Ezgo RXV Danaher Codes T Shoot Guide 2

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RXV-E Advanced Trouble-Shooting
Guide

610873

Customer Care

Table of Contents

Page

Safety

Hand Held Diagnostic Tool

Special Tool List

Wiring Diagrams

4-6

Symptoms

Error Codes

8976 AC Over Current

9024 AC Short Circuit

12576 DC Bus Timeout

11-12

12817 DC Bus High – Software Detected

13-14

12818 DC Bus High – Hardware Detected

15-16

12833 DC Bus Low

17-19

16912 Motor temp High

17168 Heat Sink Temp High

20753 15V Supply Low Voltage

20755 5V Supply Low or High Voltage
21008 Current Sensor Offset Calibration
21520 Open Drain Output Current High

23-25
26
27-28

33024 CAN Time Out

25104 Direction Error

25105 Throttle Sensor Error

25106 Reverse Alarm Test Failed

25107 Mechanical Brake Test Failed
25108 Brake Sensor Error
Additional Component Testing
Warnings

33-34
35
36-38
39

Customer Care

Vehicle Operation

Understanding the Power-up Sequence
•
•
•
•
•
•
•
•

The car will perform the following checks during the first
second of initial key – on.
Electric brake check – Controller tries to rotate the motor
¼ turn in both directions.
Park brake check – Controller disengages and reengages
the park 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 be open to
pass the start up test.
Throttle position sensor – Controller checks the TPS for 0%
throttle. .38-.56 volt
Throttle operation check – Controller checks the TPS for the
correct open and closed range. .5-4.8v

The car will not run if the controller detects a problem
with any of the circuits above.

Customer Care

Safety
Always wear personal protective equipment

Wrap battery wrenches to prevent accidental
connection.
Always properly lift the vehicle
and chock the wheels to prevent
accidental drive away.

Use a 2X4X12” to spread the load between the jack pad and the composite bumper!

Customer Care
Page 1

Hand Held Diagnostic Tool
Using The Hand Held Tool
•Turn the key switch off.
•Insert the diagnostic tool plug into the
CAN port under the cup holder / console.
•Turn the key on.
•The diagnostic tool screen will
illuminate.
•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 used to enter / reset
selections.

The Hand Held diagnostic
Unit is required for all
testing and warranty
reporting!

The three primary functions used for
electric trouble-shooting are:
• Diagnostic Report
•Errors
•Warnings

Customer Care
Page 2

Tools
The following tools will be required to perform advanced trouble shooting procedures:
1.

Handheld diagnostic tool PN# 606215

Digital volt ohm meter (DVOM)

Wire insulation piercing tools 3A. Grainger PN# 1RK18 or 3B. Radio Shack
PN# 270-334B or equivalent.

Alligator adapter clamps for meter leads Radio Shack PN#270-354 or equivalent.

2
1

3A.

3B.

Customer Care
Page 3

Controller 23 pin connector pin listing with voltages

Pin 1Pin 2Pin 3Pin 4Pin 5Pin 6Pin 7-

48 volt input when key switch is in any position other than off. (FWD, N, REV)
48v switched ground output for electric motor brake.
5v positive output for sensor circuit.
5v ground output for sensor circuit.
5v signal input from the motor encoder. 0-5 volt variable
5v signal input from the motor encoder. 0-5 volt variable
5v signal input from the brake sensor. 0-.35v is a fault, .36-3.78 is linear braking, 3.78-4.8
is 100% braking, >4.8v is a fault.
Pin 8- 48v can ground, internal 48v ground.
Pin 9- 5v signal input for the accelerator sensor. 0-.35v is a fault, .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.
Pin 11- 5v signal wire output for SOC meter. .5v at empty, 4.5v at full reading.
Pin 12- 48v positive input from key switch for forward.
Pin 13- 48v input for run/tow switch.
Pin 14- 48v positive input for resistor circuit.
Pin 15- Output CAN low.
Pin 16- 5v positive for motor temp sensor.
Pin 17- 48v positive input for charger interlock. 0v with charger plugged in. 21-28v with charger
unplugged.
Pin 18- 48v output ground circuit for the solenoid.
Pin 19- 48v positive input from accelerator switch.
Pin 20- 48v input from key switch for reverse.
Pin 21- 48v ground for the resistor control circuit.
Pin 22- 15v output for the brake light circuit.
Pin 23- Can buss high for hand held.

