Textron Ezgo RXV-E Troubleshooting Manual
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Textron Ezgo RXV-E Troubleshooting Manual

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RXV-E Advanced Trouble-Shooting
Guide
610873
Customer Care

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Pete Garcia
March 14, 2025

I have a 2012 2Five and upgraded the batteries to lithium now w m getting the 25104 code. I replaced the key switch selector? Wonder if it a amp issue?

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3 comments:
Mr. Anderson
March 14, 2025

The 25104 code in the Textron Ezgo RXV-E corresponds to a "Direction Error." This means the vehicle's controller has detected an issue with the direction selection, such as conflicting inputs or a wiring fault. After upgrading to lithium batteries, ensure the wiring and control signals are correctly connected and the controller is properly configured for the new battery type.

This answer is automatically generated

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Pete Garcia
March 15, 2025

@Mr. Anderson

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Pete Garcia
March 15, 2025

The 2Five came with a 235amp controller and reading that I might need to up grade to a 350amp controller?

0

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Summary of Contents for Textron Ezgo RXV-E

  • Page 1 RXV-E Advanced Trouble-Shooting Guide 610873 Customer Care...

  • Page 2: Table Of Contents

    Table of Contents Page Safety Hand Held Diagnostic Tool Special Tool List Wiring Diagrams 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...
  • Page 3 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 –...

  • Page 4: Safety

    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...

  • Page 5: Hand Held Diagnostic Tool

    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.

  • Page 6: Special Tool List

    Tools The following tools will be required to perform advanced trouble shooting procedures: 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. Customer Care Page 3...

  • Page 7: Wiring Diagrams

    Controller 23 pin connector pin listing with voltages Pin 1- 48 volt input when key switch is in any position other than off. (FWD, N, REV) Pin 2- 48v switched ground output for electric motor brake. Pin 3- 5v positive output for sensor circuit. Pin 4- 5v ground output for sensor circuit.
  • Page 8 RXV – E Wiring Diagram Customer Care Page 5...
  • Page 9 RXV – E Wiring Diagram Customer Care Page 6...

  • Page 10: Symptoms

    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.

  • Page 11: Error Codes

    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.

  • Page 12: 8976 Ac Over Current

    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. 2.

  • Page 13: 9024 Ac Short Circuit

    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. 2.

  • Page 14: 12576 Dc Bus Timeout

    127576 DC Bus Timeout Caused by: DC voltage has not reached 24 volts within 10 seconds after key switch start. 1. Place pos. meter probe A on +48V 2. Place pos. meter probe A on top battery terminal. Place neg. meter probe B solenoid post.
  • Page 15 127576 DC Bus Timeout Continued Resistor control wire 5. Place pos. meter probe A on 6. Disconnect resistor control module controller terminal B+. Place neg. black wire from B- on the controller. If meter probe B on controller B-. error status changes, replace the Voltage should be the same as the resistor module.

  • Page 16: 12817 Dc Bus High - Software Detected

    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. 2. Place pos. meter probe A on top 1. Verify battery pack voltage at the solenoid post.
  • Page 17 12817 DC Bus High – Software Detected Continued Resistor control wire 5. Disconnect resistor control module 6. Place pos. meter probe A on one black wire from B- on the controller. If resistor tab and neg. meter probe B error status changes, replace the on the remaining tab.

  • Page 18: 12818 Dc Bus High - Hardware Detected

    12 818 DC Bus High – Hardware Detected Caused by: Battery Pack voltage is over 67 volts. 2. Place pos. meter probe A on top 1. Verify battery pack voltage at the solenoid post. Place neg. meter probe time of fault. Voltage should be <63V. B on -48V battery terminal.
  • Page 19 12 818 DC Bus High – Hardware Detected Continued Resistor control wire 5. Disconnect resistor control module 6. Place pos. meter probe A on one black wire from B- on the controller. If resistor tab and neg. meter probe B error status changes, replace the on the remaining tab.

