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Unread 12-21-2014, 04:54 PM   #91
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Default Re: Couple of wiring questions.

I don't know where that weld is physically located, but you have already checked all those wires and they were ok.
Did you find an intermittent connection in one of those wires?
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Unread 12-21-2014, 05:12 PM   #92
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by Sergio View Post
I don't know where that weld is physically located, but you have already checked all those wires and they were ok.
Did you find an intermittent connection in one of those wires?
No, its just the only thing I haven't checked. It seems that, as far as wiring goes, (as it pertains to my situation), this could/would be the most likely source of my problem. If its wiring.

It appears to me; the key tells the solenoid to power up, the mcor to get ready?? I dont know what that Bleu to the MCOR really says to the MCOR. Then it tells the Tan wire something.

This joint basically tells the system to get ready. Im guessing. (Total Guess) that the Tan somehow, tells the Blue white to the solenoid to flip to -48??
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Unread 12-21-2014, 05:26 PM   #93
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Default Re: Couple of wiring questions.

You know what Id pay to know?

What does the Tan wire do and what tells the Blue White to flip to negative on the solenoid.


Heres me guessing again:

The key gets turned on, sends +48v to the right side small tab of the solenoid. Also sends +48v to the MCOR, also sends +48v to the Tan. But the solenoid isn't supposed to connect yet.

Everything is lit up and ready waiting for the Blue/White (Left side of the solenoid.

The MCOR hits the switch inside and that signals the Blue/White to flip?

Make sense?? So what triggers the Blue/White to flip and what does the Tan do?
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Unread 12-23-2014, 09:47 AM   #94
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Default Re: Couple of wiring questions.

You need to stop thinking of Your system as a series of switches and relays interconnected, a SEPEX system is considerably more complex.

There is a computer and software running inside the controller that is making the decisions based on input signals, some of the signals have to occur in a particular sequence as well.

The major problem right now is why Your controller is not outputting the 5v needed by the MCOR.

The MCOR uses the 5v from the controller (white wire) to create a voltage divider (purple to negative) and sends back a voltage from 0v-5v (approximate) in the yellow wire that is proportional to how far the pedal is pressed.

The speed sensor attached to the motor shaft sends approximate 48 pulses per each wheel revolution back to the controller.

The controller uses that signal to calculate how fast (RPM) the motor is spinning and adjusts the voltage and current individually for the field and armature coils of the motor to regulate a speed that corresponds to the amount of pedal input.

Those adjustments happen about 16,000 times a second.

Unless you bought a used and bad controller, You need to find out why You cannot get 5v out of the controller.

The most likely answer is that there is a short somewhere in the harness between the controller 16pin connector and the MCOR 3 pin connector.
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Unread 12-23-2014, 03:43 PM   #95
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Default Re: Couple of wiring questions.

Well, Ive checked every wire, connection etc. Cleaned the terminals tested everything. Everything is working as it should. The new MCOR seems fine as far as ohlmages. (I just created that word, I guess)

I have 2 MCOR's. 3 Solenoids, 3 Controllers.

Throughout this whole thread and all the reading and changing parts 2 things have been consistent.

1. The Black/White from the controller is 2.0V. Supposed to be 5.0V

2. The Blue/White wire to the left side of the solenoid does not flip
from +6v to -48v. (Unless I turn the Key off. Then it turns to -48v)

Also, one other thing I haven't mentioned. Only because mine was bad and figured it would work itself out when replaced. My reverse buzzer doesn't buzz when put into reverse. Again I know the wiring is right.

If I give it -48v it will buzz.

I think my MCOR is fine. I think my wiring is fine.

I think I have purchased 2 bad controllers?????

This sounds cheezy but I got this for my kids for Christmas. Doesn't look like Ill make it..

They will be cool and understand. What they probably don't understand is how they have watched me restore 15 cars in the past 10 years and I cant figure out a Golf Cart. I had no Idea it would be this complex.

So, I have 3 Controllers on my bench. Do I buy another one??? I have a gut feeling (usually its right) I'm missing something simple. Something that will make me look like a total idiot. Happened many times before.

You mean White Black #1 pin and controller 3 pin?? I ran a straight jump and had the same readings.

Last edited by Merlinhaggard; 12-23-2014 at 03:49 PM.. Reason: update
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Unread 12-23-2014, 03:53 PM   #96
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Default Re: Couple of wiring questions.

Be sure that the sonic welds are nice and tight. When I bought my 08, it wouldn't run. Owner had purchased an extra of everything in the cart and it still wouldn't run. Turned out the connection inside one of the sonic welds came apart. Ended up with a free fix plus probably another $500-$700 in extra parts
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Unread 12-23-2014, 06:39 PM   #97
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Default Re: Couple of wiring questions.

Controller #1 pin should be white/black.
If the problem is a short somewhere in the harness, running a direct jump to the MCOR will not help.

In the "it could be something simple department", have you checked that you have a good connection from Controller B- to pack negative?

It looks like that in the beginning of this thread, You had a lot of splices in the pack negative cable before You removed the OBC.
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Unread 12-23-2014, 06:41 PM   #98
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by Sergio View Post
Controller #1 pin should be white/black.
If the problem is a short somewhere in the harness, running a direct jump to the MCOR will not help.

In the "it could be something simple department", have you checked that you have a good connection from Controller B- to pack negative?

It looks like that in the beginning of this thread, You had a lot of splices in the pack negative cable before You removed the OBC.
Ill check that out. Thanks Sergio.
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Unread 12-23-2014, 06:59 PM   #99
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Default Re: Couple of wiring questions.

One more quick thing, back in posts #29, #30 and #31, it looks like You had the FNR wired wrong, did You change those wires (white and blue) per post#31?
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Unread 12-23-2014, 07:19 PM   #100
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by Sergio View Post
One more quick thing, back in posts #29, #30 and #31, it looks like You had the FNR wired wrong, did You change those wires (white and blue) per post#31?

Not yet, I can do that real quick.. Thanks.
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