Customer Care
Page 4

RESISTOR
CONTROL

BLK

ORG
ORG

BI-METAL
SWITCH

BLK

SOLENOID
COIL

RED

PURPLE/WHT

PINK

2
10

5
20

6
21

7
15

BLK

RED

BLK

GRN

REVERSE
BUZZER

BRAKE
LIGHTS

ORG/RED

BBATTERY

RESISTOR

PURPLE

BLK/WHT

GRN/BLK

TEMP
SENSOR

WHT

GRAY

RED

TOW
SWITCH

BLK

RED

BRK (-)

BLK/WHT

BRK (+)
A

BRAKE

RED/WHT

11
19

MOTOR
SENSOR
D C

3
18

ORG
17

BLU/WHT
BLK

C B A

RED
LT.GRN

BLK
ORG

C D

BLK
BLK

RED
BLK

RED

BLK/WHT

RED/WHT
BLK/WHT

3
11
9

BLK

RED

BLK/WHT

6
21

WHT

BLK

RED

INLINE
FUSE #2

RED

B+
BATTERY

RED

RED/WHT

ORG/RED

BLK/WHT

LT GREEN

B A

CAN
INTERFACE
FRONT VIEW
OF CONNECTOR

RED

GRAY

PURPLE/WHT

PURPLE

BLUE/WHT

GRN

ORG/RED

BLK

CBA

ORG
BLK

A BC

C
B
A

YEL

RED

CHARGER
RECEPTACLE

BLK
RED
YEL

BLK

BLK
WHT

Page 5

KEY SWITCH
A

YEL

RED

BLK

LT.BLUE

GRAY

YEL

PNK
LT . BLUE

GRAY

LT . BLUE

Customer Care

BRAKE
SENSOR
C B A
THROTTLE
SENSOR

INLINE
FUSE #1
A B YEL
RED
RED

WHT
BLK
D C
E B
F A

SOC
METER

RED

RED
RED
WHT

YEL

4
NC
8

RED

B+
SOLENOID

POWER
BRAKE
LIGHT
RELAY

THROTTLE
SWITCH

BRAKE
SWITCH
B

RED

2
8

4 5
7

GRN/BLK
RUN
PLUG
FRONT VIEW
OF CONNECTOR

A BC

RXV – E Wiring Diagram

LT.BLUE

RXV – E Wiring Diagram

Customer Care
Page 6

Symptoms
Crawling: Vehicle runs extremely slow. Slower than limp home. Check motor encoder. See
pages 24 - 25
Rapid solenoid engage – disengage: Occurs when the key is on and the charger is
plugged in. Check key switch and charger receptacle for failed interlock. See pages 30 & 36
Motor shuttering: Check for loose connections on the V,U,&W. Check encoder
connections and park brake harness connections. Verify throttle sensor. Inspect for dragging
park brake. Compare command speed with actual speed on the hand held. RPM should
almost be the same. If not suspect the motor or a mechanical blockage. Compare DC amp
draw and AC current. AC current should be around 50% lower than DC. If not, suspect
motor or mechanical blockage. See pages 9,10, 23, 24, 25, 33, & 34
Metallic Motor noise: Inspect for dragging park brake or failed 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 run position then lock after a few feet: Verify brake coil driver and
alignment. See pages 33 & 34
Excessively loud reverse alarm: Check for DC Bus High. See pages 13 - 16
Excessively soft reverse alarm: Check for DC Bus Low or a failed reverse buzzer. See
pages 17,18 & 32
Car goes into limp home mode: Check for DC Bus Low. See pages 17 - 19
Solenoid engages once then disengages: Happens as a result of damage in 5V circuit.
Verify brake & throttle sensors, motor encoder, SOC meter, controller. See pages 23 - 25
Charger does not turn on: Verify charge receptacle, DC cord, AC power or charger.
Vehicle does not run or engage solenoid: Check the fuse, charge receptacle, and key
switch. See pages 30 & 36
Vehicle does not run and the hand held tool will not turn on – Verify key switch voltage
and can plug connections. See page 29 & 30

