How to troubleshoot EZGO golf cart fault codes
To troubleshoot your EZGO PDS golf cart, you will need to set the cart into diagnostics mode. You can enter diagnostic mode by turning OFF the key switch and changing the direction switch from the neutral position to reverse. This must be done five times.
Once the above action is done, you will hear a beep code confirming that the cart has been correctly set to diagnostics mode. This beep also highlights the performance option supported by the golf cart.
The above beep code is followed by the golf cart signaling out the diagnostic beep code if it encounters a problem. You will then have to set the Run/Tow switch to Tow mode to proceed further.
There are a few prerequisites that you must ensure before you commence the troubleshooting. Make sure both the cart and its tire pressure are stable.
You must also ensure that the charging wall socket and the reverse buzzer are functioning properly without any fault. Keep in mind that the new batteries may not be fully charged and it’s alright if the accelerator is occasionally stuck.
EZGO diagnostic tool
There are several diagnostic tools available for the EZGO golf cart. They come in different price ranges depending on the features they have to offer.
The EZGO handheld diagnostic tool is quite handy in monitoring the various critical system functions of the golf cart as well as its battery life. The user-friendly tool is compatible with any Curtis controller and is recommended for EZGO 48V RXV and TXT model golf carts. This handheld tool is pricey and costs around USD 1,200.
The Curtis Programmer is another good option for diagnosing your EZGO RXV golf cart. This too comes in four variants namely, OEM, Dealer, Service and User. The OEM version is a handheld tool and is priced at around USD 350.
A digital multimeter is yet another essential diagnostic tool for your EZGO gas or electric golf cart. It can help you perform multiple functions on your cart such as checking the AC/DC voltage, testing the diode and batteries, measuring the current and more. This tool costs around USD 560.
The LSV/RSV Danaher RXV diagnostic tool is another useful tool to help in diagnosing your EZGO RXV golf cart equipped with a Danaher controller. This tool has a compact size and supports handheld operation. It comes with a price tag of close to USD 1,930.
EZGO RXV fault codes
The EZGO RXV golf cart has various fault codes associated with it that help in troubleshooting or diagnosing any problem with the cart.
The following table lists some of the key fault codes related to the cart along with details on what they represent.
|
EZGO RXV Fault Code |
Meaning |
|
8976 |
The motor current has exceeded the peak rated current of the controller by 50% |
|
9024 |
There is a short circuit in the motor, motor cable or controller. |
|
12576 |
The DC bus voltage fails to reach the 24VDC limit within 10 seconds of activating the key switch. |
|
12817 |
The battery pack voltage is more than 63 volts. |
EZGO TXT fault codes
The EZGO TXT golf cart is associated with multiple fault codes to help you with the diagnosis or troubleshooting of your cart. The table below highlights the key fault codes pertaining to the cart along with their interpretation.
|
EZGO TXT Fault Code |
Meaning |
|
1-1 |
The controller of the cart has failed. |
|
1-2 |
There is a problem with the throttle. |
|
1-4 |
The high pedal of the cart is deactivated. |
|
2-4 |
The solenoid coil is either disconnected or fails to function as desired. |
|
3-1 |
The solenoid driver has failed. |
|
3-3 |
The solenoid doesn’t close as required. |
|
3-4 |
The field winding is in open state. |
|
4-1 |
The armature is in open state. |
|
4-3 |
There is a solenoid drop out. |
|
1-3 |
There is a problem with the speed sensor. |
|
2-1 |
One or more batteries has a very low voltage. |
|
2-2 |
One or more batteries has a high voltage. |
|
2-3 |
There is a thermal cutback. |
|
3-2 |
The solenoid is welded. |
|
4-2 |
The motor has stalled. |
Motor temperature sensor fault EZGO RXV
The motor temperature sensor fault in an EZGO RXV golf cart is not associated with any specific code. This is indicated as a warning by the golf cart when this sensor is disconnected or shorted.
- Check if the motor temperature sensor has got disconnected and connect it back in place. On the other hand, if you notice that the sensor is shorted, you must consider getting it replaced.
- Check the external motor temperature to see if it’s less than 120°C. If not, allow the motor to cool for some time or lessen the driving grade or payload.
- Check if the thermocouple resistance range is over 400 Ohms but less than 1300 Ohms. If it’s outside this range, the motor and if needed, the controller, must be changed.
EZGO RXV HPD sequencing fault
The EZGO RXV HPD sequencing fault indicates that either the throttle, brake or both pedals fail to come to the upright position when released. This fault may also get triggered if a wrong switch is fitted for the throttle or brake.
