Need some help with an RXV...

[Obz]

Alright, looking to the GURU's to help me out with something here. I have a 2010 RXV that is having some issues. When I turn the key I don't get a beep nor a click from the solenoid, nothing. I thought maybe it was the controller, so I swapped off of another cart that works great and it has the EXACT same problem. I noticed that when I plug in the motor break I get a click and the cart moves freely (as if in neutral) even when the key is turned to off. I have NO idea what's going on. I figured replacing the controller/solenoid would do the job, but did nothing and the cart is acting the exact same. Ideas guys?

[Obz]

Oh one other item to mention, the brake gets CRAZY hot when plugged in for a little bit. I've also tried the brake on the other cart that works, and it does the same thing.

[BobBoyce]

Check the position of your run/tow switch. If your run/tow switch is in run position, you need to confirm the brake bypass plugs/sockets. You will need to look under the plastic controller cover. You will find 2 pairs of plugs/sockets. For normal operation, #1 plugs into #2, and #3 plugs into #4. If #1 is plugged into #3, then that will hold the motor brake on and released. you would need to plug #1 into #2 and #3 into #4. Here is a rundown of the motor brake circuit.

Positive 48V to the motor brake is fused by Fuse #1 (yellow wires) and is switched by the key switch. It comes out of the key switch on a red wire, passes through the run plug socket (pin 8 to pin 7) comes out (red wire) to Jumper plug #2 (pin B). Jumper plug #2 is plugged into Jumper Socket #1 (pin B). The wire continues (red wire) to the brake switch (pin A). The output from the brake switch (pin B) (white wire) goes to the motor brake plug, which plugs into the motor brake. The negative from the motor brake plug (black/white wire) goes to jumper Socket #1 (pin C) to Jumper Plug #2 (pin C) (black/white wire) to the run plug socket (pin 6 to pin 4) and comes out (black wire) to pin 2 of the controller. The controller applies negative to power on the brake, which releases the brake. If anything is wrong in this chain of wires, it can be traced out. Chances are slim of a failure in the harness like that to apply power to the brake with the key switch off. Probably the jumpers #1/#2/#3/#4 are set wrong.

Here is a wiring diagram.

[Obz]

Originally Posted by BobBoyce

Check the position of rour run/tow switch. If your run/tow switch is in run position, you need to confirm the brake bypass plugs/sockets. You will need to look under the plastic controller cover. You will find 2 pairs of plugs/sockets. For normal operation, #1 plugs into #2, and #3 plugs into #4. If #1 is plugged into #3, then that will hold the motor brake on and released. you would need to plug #1 into #2 and #3 into #4. Here is a rundown of the motor brake circuit.

Positive 48V to the motor brake is fused by Fuse #1 (yellow wires) and is switched by the key switch. It comes out of the key switch on a red wire, passes through the run plug socket (pin 8 to pin 7) comes out (red wire) to Jumper plug #2 (pin B). Jumper plug #2 is plugged into Jumper Socket #1 (pin B). The wire continues (red wire) to the brake switch (pin A). The output from the brake switch (pin B) (white wire) goes to the motor brake plug, which plugs into the motor brake. The negative from the motor brake plug (black/white wire) goes to jumper Socket #1 (pin C) to Jumper Plug #2 (pin C) (black/white wire) to the run plug socket (pin 6 to pin 4) and comes out (black wire) to pin 2 of the controller. The controller applies negative to power on the brake, which releases the brake. If anything is wrong in this chain of wires, it can be traced out. Chances are slim of a failure in the harness like that to apply power to the brake with the key switch off. Probably the jumpers #1/#2/#3/#4 are set wrong.

Here is a schematic.

That's it! It was the plugs. They were plugged in 1/3 and 2/4. Switched them around and everything is running great! Thanks for the help!!

[BobBoyce]

Originally Posted by Obz

That's it! It was the plugs. They were plugged in 1/3 and 2/4. Switched them around and everything is running great! Thanks for the help!!

Glad to hear that was it! Easy fix.

[cgtech]

Bob nailed it again! I was thinking the same thing, but late to the party.