AQ03 Model

[Sergio]

The paper clip is to go into the female socket in the 3-pin Deutsche connector that is attached to the MCOR harness since a regular meter probe will not go into the socket.

I agree that holding probes into the the pins of the MCOR itself is a 2 person job unless you have the proper accessories.

As jjance mentioned, You should have small alligator clips (with insulation boots). I prefer to use what is called a "mini grabber" probe for those male connector pins.

Another probe accessory that comes handy is a wire piercing probe (cradles the wire) or a plain back probe (long hat needle looking probe).

I am attaching a high resolution wiring diagram for your cart.

The MCOR voltage test needs to be done at the MCOR harness 3-pin connector (while it is disconnected from the MCOR).

You can do the MCOR resistance test from the controller side of the harness. The 3-pin connector needs to be plugged to the MCOR in this case.

Disconnect the 16-pin plug from the controller and do the resistance tests for the MCOR using the pins 1,2,3. The colors match the previous test description.

While You have the 16-pin connector unplugged:

Tow/Run switch on Run.
Key switch ON.
MCOR 2-pin connector by-passed.
OBC red and blue wires by-passed on harness side.
FNR on Reverse.

You should get +48v on the following pins:

Pin 5 - LT Blue (OBC lockout OFF)
Pin 6 - Green wire (MCOR pedal switch)
Pin 9 - Gray Wire (Run Mode)
Pin 10 - Tan wire (Key switch ON)
Pin 16 - Blue wire (Reverse direction)

[Andy4639]

Ok this is what I did yesterday and got the readings on the wires for the pedal. I'm going out and do the test again just to check the power part. That's what I was having trouble with.
I found a old v glide connector just now I had that will plug into the MCOR 3 wires same color except the white is black! I'll get the readings. Here is what I got.
I got the MCOR readings at the MCOR with the plug I found.

Yellow to Purple = 7.75 to 1.46

Yellow to Black = 1.100 to 7.49

Black to Purple = 6.61 the whole time.

16 wire connection with key on

#5 49.4
#6 49
#9 49.3
#10 49
#16 49.3

[Sergio]

Sorry, did not notice You updated the last post.

First, I am not sure where You got the voltage readings in post #26, the Controller only sends +5v to the MCOR through the White wire. The MCOR should also have been unplugged, so Pedal up or down should not have applied.

Your current MCOR resistance readings are fine, except I believe You transposed the results You got from the Yellow wire to the others, they are backwards from what they should be.

Here is the reason I asked for the voltage at the 16pin connector, If both Pin#5 (OBC lockout OFF) and Pin#9 (Run Mode) are +48v and You apply +48 to pin #16 (Reverse direction), the buzzer will sound regardless of key switch position, MCOR micro switch or MCOR Pedal position.

If the buzzer is working, It would appear the controller has failed.

With the same test setup as the previous post and the 16-pin disconnected, apply pack negative to Pin#7 - Orange/White wire (Reverse buzzer), if it sounds, the controller should have activated it.

Hopefully TahoeDawg will see this and look over the results.

[TahoeDawgZ71]

I agree with Sergio. It sounds as if the controller has failed.

[Andy4639]

Ok sorry guys working 12 hrs nights. I found a post that had the PDF file for the trouble shooting so now I can have some guidance.

I just went out and ran test again.

purple wire has 49.3 volts

White wire has 0.132 volts according to PDF file I got that means controller is toast. I checked cotinuity on the wires they all seem fine.



Now the yellow to purple ohm is 1.087 down to 7.50

yellow to white is 7.70 to 1.48

purple to white is 6.61 all the time.

I put - on orange and white wire for backup and it sounds but it doesn't any other way. I hasn't work since I picked the cart up.
Again thanks for the help!

I guess he needs a controller but want to hear what the experts have to say.

[CCFanatic]

PM sent

[Andy4639]

Update.
Controller installed yesterday before work. Cart is running again. CCFanatic owner wanted the old controller back sorry. I think he is getting a core off of it.
Thanks for everyones help.

[CCFanatic]

Originally Posted by Andy4639

Update.
Controller installed yesterday before work. Cart is running again. CCFanatic owner wanted the old controller back sorry. I think he is getting a core off of it.
Thanks for everyones help.

No problem