AQ03 Model

[Sergio]

If the power above (or last page...) measured correct, test the MCOR circuit (3 pin plug disconnected):

1) Controller power to MCOR (measured at the harness):

Pack positive to purple wire: +48v
White/Black wire to Pack negative: +5v

2) MCOR resistance (meter set to 20kΩ, measured at the MCOR pins):

Yellow to Purple (pedal up to pedal down): 1kΩ to 7kΩ
Yellow to White/Black (pedal up to pedal down): 7kΩ to 1kΩ
White/Black to purple (pedal up to pedal down): constant 6k

The 1kΩ, 6kΩ and 7kΩ are nominal readings, You can post your actual readings, but they should be around that range of values.

[Andy4639]

Ok key switch has 48.9 volts coming in and going out checked with key on/off.

Green wire at Micro switch connection nothing disconnected. Dark wire looks black but maybe blue has 48.9 on it with key on. This is the wire that feeds the micro switch that should be the green wire coming out of micro switch when connected going to the blue wire at OBC correct that ties into a few other wires you are talking about at the junction? Correct...sonic weld where the power splits this should be under the cart in the wire loom correct?

[CCFanatic]

Originally Posted by Andy4639

Ok key switch has 48.9 volts coming in and going out checked with key on/off.

Green wire at Micro switch connection nothing disconnected. Dark wire looks black but maybe blue has 48.9 on it with key on. This is the wire that feeds the micro switch that should be the green wire coming out of micro switch when connected going to the blue wire at OBC correct that ties into a few other wires you are talking about at the junction? Correct...sonic weld where the power splits this should be under the cart in the wire loom correct?

Yup, it will be on the pass. side frame rail right near where the loom splits with a "T"

[scottyb]

I recall 3 sonic welds in this cart. 03 IQ was the worse cart I ever tackled. It was mine too It kept going into safe mode (very slow operation) After taking to 2 other technicians, in total frustration, I ended up replacing the wire harness which fixed the problem.

[Sergio]

I thought we were talking about the blue wire at the 2 pin MCOR, which blue wire did you measure +37v on the previous post?

[Andy4639]

Green wire comes out of micro switch and goes toward back hooks to a yellow wire between the passenger side batteries loom and green goes into controller plastic plug. Yellow goes to the plug that I have disconnected with the blue wire and red wire from OBC. Sergio first post.

I have all the loom off and the wires exposed.

[Andy4639]

Originally Posted by Sergio

I thought we were talking about the blue wire at the 2 pin MCOR, which blue wire did you measure +37v on the previous post?

The blue wire at the disconnect of the OBC. you said see if I'm getting 48 volts to it I thought. Back at the OBC connection you told me to jump the blue and red wires. This blue wire has nothing to do with the micro switch wiring that I can see.

[Sergio]

All that sounds correct, this is where I am confused, I asked if You had +48v on the blue wire at the MCOR otherwise the jumper has no effect.

Originally Posted by Sergio

Are you getting +48v on the blue wire?

Originally Posted by Andy4639

No only 37 volts on blue wire in harness.

Originally Posted by Andy4639

Dark wire looks black but maybe blue has 48.9 on it with key on

So, where did the +37v reading come from?

[Andy4639]

The OBC connection where you told me to disconnect it from the OBC. Jump the red and blue wires. Back beside the controller.




This connection has the 6 wires in it.

[Sergio]

I guess some of our postings got crossed....

The Blue wire from the OBC is a Controller input signal, it has no voltage if disconnected (You may get a ghost voltage reading depending on the impedance of your meter).

The OBC sends a +48v signal on that wire if the charger is not plugged in.

Jumping the red (constant +48v) to the blue wire in the OBC 6-pin plug just tells the controller the charger is never plugged in (lockout by-pass).

Keep the OBC by-pass in place for now.

Keep the MCOR 2-pin micro switch by-pass in place for now.


Go ahead and do the MCOR tests to make sure that side is working correctly.