a Ezgo service agent a few miles from me.
Primarily, to see if I can get hold of a hand held can bus reader. One thing lead to another and I am thinking about putting the job over to them to get this buggy fired up again.

(As a precaution I did as Bob informed found the Ebay seller and got a shiny new Curtis controller sent over last week).In case the Danaher unit is duff.

Any ways the tech guy I am talking to is giving me a ball park of 8 hours to change over the controllers and install a new loom to suit if the current set up is no good.

Now I know I haven't spent any time testing anything( but for the batteries which give a healthy 12.6 v read out each), as I speak but to "those in the know" know is 8 hours labour excessive?

I only ask as it took me a half hour to re- asemble and install all the wiring. Is testing and setting up really going to take that long would you think?

Regards for now Mcalan
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Unread 12-06-2016, 03:46 PM   #9
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Default Re: RXV fault and rebuild

Quote:
Originally Posted by mcalan View Post
Hi again Bob ,CG and all.

Now having stripped and cleaned up everything on my RXV, I have thrown it all back together.
In the meantime I took in some of the advise kindly given up and found a Ezgo service agent a few miles from me.
Primarily, to see if I can get hold of a hand held can bus reader. One thing lead to another and I am thinking about putting the job over to them to get this buggy fired up again.

(As a precaution I did as Bob informed found the Ebay seller and got a shiny new Curtis controller sent over last week).In case the Danaher unit is duff.

Any ways the tech guy I am talking to is giving me a ball park of 8 hours to change over the controllers and install a new loom to suit if the current set up is no good.

Now I know I haven't spent any time testing anything( but for the batteries which give a healthy 12.6 v read out each), as I speak but to "those in the know" know is 8 hours labour excessive?

I only ask as it took me a half hour to re- asemble and install all the wiring. Is testing and setting up really going to take that long would you think?

Regards for now Mcalan
I don't know of any shop that would be willing to put forth the effort to convert a Danaher harness over to be Curtis compatible. They would just buy a new harness assembly from E-Z-GO, and you really don't want to know how much that will cost you. By the time they were done, you could buy a whole off-lease RXV for what your bill could be.

As for the time it takes to just install a controller and harness, 8 hours is excessive. I've done it in under 2 hours. Converting a harness from Danaher to Curtis takes me about an hour, but that is because I've done so many of them. The first one took me about 4 hours because I was being overly careful and using a meter to trace every wire and documenting everything.

Whichever way you go, I wish you luck with your project.
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Unread 12-07-2016, 08:40 AM   #10
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Default Re: RXV fault and rebuild

I agree with your thoughts Bob,
If the cost of a harness is anything like the hundreds of dollars that EZGO put on there site for other types, It wont be me buying one!
Looks likely that I will be following your posts and doing the conversion.
The only bug now is trying to borrow, blag or buy a curtis hand held unit
(that's assuming I realy need one ) But I would like to be able to program the cart to get 19 mph out of her.
Decisions ,Decisions?.

Thanks again
mcalan
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