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Unread 06-08-2015, 10:02 PM   #31
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Default Re: Is Controller or OBC Bad

well the fun never stops, now if we disconnect all the wires from the motor (A1,A2 F1,F2) we get 40 volts off of F2 with controller plugged up and in run and in fwd and nothing still off F1, #2) when we checked the potentiometer out earlier we did it by checking pin 9 for 5 volts and we had that (4.8 ), then we checked ohms between pins 7 and 8 by depressing go pedal, we saw ohms drop and rise as expected and thought pot to be ok. If we were told correct, someone said, we could check the pot another way. they said if we checked pin 7 we should have approx 3.8v with pedal up and should fall to 0v when completley depressed. we connected the controller up and what we found is that we get 4.8v from pin7 it stays at 4.7v no matter how we push pedal ?? am I doing something wrong ? we dbl checked sweep by checking ohms and it is operating as designed ?? has anyone seen this ?
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Unread 06-08-2015, 11:08 PM   #32
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Default Re: Is Controller or OBC Bad

If you are getting a resistance varying from 5k to 0 between pins 7 and 8 of the controller connector ( when disconnected from the controller) as you press the pedal all the way down, then the multi-step pot is working correctly.

Please make sure that you don't see 0L (Open Line) on your multi meter as it indicates an open circuit and not 0 ohms.

If that is the case but the voltage on pin #7 does not change from approx 4.8v to 0v, the controller is not provinding negative on pin #8 .
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Unread 06-09-2015, 10:35 PM   #33
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Default Re: Is Controller or OBC Bad

Sergio, I am in contact with a engineer from CTS on the controller and you know you are correct. Hearing you say that, makes me feel pretty confident that we might be on to something because, That is exactly what he said it sounded like to him. BUT hopefully he is going to get on the phone with dad and maybe they can figure out why pin 8 MIGHT NOT be providing the neg. so stay tuned I will let ya'll know what we find out. we got a call today from someone with a YAMAHA I don't know what year or model or anything yet,( he left a message and I have not called him back yet) but after trying to work on this one I am not sure if I want to try another one LOL
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Unread 06-16-2015, 07:43 PM   #34
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Default Re: Is Controller or OBC Bad

well after working with the engineer from CTS the conclusion was that the potentiometer was not compatible with the controller. HMMMMM it was the exact same mcor 4 and same model controller that was on the cart when we received it, so that makes no sense to me. we ended up taking cart to the ClubCar shop and we will let them figure it out. I will try to find out what was done to complete the repair and post when I do. Thanks for the help, we learned a lot from this one with you guys help so thanks again for the help.
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Unread 06-17-2015, 12:11 AM   #35
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Default Re: Is Controller or OBC Bad

Quote:
Originally Posted by usagcr View Post
well after working with the engineer from CTS the conclusion was that the potentiometer was not compatible with the controller. HMMMMM it was the exact same mcor 4 and same model controller that was on the cart when we received it, so that makes no sense to me. we ended up taking cart to the ClubCar shop and we will let them figure it out. I will try to find out what was done to complete the repair and post when I do. Thanks for the help, we learned a lot from this one with you guys help so thanks again for the help.
Makes no sense to me either. The MCOR4 is compatible with every 48 Volt Club Car vehicle that was built after the 16th week of the 1995 model year.
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Unread 07-06-2015, 09:11 PM   #36
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Default Re: Is Controller or OBC Bad

well we ended up getting the cart back from the CC dealer/shop. I do not think they wanted to work on it either. I am not sure what they did or did not do, but they told our customer that he has a bad motor and that it is obsolete and they could not help him he needed to come pick it up ?? I isolated the motor (disconnected all wires) and jumped A1 and F1 and jumped A2 and F2 I jacked up the cart and used a 12 volt battery for testing, to my surprise the motor started spinning, so I reversed polarity on the jumped A1/F1 and A2/F2 and the motor spun again BUT The dang thing spun in the same direction, so I reversed polarity again and again and again and the motor spins in the same direction no matter how I connect pos and neg. Now when I say the motor is spinning in the same direction I am looking at the driver side rear wheel. That is what I see spinning in the same direction. So now the customer wants to buy a motor from Buggies Unlimited and he said it was numbered 7177. When we just installed a new controller it is only 220A he will need a higher amp controller is that correct ? and is there any thing else that will need to be changed to accommodate the new motor like solenoids or anything ?? Tahoe Dawgz If you are reading this I will call you tomorrow about the motor like we discussed. But I am still concerned with my reading on PIN 7 the yellow and black wire, I still dont see a good 5v and see it drop to zero. I see around 3.5v and it will drop to zero and then return to 3.5v as accelerator pedal is depressed and released. So I told customer that I do not want to guarantee that if he puts a new motor in that his cart will operate as it is supposed to if at all. what a nightmare I told our customer to give me a day or two and I would reach out to you guru's as well as see if I can get my hands on a compatible motor and see if it fixes this demonized cart or if he would be wasting his money. Any and all advice is greatly appreciated. Thanks a million in advance
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Unread 07-06-2015, 09:43 PM   #37
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Default Re: Is Controller or OBC Bad

This is exactly why I convert all of these cars to IQ. I will be waiting for your call.
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Unread 07-06-2015, 10:55 PM   #38
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Default Re: Is Controller or OBC Bad

My cousin said it seems like someone has already made this one an IQ ?? not sure what I said to him to make him think that, but he is supposed to know. yes I will be calling. Thanks
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Unread 07-06-2015, 11:05 PM   #39
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Default Re: Is Controller or OBC Bad

It's not an IQ if it's got the Regen2 controller and the dynamic braking solenoid.
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Unread 07-07-2015, 07:50 AM   #40
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Default Re: Is Controller or OBC Bad

First of all, I am also of the opinion that when those old systems start having problems you are better off converting to an entire IQ system (harness and controller).

As far as testing the motor, You need to reverse the polarity of the coils in relation to each other for the motor to change directions.

Connect A1/F2 and A2/F1, it does not matter which side you put the positive or negative.

I did not realize that cart had an MCOR4 until You said the cart was already at the Club Car dealer.

The MCOR4 has a compatible resistance and it has the same Deutsch 3-pin connector as the old Multi-Step potentiometer, but as I said earlier, those were evolution years for that model.

The diagrams show the actual "pin" positions in the 3-pin connector are not the same as in the MCOR.

The Yellow and Purple are reversed.

If Your voltage at pin#7 is not gradually going from 3.5v to 0, but instead is staying at 3.5v and going directly to 0v, someone may have used a harness adapter that was intended for an MCOR2 to MCOR4.

If You measure the MCOR4 resistance directly at the 3-pin connector that connects into the cart harness, the pins that correspond to the purple and to the white wires on the cart harness, should not change resistance if you press the pedal, if they do, the yellow and purple wire pins are reversed for that cart.
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