RXV w/ Danaher Controller Brake Issue

Courageous Carts

RXV w/ Danaher Controller.....Brake will not release. Cant change 2,3,4 pins to make it release, and it wont release in tow and forward.
I am getting what seems to be proper ohms readings on position sensors, and proper voltage to accelerator position sensor.
Disassembled the brake after verifying ohm reading to see if it was scorched and the coil appears okay.
Its an aftermarket limo conversion and Ive verified no breaks or faulty connections in the harness and the reader isnt throwing any warnings or errors.
Does anyone have any other ideas.
Oh, I just had the controller rebuilt, new solenoid, and this brake is less than 10-hrs old.

BGW

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usgicollector

Check fuses under controller cover.

Courageous Carts

I already checked the fuses and every one has continuity.
The motor will come on, go through it's cycle and not release the brake even when under power.

BobBoyce

Is the new motor brake an OEM or it it an aftermarket one like Reliance HD? Just so you know, aftermarket motor brakes that advertise as HD or Heavy Duty don't work so well with the RXV controllers. They draw too much current and tend to cause intermittent operation which eventually leads to a blown out motor brake FET (it has a 3 amp limit) in the controller. As usgicollector mentioned, check the fuses on the underside of the plastic cover that the run/tow switch is mounted on. They each have a cap that mounts to the cover with a christmas tree fastener. Early RXVs had only 1 fuse, later years had 2. One with 2 yellow wires and one with 2 red wires. A HD motor brake could blow the fuse.

Courageous Carts

The new brake is an HD nivel brake I am not sure what amp draw the aftermarket brake has and that is a great point. I will try to check the specs on it. .The cart has five fuses attached to the controller shield that all test good.

cgtech

Also, is the plug present on the bottom of the cupholder? It has red & green wires.

Courageous Carts

The plug is present and the socket it solid with no openings. I know if they have an opening it can cause the brake to not release or the controller to not engage.
The only time the plug comes out is when I connect the programmer.......

nickdalzell1

Put car in TOW and key in N (ON) and see if you can push it around. If it releases the brake then the brake is fine and so is the brake controller FET. Accelerator sticking will also cause the brake not to release as well.

BobBoyce

Unplug and replug several times to wipe the contacts with one another to clear
possible corrosion. Did you try an OEM motor brake yet in place of the HD motor brake that we warned you about?

Courageous Carts

The accelerator seems to check out with ohms, voltage, and registers proper operation on the programmer. The cart will not release the brake without removing it weather you jump it out or put it in tow and on.
I have been working on carts for many years and this one has me stumped. There are no codes/ warnings/ or errors in the system according to the programmer.
I am beginning to wonder if the amp limiter could influence the brake.