- Check the outputs of the switches using an ohmmeter. The standard open and closed outputs are different for both switches. The throttle pedal changes state immediately on being released while the brake pedal changes state only after it’s released by about 60%. If the ohmmeter doesn’t display the desired reading for the pedals, do a replacement.
- Check if the switches are in accordance with the version or type of pedal. If not, get the right switch fitted.
EZGO RXV encoder fault
The EZGORXV encoder fault is associated with either a faulty controller or incorrect voltage on the orange wires of the encoder harness or the sensors of the accelerator and brake.
- Check if the controller of the cart is functioning properly and do a replacement if needed.
- Check the voltage reading for the orange wires of the encoder harness as well as the accelerator and brake-related sensors. If you don’t get a 5V reading for any of these components, you must change it.
What does EZGO RXV error code 25106 mean?
The EZGORXV error code 25106 indicates that the reverse warning alarm failed to function during a startup check. A controller replacement may be needed.
- Put the key switch in the OFF position and remove the Pin 23 connector from the controller.
- Set the Run/Tow switch of the cart to Tow mode.
- Check the alarm for a shorted condition by measuring the resistance between pins 10 and 13. If it’s less than or more than 0.1 Ohms, the alarm must be changed. A reading less than 0.1 Ohms indicates a short.
- Put the key switch in the R position and check the reverse warning alarm voltage reading. If it’s not equal to 48V, change the wiring.
What does EZGO RXV error code 25107 mean?
The EZGO RXV error code 25107 means that the mechanical brake of the cart fails to function as desired. The parking brake stops the motor from rotating when the park brake startup test is performed.
This problem can also happen if the key switch is turned to the OFF position and then to the ON position rapidly when the golf cart is in motion. Sometimes, you may need to do a controller replacement.
- Set the key switch in the OFF position and try moving the golf cart. You should not be able to move the cart.
- Remove the harness that is connected to the motor brake.
- Check the brake coil resistance if it’s 27 +/-3 Ohms. If it’s not in this range, get the motor brake replaced.
- Check if the friction disk is properly aligned and do an alignment if needed.
- Put the key and Run/Tow switches in ON and RUN positions and try to push the cart.
What does EZGO DC bus timeout error code 12576 mean?
The EZGODC bus timeout error code 12576 means the DC bus voltage reading is not 24 volts within ten seconds of setting the key switch to start position.
- Check the battery voltage across all the batteries of the cart. This should be at least 42VDC.
- Check the voltage reading across the contacts of the solenoid. This must be over 3VDC but lesser than 24VDC. If not, get a new solenoid fitted in place of the old one.
- Disconnect the resistor control module from the B- terminal of the controller. If there is a change in the error status, replace the module.
What does EZGO AC overcurrent error code 8976 mean?
The EZGO AC overcurrent error code 12576 means that the motor current is more than 50% of the peak rated current of the controller. This happens when the motor parameters aren’t according to the specifications.
- Set the key switch in the OFF mode and then in the ON mode once again.
- Check if you can move the cart. If not, proceed as given below.
- Disconnect the U, V and W connectors from the controller.
- Check the resistance between the U and V, V and W as well as U and W connectors. This should be within the 0.4 Ohms to 0.8 Ohms range. If the resistance is not within this range, change the motor.
- Replace the controller if the resistance is within the specified range but the cart fails to move.
EZGO RXV drive fault
The EZGO RXV drive fault indicates a fault in the motor, controller or electrical system of the golf cart.
- Check if the wire harness is corroded due to acid at the point where the wires go around the battery corners. If so, do fresh wiring in place of the old one.
- Check if the encoder is functioning as desired and get a replacement done if needed.
- Check if the main harness plug connection at the controller has become loose or shows signs of damage. Tighten the connection if it’s loose and do a new connection if damaged.
EZGO RXV battery voltage fault
The EZGO RXV battery voltage fault is represented by two red flashes and is often due to less than desired battery pack voltage.
Check the battery pack voltage of the golf cart. If the reading is less than 36 volts, you may have to charge the batteries. It’s recommended that you charge each battery individually to see if the charge is being retained.
EZGO TXT high pedal fault code
The EZGO TXT high pedal fault is associated with a 1-4 error code. The pedal gets disabled and the golf cart will not move.
- Check if the pedal is getting released fully. If not, you may have to get the pedal changed.
- Check the pedal box, switch and linkage for signs of defect. Replace the defective components.
EZGO TXT solenoid dropout error code
The EZGO TXT solenoid dropout error is represented by the 4-3 error code.
- Check the solenoid and the related wiring connection.
- If either the solenoid or wiring show signs of wearing out, replace them.
- Tighten any loose connections.