Customer Care
Page 7

Error Codes
Notes:
•If the car is experiencing an error at the time of diagnostics, the error can
be viewed on the error status screen.
•If the car is not currently experiencing the error, but has in the past; the
error can be viewed in the error log screen.
•If the failure is electrical in nature, an error will appear in the status or log
screen.
•If the fault is mechanical in nature or a design function of the vehicle; an
error code 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 will show current active faults.
Example codes: Shown are examples of
error codes stored in the error log. The
log can hold up to 7 entries. Errors will
remain in the log after a repair has been
made. LTIME represents when a fault
occurred in vehicle life time minutes which
is listed as CPU time n the battery status
screen. LTime is the last time this error occured.
Only the Ltime will update if the code is already
listed on this screen.

Customer Care
Page 8

8976 AC Over Current
Caused By: Software detects motor current 50% higher than controller
peak rated current.
1. Turn key off and back on
to reset the controller. If car
runs, return to service. If
not, proceed to remaining
steps.

B
A
A

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, replace motor.

3. 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.

4. Contact the U 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.

Customer Care
Page 9

5. Try a known good controller if error is
gone, warranty controller. Error remains,
reinstall controller and contact Customer
Care.

9024 AC Short Circuit
Caused by: Short circuit detected in controller, motor cables, motor, or failed solenoid.

1. Turn key off and back on
to reset the controller. If car
runs, return to service. If
not, proceed to remaining
steps.

B
A
A

2. Disconnect all three motor wires.
Contact the V wire lug to the pos. meter
terminal. Contact the U lug to 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
should be 0.0 – 0.2. If not, replace motor.

4. Contact the U wire lug to the pos.
meter terminal. Contact the W lug to the
negative terminal. Meter ohm resistance
should be 0.0 – 0.2. If not, replace motor.

5. Try a known good controller if error is
gone, warranty controller. Error remains,
reinstall controller and contact Customer Care.

Customer Care
Page 10

127576 DC Bus Timeout
Caused by: DC voltage has not reached 24 volts within 10 seconds after
key switch start.

B
B
A
A
1. Place pos. meter probe A on +48V
battery terminal. Place neg. meter probe B
on -48V battery terminal. Voltage should
read 42V minimum. If not, charge batteries.
If good, proceed to the following steps.

2. Place pos. meter probe A on top
solenoid post. Place neg. meter probe
B on -48V battery terminal. Voltage
should be the same as the battery 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
terminal. Voltage should be the same as
the battery set and the top solenoid post. If
voltage is >1V different between large
posts, replace the solenoid. If voltage is
1-2 volts controller has disconnected solenoid.
Voltage good proceed to step 4.

Customer Care
Page 11

4. Place pos. meter probe A on
controller terminal B+. Place neg.
meter probe B on -48V battery
terminal. Voltage should be the same
as the battery set. If not, replace the
solenoid to controller wire.

127576 DC Bus Timeout
Continued

Resistor control wire

5. 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 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 module. If error continues, see
step 7.

7. Try a known good controller if error is gone warranty
controller. Error remains reinstall controller and
contact Customer Care.

Customer Care
Page 12

12817 DC Bus High – Software Detected
Caused by: Battery pack voltage is over 67 volts. Field faults come from
excessive regenerative energy not being controlled by the resistor circuit.

B
B
A
A
2. Place pos. meter probe A on top
solenoid post. Place neg. meter probe
B on -48V battery terminal. Voltage
should be the same as the battery set.
If not, replace battery to solenoid wire.

1. Verify battery pack voltage at the
time of fault. Voltage should be <63V.
Also verify charger output is not over
67.2V

A
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
terminal. Voltage should be the same as
the battery set and the top solenoid post. If
voltage is less than 1V different between large
posts, replace the solenoid. between 1-2v
controller has disconnected solenoid.
If voltage is good go to step 4.

