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Unread 12-04-2014, 10:28 PM   #31
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Default Re: Couple of wiring questions.

The tests were supposed to be on the connector itself, sorry I was not clear.

No problem, it was just more difficult that way, but the results are the same.

The FNR switch should be Red in the middle, White on one side and Blue on the Other.

I think Your White and Blue wires are swapped at the FNR switch as White should have power on Forward. That won't prevent it from running, but You may want to swap the wires.

The last test is to make sure the MCOR is returning a voltage signal to the controller. Keep the controller connected.

Tow/run switch to Run
Key Switch ON

Meter set to 20v DC
Black probe on pack negative.
Red Probe on Pin #2 - Yellow Wire

Press the Pedal, Voltage should go from about 0.3v With Pedal Up to about 4.65v with Pedal Down.

If You get that along with all of the other test results, it looks like the controller is bad as the solenoid should have engaged.
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Unread 12-04-2014, 10:40 PM   #32
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by Sergio View Post
The tests were supposed to be on the connector itself, sorry I was not clear.

No problem, it was just more difficult that way, but the results are the same.

The FNR switch should be Red in the middle, White on one side and Blue on the Other.

I think Your White and Blue wires are swapped at the FNR switch as White should have power on Forward. That won't prevent it from running, but You may want to swap the wires.

The last test is to make sure the MCOR is returning a voltage signal to the controller. Keep the controller connected.

Tow/run switch to Run
Key Switch ON

Meter set to 20v DC
Black probe on pack negative.
Red Probe on Pin #2 - Yellow Wire

Press the Pedal, Voltage should go from about 0.3v With Pedal Up to about 4.65v with Pedal Down.

If You get that along with all of the other test results, it looks like the controller is bad as the solenoid should have engaged.


I did that and it went from .17 to 2.06

Thanks for the help!!
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Unread 12-04-2014, 10:51 PM   #33
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by TahoeDawgZ71 View Post
You've lost me here. Both of the wires are in the six pin connector. One is pin 2 and one is pin 6.
TD (Can I call you that)? What does connecting the blue to the red do? Just curious..
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Unread 12-05-2014, 10:06 AM   #34
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Default Re: Couple of wiring questions.

Quote:
I don't know what this means...
I posted the meaning of each wire signal besides the wire name and position You tested.

They represent all the conditions that must be met before the cart will move.

The MCOR signal is off, either because the Controller, MCOR, mechanical linkage or wiring.

If the problem is the controller, it will be fixed when You replace it, if not, the new controller will not work right either.

The MCOR gets its 5v from:
Pin #1 - White/black wire.
A couple of tests you can do to verify where the problem is:

Set the meter to 20vdc, Black on Pack negative, Red on Pin #1 - White/black wire.

You should get +5v, if NOT:
If You only Get around the 2.1v you measured earlier, disconnect the 3 pin connector from the MCOR and repeat the test above.

If it is still around 2.1v, the controller is likely the problem unless there is a cross wire somewhere in the White/Black wire between the controller connector and the 3 pin connector at the MCOR.
If You measured close to +5v on the test above:
Disconnect the 3 pin connector at the MCOR and measure the Voltage at the White/Black wire, You should get the same voltage You measured at the controller.

Set the meter to 20kΩ, and measure directly at the MCOR pins that correspond to the wire colors below:
  • From White/Black to Purple: Around 7kΩ (does not change with pedal movement)
  • From Yellow to Purple: (Pedal Up: around 1kΩ, Pedal Down: around 7.6kΩ)
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Unread 12-05-2014, 11:28 AM   #35
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Default Re: Couple of wiring questions.

When I said that I only meant, I didnt know what I was doing. Or what the info meant. Not what you said.

Ill try the next set.

Thanks so much Sergio
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Unread 12-05-2014, 08:16 PM   #36
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by Sergio View Post
I posted the meaning of each wire signal besides the wire name and position You tested.

They represent all the conditions that must be met before the cart will move.

The MCOR signal is off, either because the Controller, MCOR, mechanical linkage or wiring.

If the problem is the controller, it will be fixed when You replace it, if not, the new controller will not work right either.

The MCOR gets its 5v from:
Pin #1 - White/black wire.
A couple of tests you can do to verify where the problem is:

Set the meter to 20vdc, Black on Pack negative, Red on Pin #1 - White/black wire.

You should get +5v, if NOT:
If You only Get around the 2.1v you measured earlier, disconnect the 3 pin connector from the MCOR and repeat the test above.

If it is still around 2.1v, the controller is likely the problem unless there is a cross wire somewhere in the White/Black wire between the controller connector and the 3 pin connector at the MCOR.
If You measured close to +5v on the test above:
Disconnect the 3 pin connector at the MCOR and measure the Voltage at the White/Black wire, You should get the same voltage You measured at the controller.

Set the meter to 20kΩ, and measure directly at the MCOR pins that correspond to the wire colors below:
  • From White/Black to Purple: Around 7kΩ (does not change with pedal movement)
  • From Yellow to Purple: (Pedal Up: around 1kΩ, Pedal Down: around 7.6kΩ)


Sergio said:
If You only Get around the 2.1v you measured earlier, disconnect the 3 pin connector from the MCOR and repeat the test above.

If it is still around 2.1v, the controller is likely the problem

I did this and it stayed at 2.1


Then Sergio said:
Set the meter to 20kΩ, and measure directly at the MCOR pins that correspond to the wire colors below:


From White/Black to Purple: Around 7kΩ (does not change with pedal movement) It didnt change

From Yellow to Purple: (Pedal Up: around 1kΩ, Pedal Down: around 7.6kΩ)

Pedal up, I got 1Ω

As I pressed the pedal down the Ω'age went up gradually, topping out at 19.75. I did set the meter at 20kΩ
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Unread 12-06-2014, 02:37 PM   #37
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by Merlinhaggard View Post
TD (Can I call you that)? What does connecting the blue to the red do? Just curious..
It provides direct power to the controller instead of having to rely on the OBC to power it up.
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Unread 12-06-2014, 02:40 PM   #38
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by TahoeDawgZ71 View Post
It provides direct power to the controller instead of having to rely on the OBC to power it up.
Thank.. I'm just waiting on a new controller. See what happens.
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Unread 12-06-2014, 03:59 PM   #39
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Default Re: Couple of wiring questions.

Quote:
Originally Posted by Merlinhaggard View Post
Thank.. I'm just waiting on a new controller. See what happens.
I think it'll run.
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Unread 12-06-2014, 07:30 PM   #40
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Default Re: Couple of wiring questions.

I just spent probably 3 hours working on the cart.

Re-verified wiring 50 times.

Installed a 48v-12v converter.

The converter wired up gets me 12v at the headlight switch. I can see it going out when I pull the switch, but no lights. Ill track that down.

No brakes either.

Here's the relay I put in. Is the relay just for the brakes? I have 48v going in on a blue wire I think, 12v to another. When I press the brakes, I get no V's out of any of the slots.





Here's the Resistor I put on the solenoid.




What tells the brakes to light up? The pedal, obviously, but going into the relay, which wire is the trigger? Also which wire sends power once the pedal is pushed?


Thanks guys!!!!
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