Precedent Professional stops but starts again if accelerator raised and redepressed

[Mooncarter]

Waiting. And hope you people are safe.

[Rob_C]

Thanks Mooncarter,

Tracking says I should have the solenoid tomorrow.

We've had some rain for the last few days that have dampened any local fires but there's still 100 fires burning in this state and Victoria south of us is still in a bad way fire wise. Mother nature is laughing here, Queensland north of us had heavy flooding today due to deluge rain and north western Australia just had a cyclone whilst the south of that state burnt.

Cheers,
Rob

[Rob_C]

Well sadly, we still have the same issue despite the replaced solenoid only now there's no real forward motion.

Pack voltage was high 49V and connecting the charger saw it back to 51+V in a few minutes.

Depress the pedal solenoid kicks in but maybe half a second later kicks out.

The micro switch in the MCOR works as it should,resistance from the orange to the white/grey stripe wire starts out around 1200 ohms and finishes at around 7500ohms, orange to purple is the same but opposite and purple to white is around 6300 ohms. These were smooth readings, no jumping up or down between values.

I'm assuming the controller has issues but have no test info for it. If anyone can offer advice or a test regime I'd appreciate it, it's a Curtis 1510A-5250

Cheers,
Rob

[Sergio]

The resistance ranges You posted are backwards, if not by mistake that is your problem.

The White/Black wire is the top of the MCOR and should get a constant +5v from the Controller pin #1.

The Purple wire is the Low side of the Potentiometer and it should be 0v or common negative connection.

The Yellow wire is the slider and it should be near 0v with the Pedal UP, pressing the pedal it should be 0.35v when the micro-switch clicks and above 4.65v with the pedal all the way down.

The resistance from Yellow to Purple should be 1200Ω to 7500Ω.

The resistance from Yellow to White/Black should be 7500Ω to 1200Ω.

You can also measure the throttle voltage directly at Controller pin #2 to make sure the voltage levels match the proper levels described above.

[Rob_C]

Thanks Sergio,

Most likely I made a mistake on the colours as I was posting from memory and It'd be an incredible coincidence to have the correct values at the incorrect ends of the scale. I have the MCOR here but not a wiring diagram.

Would you have a test procedure for the controller at all please? (1510A-5250)

Cheers,
Rob

[Sergio]

You really need to test the throttle signal on Pin #2 of the controller 16-pin connector to make sure the voltage is within range.

If the voltage is higher than 0.35v when the MCOR micro-switch closes the Controller will get an High Pedal Detected error and deactivate the Solenoid.

This diagram should match what You have, the 1510 is the stock controller:

[Rob_C]

Thanks very much Sergio,

I appreciate the input and will go out and check it at some point during the day (assuming the customer is home) and report back.

Cheers,
Rob

[Rob_C]

G'day Sergio,

I got back there this morning.

MCOR resistance values are correct as described.

Voltage at pin #1 is a constant 4.7V
Voltage at Pin #2 with the pedal up is 0.315V
Voltage at pin#2 when the solenoid engages is 0.91V
Voltage at Pin #2 pedal fully depressed is 4.629V

Today sometimes when you pressed the throttle (with one wheel in the air) the solenoid would cut in and out almost immediately with no rear wheel movement, at other times the cart would run up to around 3/4 speed then the solenoid would drop back out.

Cheers,
Rob

[Rob_C]

Anyone able to offer advice please?

[Rob_C]

I found the following test procedures from Sergio elsewhere on this site and have added the test values in blue at the appropriate points.
http://www.buggiesgonewild.com/elect...-little-3.html

Initial pack voltage was 49.5V

To safely troubleshoot the cart you will need to raise one of the rear wheels OFF the ground.

I am not sure if you tested the battery and high current system under load as I had suggested to do prior to by-passing the OBC, so we will test that as well.

With one rear wheel lifted put the cart in FWD and turn the key ON.

Place your meter positive probe on controller B+ and the negative probe on the pack negative battery post.

Measure the Voltage (pre-charge voltage). 49.05V

Slowly press the pedal until You hear the Solenoid "click"

Measure the voltage (it should be higher).49.45V

Slowly press the accelerator and record the voltage to see if it drops as the pedal is pressed.Unabkle to run this one as the solenoid drops out almost immediately

Verify that the rear wheel turns in the opposite direction when you put the FNR in REV (to make sure the field driver is working).Yes, albeit briefly due to the solenoid

Please post your measurements so we can be sure the Controller is getting enough voltage trough the Solenoid and cables.



If the issue is not with the high current feed, You will need to check the Controller 16-pin connector for the necessary signals.

With one rear wheel lifted put the cart in FWD and turn the key ON and press the pedal just enough the click the Solenoid.

Put the meter negative probe on the pack negative battery post.

Test the following pins on the Controller 16-pin connector with the meter positive probe.

Pin 5 - Light Blue Wire.Pedal Up 40.2V, Down 40.1V
Pin 6 - Green Wire.Pedal Up 0V, Pedal Down, OL Voltage outside range
Pin 8 - White Wire.Pedal Up 49.5V, Down 49.4V
Pin 9 - Gray Wire.Pedal UP 49.5V, Down 49.4V
Pin 10 - Tan wire.Pedal Up 49.5V, Down 49.4V

All of those pins should show near pack voltage. Pin 5 and Pin 6 do not?

To test the Throttle signal, set the meter to 20vDC and place the meter negative probe on pack negative battery post.

Put the meter positive probe on Pin 2 - Yellow wire.

The voltage should range from around 0.3v with the pedal UP to more than 4.65v with the pedal all the way DOWN. 0.31 up to 4.63 down

To test the Controller Output, set the meter to 200vDC, FNR in FWD and Key ON.

Place the meter positive probe on Controller M- and meter negative probe on Controller B-. 48.94V

The voltage should vary from near pack voltage when the Solenoid "clicks" to near 0v with the pedal all the way DOWN.Unable to run this one due to the solenoid dropping out