Customer Care
Page 13

4. 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 voltage is still not the
same verify steps 2 – 4.

12817 DC Bus High – Software Detected
Continued

Resistor control wire

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.

6. Place pos. meter probe A on one
resistor tab and neg. meter probe B
on the remaining tab. Verify 0.2 – 0.5
ohms. If resistance is out of spec.
replace resistor. If resistance is good,
go to step 7.

7.Try a known good controller if error is gone, warranty
controller. Error remains, reinstall controller and
contact Customer Care.

Customer Care
Page 14

12 818 DC Bus High – Hardware Detected
Caused by: Battery Pack voltage is over 67 volts.

B
B
A
A
2. Place pos. meter probe A on top
solenoid post. Place neg. meter probe
B on -48V battery terminal. Voltage
should be the same as the battery set.
If not, replace battery to solenoid wire.

1. Verify battery pack voltage at the
time of fault. Voltage should be <63V.
Also verify charger output is not over
67.2V

A
3. Turn key switch to the on position. The
4. Place pos. meter probe A on
solenoid should click. Place pos. meter
controller terminal B+. Place neg.
probe A on bottom solenoid post. Place
meter probe B on controller B-.
neg. meter probe B on -48V battery
Voltage should be the same as the
terminal. Voltage should be the same as
battery set. If not, replace -48V battery
the battery set and the top solenoid post. If
wire to B-. If voltage is still not the
voltage is less than 1V different between large
same verify steps 2 – 4.
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.

Customer Care
Page 15

12 818 DC Bus High – Hardware Detected
Continued

Resistor control wire

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.

Resistor Control Module
7. Try a known good controller if error
is gone, warranty controller. Error
remains, reinstall controller and
contact Customer Care.

Customer Care
Page 16

12833 DC Bus Low – Software Detected
Caused by: Controller DC Bus voltage has dropped below 18 volts.

A
1. Verify proper open circuit battery
voltage. Should be 48V or higher at the
time of testing. Verify loaded voltage by
performing a discharge test. Check for
12V accessory taps and verify accessory
usage.

2. Check all battery terminal
connections. Torque to 95 – 105 inlbs.

3. Check for less than 0.1 ohms
resistance on each battery wire.

4. Place pos. meter probe A on top
solenoid post. Place neg. meter probe
B on -48V battery terminal. Voltage
should be the same as the battery set.
If not, replace battery to solenoid wire.

Customer Care
Page 17

12833 DC Bus Low – Software Detected
Continued

B
A
5. 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
terminal. Voltage should be the same as
the battery set and the top solenoid post. If
voltage is less than 1V between large
posts, replace the solenoid. If voltage drop
is 1-2v controller has disconnected solenoid.
Voltage is good go to step 6.

Resistor control wire

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 voltage is still not the
same verify steps 2 – 5.

8. Place pos. meter probe A on one
resistor tab and neg. meter probe B
on the remaining tab. Verify 0.2 – 0.5
ohms. If resistance is out of spec.
replace resistor. If resistance is good,
go to step 9.

7. Disconnect resistor control module
black wire from B- on the controller. If
error status changes, replace the
resistor module. If error continues, see
step 8.

Customer Care
Page 18

12833 DC Bus Low – Software Detected
Continued

Tech Tip:
Always verify accessories and
usage. Warranty requires a 4812v DC to DC converter for all
accessories. The converter will
allow equal accessory draw on
all four batteries.
Resistor Control Module
9. Replace resistor control module with
known good unit. Module may be
staying “on” which causes a drain on
the battery set. Resistor coil will be hot
if the module is on. If module checks
good, go to step 10.

Tech Tip: V56 eliminates this feature
The RXV-E car is designed to
default to the “Limp home mode” at
25% SOC. The vehicle will shut
down completely at 20% SOC. If
this happens in operation, perform
a discharge test on the batteries
and check the charge history on
the hand held tool.