  • Page 20: 12833 Dc Bus Low

    12833 DC Bus Low – Software Detected Caused by: Controller DC Bus voltage has dropped below 18 volts. 1. Verify proper open circuit battery 2. Check all battery terminal voltage. Should be 48V or higher at the connections. Torque to 95 – 105 in- time of testing.
  • Page 21 12833 DC Bus Low – Software Detected Continued 5. Turn key switch to the on position. The 6. 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-.
  • Page 22 12833 DC Bus Low – Software Detected Continued Tech Tip: Always verify accessories and usage. Warranty requires a 48- 12v DC to DC converter for all accessories. The converter will allow equal accessory draw on all four batteries. Resistor Control Module 9.

  • Page 23: 16912 Motor Temp High

    16912 Motor Temp High Caused by: Overloaded vehicle or motor temp reaching 120 Celsius or higher. 1. Check motor surface temperature 2. Verify thermo-coupler resistance. for 120 Celsius. (248 Fahrenheit) If Place pos. meter probe A on the pink cold, go to step 2. If hot, reduce wire terminal.

  • Page 24: 17168 Heat Sink Temp High

    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.

  • Page 25: 20753 15V Supply Low Voltage

    20753 15 Volt Supply Low Voltage Caused by: Problem with the controller’s internal 15V supply for brake light circuit. Fastener Relay Harness Plug 1. Verify that the brake relay is properly plugged into the vehicle harness. If yes proceed to step 2. 2.

  • Page 26: 20755 5V Supply Low Or High Voltage

    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. 1. Disconnect the 23 pin controller 2. Plug all connectors back in. Place connector.
  • Page 27 20755 5 Volt Supply Low or High Voltage Continued 5. Place pos. meter probe A on the green 6. Leave meter probes in place. Slowly wire of the brake sensor. Place neg. meter depress the pedal to the floor. Voltage probe B on the black wire at the pedal should steadily increase from .5v to position sensor.
  • Page 28 20755 5 Volt Supply Low or High Voltage Continued 9. Leave probes in position. Continue 10. Inspect SOC meter plug for to rotate the tires until around 5V is damage or tampering. If damaged, observed. If bad, replace the motor. If replace the SOC meter.

  • Page 29: 21008 Current Sensor Offset Calibration

    21008 Current Sensor Offset Calibration Error Caused by: Error detected in the controller current measurement hardware. 1. Disconnect all three motor wires. 2. Contact the V wire lug to the pos. meter Contact the V wire lug to the pos. meter terminal A.

  • Page 30: 21520 Open Drain Output Current High

    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. 2. Turn key switch to the on position. The 1. Place pos. meter probe A on top solenoid should click.
  • Page 31 21520 Open Drain Outputs Current High Continued 5. Place pos. meter probe A. on the 6. Disconnect resistor control module gray wire of the brake coil harness. black wire from B- on the controller. If Place the neg. probe B on the black error status changes, replace the wire.

  • Page 32: 33024 Can Timeout

    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.

  • Page 33: 25104 Direction Error

    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.

  • Page 34: 25105 Throttle Sensor Error

    25105 Throttle Sensor Error Caused by: The throttle position sensor is out of operational range. Pedal stop bumper 1. Verify the pedal stop bumper is in 2. Plug all connectors back in. Place the correct position. If not, correct and pos.

  • Page 35: 25106 Reverse Alarm Test Failed

    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.

  • Page 36: 25107 Mechanical Brake Test Failed

    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.
  • Page 37 25107 Mechanical Brake Test Failed Continued 4. After inspection, reinstall the park 5. See the Tech tip on the previous brake and leave the bolts loose. Turn the page. Verify energy leaving the key switch to on and the tow switch to controller with the hand held diagnostic tow.

  • Page 38: 25108 Brake Sensor Error

    25108 Brake Sensor Error Caused by: The brake pedal position sensor is out of operating range. Brake Pedal Bumper 1. Verify the pedal stop bumper is in 2. Place pos. meter probe A on the the correct position. If not, correct and orange wire at the #3 position on the secure in place.

  • Page 39: Additional Component Testing

    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.
  • Page 40 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.
  • Page 41 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...

  • Page 42: Warnings

    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: Drive Fault – Indicates the current error is the result of a condition internal to the controller. Trouble shoot according to the error message displayed.
  • Page 43 Notes ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ ______________________________________________________________________ Customer Care Page 40...
  • Page 44 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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