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Unread 03-31-2012, 05:30 PM   #21
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

The cart is a series and the batteries are (NAPA No: 8148 N) (GC-2) (85 min. @ 75 amps).....going back to what everyone originally asked about the batteries being fully charged...I charged them the entire first night and have 51 volts in the pack...is additional charging needed?????
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Unread 03-31-2012, 10:20 PM   #22
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

Quote:
Originally Posted by jcoxsouthernforest View Post
The cart is a series and the batteries are (NAPA No: 8148 N) (GC-2) (85 min. @ 75 amps).....going back to what everyone originally asked about the batteries being fully charged...I charged them the entire first night and have 51 volts in the pack...is additional charging needed?????
Since it's series, that is why you do not have a tow/run switch. I will post the test procedures for the MCOR but it is a fact that when MCORs go bad they can cause a shutter and slow acceleration.

How to Test an MCOR.

MCOR Voltage Test without the IQDM Handset
1. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position
jack stands under the frame crossmember between the spring mount and side stringer, just forward of
each rear wheel. See WARNING “Lift only one end...” in General Warning, Section 10, Page 10-1.
See following NOTE.
NOTE: The key switch should be placed in the OFF position and left in the OFF position for the duration of
this test.
2. With the batteries connected, place Tow/Run switch in RUN. Using a multimeter set to 200 volts DC,
place red (+) probe on battery no. 1 positive post and place black (–) probe (with insulation-piercing
probe) on the purple/white wire (1) at a point close to the three-pin connector at the MCOR (Figure
11-11). The reading should be approximately 48-50 volts (full battery voltage).
Figure 11-11 Test MCOR: Purple/White Wire (+)
ELECTRICAL SYSTEM AND TESTING Troubleshooting
2008 IQ Plus Electric Vehicle Maintenance and Service Supplement Page 11-19
11
3. If reading is zero volts, check the purple/white wire continuity from the three-pin connector at the MCOR
to the 24-pin connector at the speed controller. Check terminal positions in three-pin connector at the
MCOR and the 24-pin connector. If all of the continuity readings are correct and the connectors are wired
correctly, replace the speed controller.
4. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 8 negative post and the red
(+) probe (with insulation-piercing probe) on the white wire (2) at a point close to the three-pin connector
at the MCOR (Figure 11-12). The reading should be approximately 4.65 volts.
5. If reading is zero volts, check the white wire continuity from the three-pin connector at the MCOR to the
24-pin connector at the speed controller. Check terminal positions in three-pin connector at the MCOR
and the 24-pin connector. If all of the continuity readings are correct and the connectors are wired correctly,
replace the speed controller.
6. With multimeter set to 20 volts DC, place the black (–) probe on battery no. 8 negative post and the red
(+) probe (with insulation-piercing probe) on the yellow wire (3) at a point close to three-pin connector at
the MCOR (Figure 11-13). The reading should be approximately 0.32 volts with the pedal up. Slowly
press the accelerator pedal and note the readings on the multimeter. As the pedal is pressed, the reading
should increase until it reaches 4.65 volts when the pedal is fully pressed.
7. If reading does not increase as the pedal is pressed, replace the MCOR.
8. If the reading is not approximately 4.60 volts with the pedal fully pressed, the vehicle will not operate at
rated top speed. Check the MCOR resistance.
8.1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally start-
Figure 11-12 Test MCOR: White Wire (+)
Figure 11-13 Test MCOR: Yellow Wire (+)
Passenger Side Frame Rail
3
ELECTRICAL SYSTEM AND TESTING Troubleshooting
Page 11-20 2008 IQ Plus Electric Vehicle Maintenance and Service Supplement
11
ing...” in General Warning, Section 10, Page 10-1.
8.2. Disconnect the 24-pin connector at the speed controller.
8.3. Set a multimeter to 20k ohms. Connect the red (+) probe of the multimeter to the yellow wire at the
MCOR three-pin connector with an insulation piercing probe. Connect black (–) probe to the purple/
white wire with an insulation-piercing probe.
8.4. With the accelerator pedal fully up (not pressed), the multimeter should read approximately 1k
ohms.
8.5. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should rise as
the pedal is pressed. When the pedal is all the way to the floor, the multimeter should indicate
between 5.67k ohms and 7.43k ohms.
8.6. Using a multimeter set for 20k ohms, connect the red (+) probe of the multimeter to the yellow wire
at the MCOR three-pin connector with an insulation piercing probe. Connect black (–) probe to the
white wire with an insulation-piercing probe.
8.7. With the accelerator pedal fully up (not pressed), the multimeter should indicate between 5.67k
ohms and 7.43k ohms.
8.8. Slowly press the accelerator pedal while monitoring the multimeter. The resistance should drop as
the pedal is pressed. When the pedal is all the way to the floor, the multimeter should indicate
approximately 1k ohms.
8.9. If the MCOR does not operate as described, replace the MCOR.
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Unread 04-01-2012, 10:35 AM   #23
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

Another find on our cart.....with the meter out again I have an issue with the volts on the motor terminals....mine has an A1, A2, S1, & S2.....with the pedal pushed I get full volts on A1 (51 volts), and only 34 volts on A2, however when the motor levels out and runs at full speed I have 51 volts on all.....anyone have any ideas??????
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Unread 04-02-2012, 09:59 AM   #24
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

Quote:
Originally Posted by jcoxsouthernforest View Post
Another find on our cart.....with the meter out again I have an issue with the volts on the motor terminals....mine has an A1, A2, S1, & S2.....with the pedal pushed I get full volts on A1 (51 volts), and only 34 volts on A2, however when the motor levels out and runs at full speed I have 51 volts on all.....anyone have any ideas??????
I don't think this is not normal. The voltages vary.. Try to address the MCOR before going further.
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Unread 04-02-2012, 06:52 PM   #25
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

Cheapjeep2.....I took the MCOR off my father-in-laws CC which is a year newer than ours (same part #) and tried it...still no go......my MCOR worked well on his cart......any further thoughts???????
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Unread 04-02-2012, 09:59 PM   #26
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

Well that is good now you know you have eliminated that. I am not sure what else to check at the moment, possibly the controller. Anyone?
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Unread 04-03-2012, 05:45 PM   #27
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

Thanks....the MCOR is good...while on jackstands the cart slowly gains speed and levels out for a second then slows almost to a stop....then starts the same way over and over again....I am totally lost!
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Unread 04-03-2012, 09:12 PM   #28
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

My vote from what you are telling me that the problem is the the controller, but this is where we need TahoeDawg to chime in. Perhaps you can send him a private message and ask him to read this thread.
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Unread 04-03-2012, 11:52 PM   #29
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

Take a clear picture of your battery compartment and post it here.
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Unread 04-04-2012, 06:39 PM   #30
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Default Re: 2003 48 volt CC....installed 6-6volt batteries instead of 6-8 volt

Batt. 1.jpg

Batt. 2.jpg
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