Customer Care
Page 19

10. Try a known good controller if error is
gone, warranty controller. Error remains,
reinstall controller and contact Customer
Care.

16912 Motor Temp High
Caused by: Overloaded vehicle or motor temp reaching 120 Celsius or
higher.

A
1. Check motor surface temperature
for 120 Celsius. (248 Fahrenheit) If
cold, go to step 2. If hot, reduce
loading.

2. Verify thermo-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
motor. If good, and the fault still
appears in Error Status, Try a known good
controller, if error is gone warranty
controller. Error remains, reinstall controller
and contact Customer Care.

Maximum allowed 1 leading 3 trailing

Customer Care
Page 20

17168 Heat Sink Temp High
Caused by: Overloaded vehicle or controller reaching 100 Celsius or higher.

Take temperature here.

1. Verify controller heat sink surface temperature. The
temperature should be <80 Celsius. (176 Fahrenheit)

2. Reduce payload or loading.

3. Try a known good controller, if error
is gone, warranty controller. Error
remains, reinstall controller and contact
Customer Care.

Customer Care
Page 21

20753 15 Volt Supply Low Voltage
Caused by: Problem with the controller’s internal 15V supply for brake light circuit.
Fastener

Relay

Harness Plug
B

1. Verify that the brake relay is properly
plugged into the vehicle harness. If yes
proceed to step 2.
2. Unplug relay from harness. Place
pos. probe of meter on the 85
terminal. Place neg. probe of meter
on 86 terminal. Verify 1-50 ohms
resistance. If not replace the relay.
(Shorted) If good, go to step 3.
3. Place pos. probe of meter on the red
wire terminal of the relay harness. Place
neg. 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 wire) of
the controller 23 pin connector 1st. Check
continuity between 85 terminal of harness
and pin #1 (Red wire) of the controller 23 pin
connector 2nd. If continuity is not found,
replace the harness. If a short is found
between 85 and 86 with the controller 23 pin
connector unplugged, replace the harness.
If continuity is good in the harness; Try a known
good controller if error is gone, warranty
controller. Error remains, reinstall controller and
contact Customer Care.

Customer Care
Page 22

20755 5 Volt Supply Low or High Voltage
Caused by: Short in the 5V wire harness, malfunction in the 5V sensor
supply, shorted SOC meter, or a shorted resistor control module.

A
B
1. Disconnect the 23 pin controller
connector. Place pos meter probe A on
orange wire terminal of either sensor
connector. (Throttle or Brake position)
Place neg. meter probe B on the black
wire terminal. The reading should be
>10K ohms. If bad, replace the control
harness. If good, go to step 2.

2. Plug all connectors back in. Place
pos. meter probe A on the orange 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
try a known good controller. If good, go to
step 3.

3. Place pos. meter probe A on the
yellow wire of the accel sensor and place neg.
meter probe B on the black wire at the pedal
position sensor. Leave harness connected to
the sensor. Voltage value should be between
0.38V and 0.56V. If good, go to step 4. If
bad, verify harness.

Customer Care
Page 23

4. Leave meter probes in place. slowly
depress the pedal to the floor. Voltage value
should increase from .5v to between 4.5V
and 4.8V. Above 4.8v is a fault. If good, go
to step 5. If bad, replace sensor.

20755 5 Volt Supply Low or High Voltage
Continued

5. Place pos. meter probe A on the green
wire of the brake sensor. Place neg. meter
probe B on the black wire at the pedal
position sensor. Leave harness connected
to the sensor. Voltage value should be
between 0.38V and 0.56V. If good, go to
step 6. If bad, verify harness.

6. Leave meter probes in place. Slowly
depress the pedal to the floor. Voltage
should steadily increase from .5v to
between 4.5V and 4.8V. 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 observed. If
bad, replace harness. If good, go to
step 8.

8. Place the pos. meter probe on the
small red encoder wire. Place the
neg. probe on the white or blue wire.
Rotate the back tires with the car in
neutral and the tow switch in tow.
Close to 0V should be observed. Go
to step 9.

Tech Tip: The motor encoder can be tested with an encoder tester available through
Customer Care. The only other accurate test is with a multimeter that has "hertz" test
capability.

