Ezgo RXV New Controller Needed?

[andrewuk311]

Two weeks ago, I was driving my cart (2010 EZGO RxV - Danaher) home and slammed on the brakes at an intersection. After that, the cart would no longer move, would not go in tow mode, and I had to use the plug underneath the cover to disengage the motor brake. I pushed the cart home and read around on this board. It sounded like a motor brake, so I ordered a new brake and replaced it. I even removed it and reinstalled it to ensure I didn’t overtighten it. No luck. When I turn the key, the reverse buzzer sounds and the solenoid clicks once. No twist test.

I just got my cart back from the local shop and they told me the fault codes are 1. Drive fault and 2. AC short circuit. They indicated a new controller is needed.

My question is does this sound correct, would a controller suddenly fail due to a hard stop? Do these faults indicate a failed controller? Is there a way to test the controller on the cart, or bench test it after removal? Any other suggestions are appreciated.

Thanks!

[BobBoyce]

Originally Posted by andrewuk311

Two weeks ago, I was driving my cart (2010 EZGO RxV - Danaher) home and slammed on the brakes at an intersection. After that, the cart would no longer move, would not go in tow mode, and I had to use the plug underneath the cover to disengage the motor brake. I pushed the cart home and read around on this board. It sounded like a motor brake, so I ordered a new brake and replaced it. I even removed it and reinstalled it to ensure I didn’t overtighten it. No luck. When I turn the key, the reverse buzzer sounds and the solenoid clicks once. No twist test.

I just got my cart back from the local shop and they told me the fault codes are 1. Drive fault and 2. AC short circuit. They indicated a new controller is needed.

My question is does this sound correct, would a controller suddenly fail due to a hard stop? Do these faults indicate a failed controller? Is there a way to test the controller on the cart, or bench test it after removal? Any other suggestions are appreciated.

Thanks!

Can a Danaher controller fail from a hard stop? Yes. When you hit the brake pedal hard, the first thing the controller does is apply full regenerative braking. The rapid voltage rise from that could have damaged the controller prior to the resistor control activating to load down the battery pack. By the time the motor brake locks up, the damage to the controller could have already been done. So it is possible, but not common.

You would need to keep the controller in the cart to test it. Only facilities with a test fixture (like FSIP) can test a controller on the bench. Drive fault and AC short circuit can be caused by a motor failure as well. The motor takes abuse from hard stops as well.

[andrewuk311]

Originally Posted by BobBoyce

Can a Danaher controller fail from a hard stop? Yes. When you hit the brake pedal hard, the first thing the controller does is apply full regenerative braking. The rapid voltage rise from that could have damaged the controller prior to the resistor control activating to load down the battery pack. By the time the motor brake locks up, the damage to the controller could have already been done. So it is possible, but not common.

Thanks Bob, good to know that it is possible! I’m prepared to replace the controller if needed, but want to be certainI’m not going to have an issue with the new controller installed. I’d hate to spend $1k+ on the controller and not fix the problem, or worse, damage another controller.

[BobBoyce]

Originally Posted by andrewuk311

Thanks Bob, good to know that it is possible! I’m prepared to replace the controller if needed, but want to be certainI’m not going to have an issue with the new controller installed. I’d hate to spend $1k+ on the controller and not fix the problem, or worse, damage another controller.

Contact PingEye3, he has a spare Danaher controller that he bought to test an RXV. It's a working controller. Here is his last post about it...

http://www.buggiesgonewild.com/elect...ml#post1467230

Bob

[andrewuk311]

Originally Posted by BobBoyce

Contact PingEye3, he has a spare Danaher controller that he bought to test an RXV. It's a working controller. Here is his last post about it...

http://www.buggiesgonewild.com/elect...ml#post1467230

Bob

Thanks Bob! I’ll see if I can buy that controller off him, much appreciated!