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Unread 01-04-2018, 11:53 AM   #1
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Default 2012 RXV brake problem - Curtis Controller

Helping a friend with his locked up RXV brake. I am following the RXV 48v AC Curtis Advanced Trouble-Shooting Guide.

Step 1 - Failed: Cart does not roll with key off and switch in tow position.
Step 2 - Failed: Checked wires to brake and no voltage observed in either run or tow with key in any position.
Step 3 - Passed: Reading 25.5 ohms on the brake coil

The cart's brake lights stay on when key is turned on, I think this means it is failing the Controller startup test of the brake.

Anybody have advice how/where to troubleshoot no voltage on the brake wires?
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Unread 01-04-2018, 12:25 PM   #2
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Default Re: 2012 RXV brake problem - Curtis Controller

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Originally Posted by agpfl View Post
Helping a friend with his locked up RXV brake. I am following the RXV 48v AC Curtis Advanced Trouble-Shooting Guide.

Step 1 - Failed: Cart does not roll with key off and switch in tow position.
Step 2 - Failed: Checked wires to brake and no voltage observed in either run or tow with key in any position.
Step 3 - Passed: Reading 25.5 ohms on the brake coil

The cart's brake lights stay on when key is turned on, I think this means it is failing the Controller startup test of the brake.

Anybody have advice how/where to troubleshoot no voltage on the brake wires?
Check the fuses in the fuseholder caps that are attached to the edge of the plastic cover that goes over the controller and solenoid. One side of the cover has connections marked as #1/#2/#3/and #4. The other side has 2 connectors that go into caps, one should have yellow wires and the other red. One has a 10 Amp fuse for the keyswitch and the other has a 7.5 Amp fuse for the motor brake +48V. If those fuses are good, check the Run Plug under the cupholder assembly. Unplug and replug to make sure it's making a good connection. The run/tow switch only provides power to the motor brake when the key is on. The brake emergency bypass procedure printed under that plastic cover that uses the #1/#2/#3/#4 connectors applies power to the motor even with the key off. Good luck.

Bob
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Unread 01-04-2018, 02:00 PM   #3
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Default Re: 2012 RXV brake problem - Curtis Controller

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Originally Posted by BobBoyce View Post
Check the fuses in the fuseholder caps that are attached to the edge of the plastic cover that goes over the controller and solenoid. One side of the cover has connections marked as #1/#2/#3/and #4. The other side has 2 connectors that go into caps, one should have yellow wires and the other red. One has a 10 Amp fuse for the keyswitch and the other has a 7.5 Amp fuse for the motor brake +48V. If those fuses are good, check the Run Plug under the cupholder assembly. Unplug and replug to make sure it's making a good connection. The run/tow switch only provides power to the motor brake when the key is on. The brake emergency bypass procedure printed under that plastic cover that uses the #1/#2/#3/#4 connectors applies power to the motor even with the key off. Good luck.

Bob
Bypass procedure works. Able to push the cart and have 48v on brake cable.

Check/replaced the fuse, no change.

Checked the run plug and there must be a problem here. Looks like the run plug had corroded a while ago and someone twisted together some of the wires, but they have come loose. There are 3 red, 2 black, and one black white. How should these be connected together?
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Unread 01-04-2018, 03:06 PM   #4
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Default Re: 2012 RXV brake problem - Curtis Controller

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Originally Posted by agpfl View Post
Checked the run plug and there must be a problem here. Looks like the run plug had corroded a while ago and someone twisted together some of the wires, but they have come loose. There are 3 red, 2 black, and one black white. How should these be connected together?
I think I got the wires connected correctly. Only blew one fuse. Got black-white to black, and red to red. From the wiring harness it looks like the 2 black go to the same B- battery and 2 red go to the same brake light relay. So its a matter of getting lucky on connecting the red wires.

I have 48v to the brake cable with switch on run and key to on. I can push the cart.

The brake lights are still on though and the cart is still not running.
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Unread 01-04-2018, 07:52 PM   #5
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Default Re: 2012 RXV brake problem - Curtis Controller

Also forgot to mention that when the run/tow set to run and I turn the key to on, the cart lurches. First back, then forwards.
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Unread 01-04-2018, 08:33 PM   #6
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Default Re: 2012 RXV brake problem - Curtis Controller

Failed motor brake
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Unread 01-05-2018, 12:00 AM   #7
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Default Re: 2012 RXV brake problem - Curtis Controller

It may be the other connections on the Run Plug. There are + and - loop connections for the motor brake, as well as several other terminals for other functions. One of those is a motor brake sense line to the controller. See if you can borrow a Run Plug from somewhere and see if it fixes it. If so, copy the connections to your Run Plug. Beware though, there are controller ports wired to the Run Plug socket. If you short the wrong connections, you can damage ports on the controller. A norman Run Plug does not have pins for those connections.
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Unread 01-05-2018, 09:16 AM   #8
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Default Re: 2012 RXV brake problem - Curtis Controller

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Originally Posted by BobBoyce View Post
It may be the other connections on the Run Plug. There are + and - loop connections for the motor brake, as well as several other terminals for other functions. One of those is a motor brake sense line to the controller. See if you can borrow a Run Plug from somewhere and see if it fixes it. If so, copy the connections to your Run Plug. Beware though, there are controller ports wired to the Run Plug socket. If you short the wrong connections, you can damage ports on the controller. A norman Run Plug does not have pins for those connections.
All the wires were out of the run plug.



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Unread 01-05-2018, 12:00 PM   #9
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Default Re: 2012 RXV brake problem - Curtis Controller

Your Run Plug socket is totally missing! Why would someone cut it out like that? At least with the Curtis Controller, it's not used for the CAN Bus in a 2012, but in later years (2014 on) Curtis resumed use of the CAN Bus for communications with a GPS system. It looks like you are missing the wire that connects the motor brake to the controllers motor brake sense wire. That splits off of the Run Plug socket and connects to the controller so that it can sense the state of the motor brake. Without that wire, the controller will not pass its poweron testing. Where are you located? There is a way to disable that test in the controller, but it requires an OEM or higher level programmer to do it.

I'll see if I can get some pictures of the Run Plug socket and a Run Plug for you later.

Bob
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Unread 01-05-2018, 12:18 PM   #10
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Default Re: 2012 RXV brake problem - Curtis Controller

In Ft. Lauderdale

The run plug and assembly is there but not used. You can tell all the wires were corroded. Looking at the wiring diagram, it looks like there should be 6 wires that run to the run plug area. 3 red, 2 black, and 1 black-white. All are there and accounted for. 2 pairs of those wires are twisted together.
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