Customer Care
Page 24

20755 5 Volt Supply Low or High Voltage
Continued

9. Leave probes in position. Continue
to rotate the tires until around 5V is
observed. If bad, replace the motor. If
good, go to step 10.

10. Inspect SOC meter plug for
damage or tampering. If damaged,
replace the SOC meter. If good, go to
step 11.

11. Check SOC harness plug for
voltage. Place pos. meter probe 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.
meter probe A on the gray wire
terminal. Place the neg. probe B on
the black wire terminal. .5V at empty
and 4.5v at full should be observed
based on state of charge. If good,
replace the SOC meter. If bad, go
back to step 2.

Caution: Do not short any 5V circuit wire to any 48V circuit wire
or component. The controller and/or sensors will be destroyed!

Customer Care
Page 25

21008 Current Sensor Offset Calibration Error
Caused by: Error detected in the controller current measurement hardware.

A
B

1. 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,
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 the U 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.

4. Try a known good controller if
error is gone, warranty controller.
Error remains, reinstall controller
and contact Customer Care.

Customer Care
Page 26

21520 Open Drain Outputs Current High
Caused by: Open drains (stuck closed or shorted) reverse buzzer,
solenoid, park brake, resistor control module, or brake relay.

A
A
2. 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 terminal.
Voltage 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,
replace solenoid.

1. Place pos. meter probe A on top
solenoid post. Place neg. meter probe
B on -48V battery terminal. Voltage
should be the same as the battery set.
If not, replace battery to solenoid wire.

A
3. Place pos. meter probe on the red
wire of the buzzer. Place neg. meter
probe on the black wire. Battery voltage
should be observed while the car is in the
reverse direction and the buzzer will
sound. Voltage should diminish in the
forward direction. If voltage is good and
no sound, replace the buzzer. If voltage
is bad, check key switch and harness.

4. Check the brake coil driver for the
correct ohm range. The range should
be 27+/- 3ohms. If wrong, replace
brake coil driver. If good, go to step 5.

Customer Care
Page 27

21520 Open Drain Outputs Current High
Continued

A
B

5. Place pos. meter probe A. on the
gray wire of the brake coil harness.
Place the neg. probe B on the black
wire. Voltage should read around
12V-18V when the tow switch is in
the tow position. If bad, verify
harness. If good, go to step 6.

6. Disconnect resistor control module
black wire from B- on the controller. If
error status changes, replace the
resistor module. If error continues, see
step 7.

7. Unplug relay from harness. Place
pos. probe of meter on the 85
terminal. Place neg. probe of meter
on 86 terminal. Verify 1-50 ohms
resistance. If not replace the relay.
(Shorted) If good, go to step 8.
8. Check continuity between the 86 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 continuity is not found,
replace the harness. If a short is found
between 85 and 86 with the controller 23 pin
connector unplugged, replace the harness.
If continuity is good in the harness; Try a known
good controller.
Attention: If all devices check out, Try
a known good controller.

Customer Care
Page 28

33024 CAN Timeout
Caused by: The controller and the hand held diagnostic tool stop
communicating.
1. Turn key off and back on
to reset the controller. If the
hand held screen returns,
continue to diagnose. If
screen does 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 wires. If bad, re-insert
or replace harness.

Tech Tip: Intermittent car
operation can come from
loose wire connections
on the CAN plug and
harness. This condition
will not show a fault
code on the hand held
diagnostic unit.

Customer Care
Page 29

25104 Direction Error
Caused by: Shorts in the key switch or wiring. Forward and Reverse directions
may be energized simultaneously.
1. Remove the key switch
and turn the key to the
forward position. Place pos.
meter probe A on the A pin of
the switch. Place the neg.
meter probe 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 turned in the
opposite direction. If
continuity can be read on all
three pins in the same key
direction (Forward), then
replace the switch.

