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



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Unread 12-30-2017, 04:23 PM   #1
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Default EZGO RXV Brake Operation Proper Sequence

First of all Happy New Year to all.

Hello cgtech, this one is aimed straight at you. I am the go to guy for golf cart repairs at my club. Mostly CC DS, CC Prec, Yamaha G29 and TXT. This is the first diagnosis/repair I have attempted on the RXV. ugh...

This one is a 2012 from our old club fleet, when new fleet was bought. It is a Danaher controller. The cart drives perfect, the brakes work well, the parking brake holds and seems to be working properly, except:

This is the sequence that is happening. When the cart comes to a stop, the parking brake holds. When you put foot on accel to go again, it will not move UNTIL you press the brake again far enough to actuate the brake switch, then it will take off again. If you bring it to a steady stop and as you do, press the pedal down far enough to the switch and then it will run again right away. If aggressively braking to a stop, it would run again. If casually stopping and not using much brake pedal, then the issue appears again and you must press the brake down fully to reset and then go again.

This doesn't seem like normal operation. If it is not, what do you think the problem is?

Thanks for your help.
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Unread 12-30-2017, 10:43 PM   #2
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Default Re: EZGO RXV Brake Operation Proper Sequence

It's not normal operation. Not sure what would cause that. I would surely check out that switch. The motor brabe is actuated by the controller, when chosen by the controller. But, the signal can be interrupted by pressing the brake far enough to hit the interrupt switch.
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Unread 12-31-2017, 12:44 AM   #3
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Default Re: EZGO RXV Brake Operation Proper Sequence

Well, darn, CG. I thought you would snap your thumb and say do this & that and you are good to go.... I have to do some reading up on the operation of the brake system of the RXV, I am so new to it.

There is a brake sensor as well as the brake switch in the wiring drawing I have. Does the brake sensor apply more braking the farther the pedal is pressed? What role does the switch near the far end of brake travel play in the circuit? It didn't release the brake, but it allowed the cart to move when the accel pedal is pushed.

Attached is a pdf of the Curtis Advanced Troubleshooting I am using as a reference because I have not found the same thing for the Danaher controller. I assume that most of the wiring & operation is the same. Page 22 is the wiring drawing.
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File Type: pdf RXV 48V AC Curtis Advanced Trouble-Shooting Guide.pdf (3.26 MB, 0 views)
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Unread 12-31-2017, 01:50 AM   #4
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Default Re: EZGO RXV Brake Operation Proper Sequence

Quote:
Originally Posted by PingEye3 View Post
Well, darn, CG. I thought you would snap your thumb and say do this & that and you are good to go.... I have to do some reading up on the operation of the brake system of the RXV, I am so new to it.

There is a brake sensor as well as the brake switch in the wiring drawing I have. Does the brake sensor apply more braking the farther the pedal is pressed? What role does the switch near the far end of brake travel play in the circuit? It didn't release the brake, but it allowed the cart to move when the accel pedal is pushed.

Attached is a pdf of the Curtis Advanced Troubleshooting I am using as a reference because I have not found the same thing for the Danaher controller. I assume that most of the wiring & operation is the same. Page 22 is the wiring drawing.
While operationally, the Danaher and Curtis controllers behave very similar, the technology and programming are very different. The Danaher controller has a very basic self-test protocol, where every encoder is on a common 5V rail. This means that there is only one encoder test, where throttle encoder, brake encoder, and both halves of the motor speed encoder are all tested together. There is no seperate brake switch test, but there is a motor brake test. Like the Run Plug under the cupholder assembly, the brake switch interrupts the +48V to the motor brake. If the brake switch opens prior to that test, it opens the +48V appearing at the motor brake FET in the controller. That will cause a motor brake test fail. The controller cannot tell if the lack of +48V is caused by a motor brake failure, a brake switch open, a Run Plug missing, or a blown fuse.

The Curtis controller powers on each encoder seperately, tests each encoder output, and probes each switch seperately. It can tell if there is a problem with the motor brake, or if the problem is in the Run Plug/brake switch circuit. This is why there are more pins on the Curtis controller.

With the symptom you are describing, it sounds very much like the motor brake FET is beginning to fail and latch partially on. Pressing the brake pedal to beyond brake pedal encoder value 100% will interrupt brake motor +48V and releasing it restores +48V to the motor brake. This action results in a resetting of the motor brake FET latching. You can verify this by trying another known good Danaher controller and see if the problem is resolved.

If the FET needs replacing, it is not a job for someone without experience in changing surface mount high power FETs. I've done it, but I have experience in this.

Bob
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Unread 12-31-2017, 10:16 AM   #5
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Default Re: EZGO RXV Brake Operation Proper Sequence

Bob, thanks for that explanation. You described the problem to a tee. I could replace that FET with a little instruction help, including getting the exact part needed. But, if I can get my hands on a replacement Danaher controller I will try that first as you suggested.

Thanks for your help.

Happy New Year
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Unread 12-31-2017, 11:03 AM   #6
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Default Re: EZGO RXV Brake Operation Proper Sequence

pm sent.
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Unread 12-31-2017, 11:48 AM   #7
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Default Re: EZGO RXV Brake Operation Proper Sequence



Happy New Year
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Unread 12-31-2017, 03:08 PM   #8
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Default Re: EZGO RXV Brake Operation Proper Sequence

Bob, knowing the situation with the brakes here, would you recommend paying $400 for a used Danaher controller, in hopes of fixing the problem? It was pulled for a 350A Curtis upgrade.
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Unread 12-31-2017, 04:11 PM   #9
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Default Re: EZGO RXV Brake Operation Proper Sequence

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Originally Posted by PingEye3 View Post
Bob, knowing the situation with the brakes here, would you recommend paying $400 for a used Danaher controller, in hopes of fixing the problem? It was pulled for a 350A Curtis upgrade.
It's a good price, they usually go for more. If you can even find one when you need it. It'll give you a controller to test with, then after you fix the other one you'll have a spare.
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Unread 12-31-2017, 04:21 PM   #10
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Default Re: EZGO RXV Brake Operation Proper Sequence

Thanks for the advice, I will take it and get it. If all goes well, I may try and repair the old one.
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