Swapped Batteries Cart Won't Run

Muddog

CC DS Series

Swapped out a set of Interstates for some Mid 2016 Trojans.
Cart ran fine with the Interstates.
Trojans charged like they should to 50+ volts, charger cut off like it should.
Stepped on pedal and cart won't move, if you jack it up and press pedal to floor, the wheels will barely move. Pack voltage 50.1 with no drop when pedal is pressed. Stays at 50.1.
All cables and connections are good.
Good F/R switch.
Solenoid clicks.
Have pack voltage into and out of solenoid when pedal is pressed.
MCor is reading .5K ohms to 7k ohms. I've checked everything I could according to manual.
Could it be in the controller or motor?

BGW

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scottyb

Cart ran good before the battery swap. Most likely you have not connected the batteries properly.

Muddog

Probe on positive on # 1 and probe on neg on #6 50.1 volts

Sergio

That MCOR reading looks like was taken right at the MCOR, You may have accidentally disconnected the green wire from micro-switch #3.


Disconnect the 2 quick connectors from Controller Terminal #2 and #3 and measure the MCOR resistance range between those 2 wires with the FNR in Forward.

Muddog

That reading was at purple and yellow wires disconnected from controller.
Reading across #2 & #3 wires, green and yellow. Pedal up 5.8K ohms pedal down 2.8k ohms

Sergio

Were the wires disconnected from the Controller and the FNR in Forward on the test above?

Based on your previous test of the bottom side of the MCOR, You should have got a range around 7kΩ to 0.5kΩ between the Green and Yellow wires.

Muddog

First test: Purple wire disconnected from lug and yellow wire disconnected from terminal.
Pedal up: .5K ohm
Pedal down:7k ohms

Test 2:Terminal wires 2 & 3 disconnected green/yellow F/R switch in forward.
Reading across yellow/green wires
Pedal up: 5.8K ohms
Pedal down: 2.8K ohms

Sergio

Those numbers don't make sense, when the FNR is in Forward, the Green wire should go straight to the Top of the MCOR (0Ω resistance from Controller #2 green wire to MCOR black wire).

The Yellow "wiper" wire goes from the Bottom (purple) to the Top (black) as you press the pedal, You cannot get a different amount of resistance change as You are getting (6.5kΩ vs 3kΩ) unless there are other factors involved.

The low 0.5kΩ resistance would indicate a newer MCOR, but I have seen pictures of a Chinese MCOR posted here that have capacitors soldered between the resistance tracks of their MCOR version, that could certainly cause this strange readings.

You may want to measure the actual Throttle voltage since that is how the Controller works anyway.

Pull the Yellow wire from Terminal #3 just far enough so You can put your meter positive probe there, leave everything still connected to the Controller and the FNR in forward.

You should get close to 0-5v as You press the pedal.

If You don't, make sure none of the throttle wires got "pinched" under the batteries.

kenhouser

this may be a stupid question but have you reset the OBC
changing Batteries sometimes gets them confused.

Sergio

He said the solenoid is clicking, so the OBC is not causing a "lock-out".