Tech Tip: This test can also
be performed using the
hand held tool and scrolling
down to the direction
functions in the Diagnostics
Menu

Customer Care
Page 30

25105 Throttle Sensor Error
Caused by: The throttle position sensor is out of operational range.
Pedal stop bumper
A

1. Verify the pedal stop bumper is in
the correct position. If not, correct and
secure in place.

2. Plug all connectors back in. Place
pos. meter probe A on the orange wire
at the #3 position on the controller
plug. Place neg. probe B on the black
wire at the #4 position on the controller
plug. 5V should be observed. If bad,
check all 5V components first, then try a
known good controller. If good, go to
step 3.

3. Place pos. meter probe A on the
yellow wire of the accel position sensor.
Place neg. meter probe B on the black wire
at the pedal position sensor. Leave harness
connected to the sensor. Voltage value should
be between 0.38V and 0.56V. If good, go to
step 4. If bad, verify harness.

4. Leave meter probes in place. Slowly
depress the pedal to the floor. Voltage
should steadily 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.

5. Try a known good controller if error is gone, warranty controller.
Error remains, reinstall controller and contact Customer Care.

Customer Care
Page 31

25106 Reverse Alarm Test Failed
Caused by: The reverse alarm failed at start up check or an incomplete
reverse alarm circuit.
1. Unplug the 23 pin
connector at the speed
controller. Check the
resistance value
between 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 should be
present when the car is in
the reverse direction. If not,
verify key switch then try a
known good controller. If error
is gone warranty controller.
Error remains reinstall controller
and contact Customer Care.

Customer Care
Page 32

25107 Mechanical Brake Test Failed
Caused by: Park brake failed to prevent the motor from rotating during the
start up test. Can be caused by turning the key switch off and back to drive
while the vehicle is moving.
1. Turn the key switch off and try to push the vehicle.
The tow switch must be in the run position. If the car
can be pushed, got to step 2.

A
B

3. Verify friction disk alignment.
Remove the park brake and inspect
the friction disk. Go to step 4.

2. Verify the brake coil driver by placing
the pos. meter probe A on one driver
terminal and the neg. 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.

Tech Tip: With the key switch in the on position, flip to tow
switch to tow. An audible noise should be heard and the car
should roll freely. If not, check for power leaving the controller
and activation of the coil driver. The handheld diagnostic tool
will show this on the diagnostic report screen. Check
“E Brake Cur” for .497-.501 Amps. If bad, check the harness and
then try a known good controller. If good, see step 5.

Customer Care
Page 33

25107 Mechanical Brake Test Failed
Continued
A
B

4. After inspection, reinstall the park
brake and leave the bolts loose. Turn the
key switch to on and the tow switch to
tow. The coil driver should electronically
disengage. Torque the three bolts to 53
-71 in-lbs in small equal increments.
Flip the tow switch back and forth from tow
to run. This will align the friction disk.

6. Turn key to the on
position with the tow switch
in the run position. Go to
step 7.

5. See the Tech tip on the previous
page. Verify energy leaving the
controller with the hand held diagnostic
tool. Now verify voltage to the 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 voltage appears in
the run position, replace the tow
switch. If no voltage appears in the tow
position with the key on, replace the
harness.

Tech Tip: The
tow switch
should show
full resistance
in the run
position and the
23 pin
connector
disconnected.

Customer Care
Page 34

7. If the car can be pushed verify
step 3. Then try a known good
controller, if error is gone, warranty
controller. Error remains, reinstall
controller and contact Customer Care.

25108 Brake Sensor Error
Caused by: The brake pedal position sensor is out of operating range.
Brake Pedal Bumper
A

1. Verify the pedal stop bumper is in
the correct position. If not, correct and
secure in place.

2. Place pos. meter probe A on the
orange wire at the #3 position on the
controller plug. Place neg. probe B on
the black wire at the #4 position on the
controller plug. 5V should be observed.
If bad, check all 5V components first,
then try a known good controller. If good
go to step 3.

