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Unread 12-31-2013, 09:52 AM   #11
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Default Re: Inside An MCOR 01-04 DS

Any chance you can measure the open and closed throttle resistances on the pot? I'm just curious! That unit seems awful expensive to just have those 2 main components!
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Unread 12-31-2013, 11:00 AM   #12
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Default Re: Inside An MCOR 01-04 DS

I can do that...
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Unread 12-31-2013, 11:10 AM   #13
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Default Re: Inside An MCOR 01-04 DS

They call this a 0-5k pot. These are common readings though...

MCOR Test
Across MCOR White-Purp/white 6.85k
Yellow-White 7.98k pedal up - Pedal down. 1.75k
Yellow-purp/white 1.13k pedal up - Pedal down. 7.7k

These are readings at the 16 pin motor controller plug. May be a little lower value directly at the MCOR.
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Unread 01-03-2014, 08:24 PM   #14
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Default Re: Inside An MCOR 01-04 DS

These are pics of the Old and New switch, mounted switch, dielectric grease and then PCB soldered in and ready for the lid. I ended up tearing down an old pool deck this afternoon, so I just let the RTV cure on the lid and will try it out tomorrow.
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File Type: jpg New Switch.jpg (235.3 KB, 0 views)
File Type: jpg mounted.JPG (128.7 KB, 0 views)
File Type: jpg Dielectric Grease.jpg (179.6 KB, 0 views)
File Type: jpg Ready for Lid.jpg (161.3 KB, 0 views)
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Unread 01-04-2014, 02:58 PM   #15
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Default Re: Inside An MCOR 01-04 DS

Nice Job! Too bad they make these things to throw away rather than to service. The case could be screwed together with an "o" ring to seal it rather than glued.
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Unread 01-04-2014, 03:34 PM   #16
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Default Re: Inside An MCOR 01-04 DS

Here it is sealed up. I used Ultra Grey RTV. It is a high torque sealant. Meaning it resists twisting and is harder than the Blue, Red or Black. It is tough for this type of service.
I GPS'd the cart with the used MCOR and got 14.5 mph. I then swapped for the one I repaired and ran 17.5 mph! There must be a little ohm difference between the two POTs that I will measure out of curiosity.
The cart is running perfectly with either. It was just bumping a few inches or cutting out when going down the road. Now it goes every time I press the go pedal. These are repairable if you have the knowledge, tools and time for $25. The switch is from Newmark.com, an ITW(Licon)#11-304 for any of you diy'ers.
I would have tried a hot air gun to open the case but I couldn't find mine in my messy shop, so I cut it open with a Sonic Crafter.
I hope this thread helps anyone wanting to attempt a MCOR repair.
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File Type: jpg Sealed.jpg (105.1 KB, 0 views)
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Unread 01-04-2014, 04:03 PM   #17
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Default Re: Inside An MCOR 01-04 DS

Used/Replacement MCOR: 14.5 mph
Yellow to White 6.48k up, 1.07k down
Yellow to Purple/White 1.09k up, 6.4 down

Repaired Original MCOR: 17.5 mph
Yellow to White 7.9k up, 1.6k down
Yellow to Purple/White 1.13k up, 7.7k down

These readings were taken right off the pins of the MCORs.
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Unread 01-04-2014, 04:18 PM   #18
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Default Re: Inside An MCOR 01-04 DS

You may have stumbled upon a possible speed upgrade!
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Unread 01-04-2014, 05:27 PM   #19
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Default Re: Inside An MCOR 01-04 DS

Blade, you noticed that too..? lol
I was waiting for someone to notice that...

My sealant job is a little messy, but I put one bead on to close it up and then a second coat over the seam just for good measure.
I don't think that I will have any problems with that. Water could more easily get in around the input shaft, the way it is made.
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Unread 01-04-2014, 08:41 PM   #20
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Default Re: Inside An MCOR 01-04 DS

This is very interesting, I'm looking forward to the longer term test results as well. Cost effective speed upgrade = awesome!
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