Max Brake wire problem.

[Boehler]

A few days ago I unplugged the wires from the back of the controller. The modular plug on the sensor wire cane out in pieces. I attempted to repair it by splicing on an end from an ether net cable. I must have done something incorrectly.

Now the controller says "sensor not connected". When I depress the brake pedal, a letter "P" appears near the upper left of the display.

Any advice on how to correct the attempted repair, or better yet where to get a replacement sensor wire.

 

[SnoKing]

Di & Dutch! Snoking

 

[Dutch & Di]

I did talk to him today. Unfortunately, we haven't had any sensor cables for almost a year. Because it is the plastic end of the sensor that plugs into the controller and not the round plug it that goes into the sensor,we cant investigate a wire that might have lost it's coating or something like that. Neither dutch nor I could offer any suggestions other than trying to find an Ethernet computer cable that would have the same end, a Big box store like Best Buys or maybe a hobbyist who would have various plastic ends. Because it is not plugged in, you will receive the "sensor not connected" message. I would have to do some digging to refresh my memory on what the "P" is for. I wish we could have been of further assistance. Hugs, Di

 

[SnoKing]

If I get a chance, I will check mine out and provide details. I have RJ45 ends and the crimp tool. Snoking

 

[Boehler]

Thanks!
If you could check to see which of the three conductors at the sensor end have continuity with which wire position on the other (controller) end, I should be able to connect a RJ45 end. Buying a crimp tool is way cheaper than buying a new, and probably inferior brake controller.

 

[SnoKing]

Ok, here you go! At the loadcell end we will call the three terminals in the plug Top, Left and Right based on the photo.

#ad


On the RJ45 end we will call the bottom pin 1 and the top one 8 based on the photo.

#ad


Top goes to 5
Left goes to 8
Right goes to 7

Good luck. Appears you can just use a standard Cat 5 patch cable and cut off the RJ45 under the hood and hook up the the three wire base on the info above. That way you do not need a crimp tool and the associated problems of doing it correctly. There are different ends for solid vs twisted strand wires etc. You will see that is what they did on the OEM cable.

SNOKING

 

[SnoKing]

OK, where did you go! I did my end, how about a report back? SNOKING

 

[RVTRKN]

There is probably a shield that should be spliced as well, which is usually aluminum that wraps around the wires inside the protective jacket

 

[Boehler]

Snoking, thanks for the reply. The information is exactly what I was looking for. The pictures most helpfull.

I made the connections and tested the results with an ohm meter. After hooking it all back up, I still got the same "sensor not connected" message. All I can figure is that something is FUBAR inside the controller itself. Perhaps something somehow got hot and that was what damaged the modular plug in the first place.

Thanks for all the help, but it looks like time to get out the checkbook and get a new brake controller.

 

[RVTRKN]

Before you buy another controller, check the female connector at the Max Brake. I would bypass the plug at the controller, by hardwiring the three wires and then testing. It's going in the trash anyway, it's just time lost if it didn't work.

 

[SnoKing]

If the RJ45 jack is damaged it should not be that hard to replace. Have you done a physical inspection of the circuit card inside the controllers. That is open of the standard early steps in trouble shooting electronics. First all the connections, then the physical inspection looking for burnt items, capacitors that are puffed up on the ends, etc.

The loadcell should be a low current device and or one that varies voltage, and I do not see it burning up it's connections. The Cat5 cable leads are 22 or 24 gauge wires, which will not handle a lot of current.

Post some close up pictures of the main circuit card.

SNOKING

 

[Boehler]

Thanks guys. I'll be out of town for a few weeks. When I get back I'll take a look inside, and try to get some pics.

 

[Boehler]

I know it's been a while since my last post. Time flies when I'm having fun. I didn't have time to continue trying to work with the Max Brake before a trip to South Carolina in early June. I got a Direct Link controller, and it seem to do the job fairly well. I still think the Max Brake was better.

Long story short, I'm now pretty well settled in the Gulf Shores, AL area for the winter and got a chance to re-look at the Max Brake. With the help of a knowledgeable friend we checked the continuity from the sensor plug to the circuit board and visually inspected the board for anything loose, burnt-looking, or misshapen. Found no problems.

I reinstalled the Max Brake and still got the "sensor not connected" message. I attempted to perform the calibration procedure but was unable to make the numbers on the screen change with the brake pedal. I am beginning to suspect the sensor itself, even though it going bad at the same time as the modular plug would seem to be a remarkable coincidence.

Is there any way to check the sensor, or replacement sensors available?

Any help or advice will be greatly appreciated.

 

[Dutch & Di]

Sorry for the delay in responding. I tried twice to do it from my phone and I could put the response in but it would NOT send, sooo
There are several things we can try to see if we can get you back up and running but I can't do them via this forum or by e-mail. If you would like to call me at 941-416-0918 10 am to 10 pm central time 7 days a week{tomorrow, Friday it would be after 2 pm}, I'll be happy to work with you to see if I can help. It it does turn out that it is a part issue I do have just a few parts left. Hugs, Di

 

[p-Bar]

Why don't we plug it in to a known working system and troubleshoot it from there?

 

[Dutch & Di]

I'm still available to try and trouble shoot this for you if you'd like to call me at 941-416-0918 10 am to 10 pm 7 days a week central time to right now. I'll be happy to help if I can but I do not try and trouble shoot over internet or e-mail as there are too many chances of miscommunication or mixups.
You are always free to use other options & forum suggestions. Hugs, Di

I know it's been a while since my last post. Time flies when I'm having fun. I didn't have time to continue trying to work with the Max Brake before a trip to South Carolina in early June. I got a Direct Link controller, and it seem to do the job fairly well. I still think the Max Brake was better.

Long story short, I'm now pretty well settled in the Gulf Shores, AL area for the winter and got a chance to re-look at the Max Brake. With the help of a knowledgeable friend we checked the continuity from the sensor plug to the circuit board and visually inspected the board for anything loose, burnt-looking, or misshapen. Found no problems.

I reinstalled the Max Brake and still got the "sensor not connected" message. I attempted to perform the calibration procedure but was unable to make the numbers on the screen change with the brake pedal. I am beginning to suspect the sensor itself, even though it going bad at the same time as the modular plug would seem to be a remarkable coincidence.

Is there any way to check the sensor, or replacement sensors available?

Any help or advice will be greatly appreciated.