B
A
3. Place pos. meter probe A on the green
B
wire of the brake position sensor and place
neg. meter probe B on the black wire of the
A
brake position sensor. Leave harness connected
to the sensor. Voltage should be between
0.38V and 0.56V. If good, go to step 4. If bad,
4. Leave meter probes in place. Slowly
verify harness.
depress the pedal to the floor. Voltage
should steadily increase from .5v to between
4.5V and 4.8V. Above 4.8v is a fault. If good
go to step 5. If bad, replace sensor.

5. Try a known good controller if error is gone,
warranty controller. Error remains, reinstall
controller and contact Customer Care.

Customer Care
Page 35

Charger Receptacle Test
1. Place the pos. meter probe A
on the lower left terminal of the
charge receptacle. Place the
neg. probe B on the lower right
terminal. Battery voltage should
be observed. If not, check
loaded battery pack voltage
then replace the charge
receptacle.
A

2. Place the pos. meter
probe A on the lower left
terminal of the charge
receptacle. Place the neg.
meter probe B on the upper
terminal. Battery voltage
should be observed. If not,
replace the receptacle.

Customer Care
Page 36

Throttle & Brake Switch Test
1. Throttle switch is normally open.
Disconnect the throttle switch
harness. Place the pos. meter
probe on one red wire. Place the
neg. meter probe on the other
red wire. An open circuit should
be observed when the pedal is
released. 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 the pos. meter
probe on one red wire. Place the
neg. meter probe on the other
red wire. An open circuit should
be observed when the pedal is
depressed. Full continuity should
be observed with the pedal
released. If continuity is wrong,
replace the brake switch.

Customer Care
Page 37

Resistor 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,
replace the sensor.

Customer Care
Page 38

Warnings
May occur in conjunction with error codes.
Warnings may not necessarily cause the
vehicle to stop. Warnings may cause a
loss in vehicle performance.
Warning List:
1.

Drive Fault – Indicates the current error is the result of a condition internal to the controller. Trouble shoot
according to the error message displayed. If no errors are displayed, replace the controller.

DC Bus Low – DC Bus voltage is <24 volts. See pages 17 - 19

DC Bus High – DC Bus voltage is >67 volts. See pages 13 - 16

BDI Calibration – The DC Bus measurement system is not calibrated. Replace the controller.

Motor Temp High – Motor temperature is >140 C but less than 150 C. See page 20

Motor Temp Sensor – Motor temp sensor not connected. See page 20

Heat Sink Temp Low – Controller heat sink temp is < - 20C. Reduced speed may go away after controller
warms up.

Heat Sink Temp High – Measured heat sink temp is >85C but less than 115C. See page 21

Heat Sink Temp Sens – Heat sink temp sensor is shorted or not connected. Warm vehicle or replace the
controller.

10.

Default Parameter – This warning is normal when the controller is first powered up. Any time after this
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 Meas Cal – The controller’s AC current measurement system is not calibrated. Replace the
controller.

13.

Speed Sensor – Indicates sensor or wire failure. See page 31

14.

OD Current High – The current in an open drain (park brake, resistor control, or brake relay) is >2.5
amps. See pages 27 - 28

15.

Charger Connected – The battery charger is connected to the car preventing accidental drive away. Verify
charger handle insertion. See page 36

16.

Brake Slipping – The controller has detected motor rotation while the park brake is engaged. Can occur
when the key is turned off while the vehicle is in motion. See pages 33 - 34

17.

Throttle Switch Closed – If this warning occurs with the key switch on: The throttle switch is closed at key
start. Switch must be opened briefly before driving is permitted. If this warning occurs any other time:
Energy dump monitoring detects the energy dump circuit is continuously on for >30 seconds. See page
37

18.

Brake Switch Open – Current in the brake circuit is <100 mamps with the park brake energized. This
warning can occur in panic stop situations. See page 37

19.

BDI Low – Battery pack voltage is below 25% SOC. See pages 17- 19

Customer Care
Page 39

Notes
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Customer Care
Page 40

E-Z-GO Division of Textron, Inc.,
1451 Marvin Griffin Road, Augusta, Georgia 30906 - 3852 USA

Copyrighted Material
This manual may not be reproduced in whole or
in part without the express permission of
E-Z-GO Division of Textron, Inc.
Technical Communications Department

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