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Unread 09-28-2016, 08:57 PM   #41
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Default Re: Power Surging?

Where did you take the ohm reading as it is different than post #3 results?

Edit:

I am assuming You took that reading from Yellow to Pack Negative or B-.

That is a good reading to compare to the other half of the MCOR on post #3, but make sure that Terminal #3 - Green Wire - is unplugged from the Controller for the test.

Definitely try the MCOR-4.

Last edited by Sergio; 09-28-2016 at 10:16 PM.. Reason: More Information
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Unread 09-29-2016, 08:58 AM   #42
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Default Re: Power Surging?

Quote:
Originally Posted by Sergio View Post
Where did you take the ohm reading as it is different than post #3 results?

Edit:

I am assuming You took that reading from Yellow to Pack Negative or B-.

That is a good reading to compare to the other half of the MCOR on post #3, but make sure that Terminal #3 - Green Wire - is unplugged from the Controller for the test.

Definitely try the MCOR-4.
I took the ohm reading at the yellow wire (terminal #3) at controller and B-. Had the wife push the pedal. And yes, the pedal depressed ohms were different than before with the old resistor. I did not unplug the green wire, but will test again this afternoon.
I can only assume the MCOR needs to changed, or I have a mysterious short in the wiring harness somewhere. At this point, I'm questioning all components. I keep thinking there is something simple that I'm overlooking, but I can't find it. May need another set of eyes.
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Unread 09-29-2016, 09:52 PM   #43
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Default Re: Power Surging?

Unplugging the green wire did not change anything. Ohms are the same.
I tried a few different wiring combos with the old and new resistor and nothing worked. Even tried wiring everything back up to the micro switch with old then the new resistor, nothing.
Removed the MCOR and was going to replace with MCOR4, but the connectors were different, so I gave up. Still get the 3 red controller blinks no matter what I do.
Is there anything else I can do?
Could it be a motor issue, OBC, wiring harness? Just thinking of what's possible.
I can't stand the thought of taking it to someone. I can't stand something beating me like this, but I'm losing interest and I need to leave it alone for a while.
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Unread 09-29-2016, 09:58 PM   #44
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Default Re: Power Surging?

Not sure if it means something, but after turning off the shop lights in defeat, I noticed the low battery warning light was on. It would come on for @10 seconds then go off @5 seconds, then repeat. Batteries pack is 50.5
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Unread 09-29-2016, 10:24 PM   #45
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Default Re: Power Surging?

I think that blink pattern is the error code when the charger is plugged to the cart but the AC is unplugged.

That reading of 5400Ω is too low, it should be more like 7860Ω.

Make sure the purple wire from the MCOR is making good contact with the B-controller Terminal and please measure the resistance again from Yellow to B-.

Since we know that without the resistor and with MCOR 2-pin by-passed it did not trigger the fault, the best thing would be to download the free software from Alltrax, get a usb-serial cable and change the programming to disable HPD.

Getting the software and cable will get you a break and it is a good idea to check the other settings on the controller.
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Unread 09-29-2016, 10:37 PM   #46
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Default Re: Power Surging?

Quote:
Originally Posted by Sergio View Post
I think that blink pattern is the error code when the charger is plugged to the cart but the AC is unplugged.

That reading of 5400Ω is too low, it should be more like 7860Ω.

Make sure the purple wire from the MCOR is making good contact with the B-controller Terminal and please measure the resistance again from Yellow to B-.

Since we know that without the resistor and with MCOR 2-pin by-passed it did not trigger the fault, the best thing would be to download the free software from Alltrax, get a usb-serial cable and change the programming to disable HPD.

Getting the software and cable will get you a break and it is a good idea to check the other settings on the controller.
The 5400 ohm is with the new 3.9 resistor. I do get 7800 with the old (original) resistor.
Can I run the cart indefinitely with the HPD setting disabled, or is it a temporary solution?
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Unread 09-29-2016, 10:59 PM   #47
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Default Re: Power Surging?

I am a little confussed, on post #3 You said the resistance From Green wire to Yellow wire with the cart in Forward (no resistor) was:
It's steady at 1140 when pedal is fully depressed. 7900 at rest, pedal up.

You could not get down to 1140Ω (pedal depressed) if there was a resistor there as it would be in series with the Green wire.

The measurement from Purple wire (B-) to Yellow wire should be other side of the MCOR (no resistor there) and change resistance in the opposite direction, but pretty close in range.

The last value to test is the reading from Green wire to Purple Wire (B-), that should be steady regardless of pedal (we can discount the resistor if it is there).

I just want to male sure there is not a cross-wire somewhere.

You can run with the HPD disabled, I am saying this because the pedal is just a little too high when the MCOR micro-switch closes.
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Unread 09-30-2016, 09:28 AM   #48
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Default Re: Power Surging?

Quote:
Originally Posted by Sergio View Post
I am a little confussed, on post #3 You said the resistance From Green wire to Yellow wire with the cart in Forward (no resistor) was:
It's steady at 1140 when pedal is fully depressed. 7900 at rest, pedal up.

You could not get down to 1140Ω (pedal depressed) if there was a resistor there as it would be in series with the Green wire.

The measurement from Purple wire (B-) to Yellow wire should be other side of the MCOR (no resistor there) and change resistance in the opposite direction, but pretty close in range.

The last value to test is the reading from Green wire to Purple Wire (B-), that should be steady regardless of pedal (we can discount the resistor if it is there).

I just want to male sure there is not a cross-wire somewhere.

You can run with the HPD disabled, I am saying this because the pedal is just a little too high when the MCOR micro-switch closes.
Let me check again this afternoon with a clearer head. I was very frustrated last night and may have measured or reported incorrectly. And I'll check purple/green B- also.
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Unread 10-02-2016, 08:15 PM   #49
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Default Re: Power Surging?

After taking a few days off, I measured everything (ohms) again. All with the cart in forward and key on. I took 2 sets of readings. One with the new 3.9K resistor inline and one without (straight wired green to black, no micro switch or white wire). Readings were identical.

yellow to B-
pedal up 1100
pedal down 7800

yellow to green
pedal up 7900
pedal down 1100

yellow to purple
pedal up 1100
pedal down 7900

green to purple
pedal up 6800
pedal down 6800

Ohms are steady with the pedal, no fluctuations. Cart still won't move. Still get the 3 red controller blinks (HPD). Pack voltage is 51.4 each battery is 8.5-8.7V. Solenoid clicks every time.

I removed the MCOR and mounted the MCOR4 but then realized the two harness connectors were different and would not work on new MCOR.

Looking at the Alltrax website, the download doesn't state that it's compatible with Windows 7 (what I have). I do have a USB-serial cable.
Any thoughts?
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Unread 10-02-2016, 09:40 PM   #50
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Default Re: Power Surging?

Any Reading from B- or Purple wire should be the same, is the Purple wire connected to B-?

Any reading from the Green wire should increase when the Resistor is inline with the Green wire.

I never used the Controller Pro software, but It looks like the warnings on Alltrax site are related to to the USB-Serial adapter driver compatibility, since You have a cable that works with your system already, try the software.
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