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Unread 07-29-2009, 09:40 AM   #1
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Default '03 IQ is a still a Nightmare

The cart:
2003 CC 48v IQ NEV. Not modified, Factory cart, 4 wheel brakes, Head & Stop Lights, Turn Signals, Programed Code 3, Stock Cart.
The history
Found dead on craigslist Cart was given to teenage boys by absent Father ( in lue of Fatherhood?) Boys said cart quit running while offroading in the rain. Cart had 5 8v and 1 6v Trojans. All secondary wiring had been cut up or disconnected in order to try to diagnose the problem Mom sold the cart
The Problem
THe cart begins to accelerate as normal but, when it gets to about 5 mph it drops out, like it was thrown into neutral, or the motor is shut off. If you hold the gas peddle steady it will come back on then quickly drop out again in a herky jerky sort of on/off notion.... If you stop. And start gently it will go on up to speed but, if you go down hill and it gets going fast you will find that at the bottom of the hill the on/off problem is back . If you you stop you can gently start out again as long as you do not go full throttle it will continue.... the dropping out happens at all/any throttle position...(ps: it's not the MCOR)
Diagnostics
All diagnostics for IQ carts known to myself and 2 other techs have been run resulting in a clean report from a hand held plug in computer and a controller diagnostic bench test results below....all coming up good/clean.
Troubleshooting
All batteries were replaced and wiring repaired per original diagram.... Deduction and diagnostics led us to believe that every part was suspect at one point or another. So having access to parts here is what was replaced.... The controller (twice) , The MCOR (Twice) The solenoid, the OBC, The Motor, The Speed Sensor
Conrtoller report
The Guy who I bought the New Controllers from also rebuilds them () So when I return the 1st one as defective he sent me a second which ran the cart the same.
When I asked for a third one I got this report

Good morning Scotty
I have tested the second controller you sent me back .First I tested it on the circuit board tester , no defect found , next I hooked up the programmer to look at fault codes , it showed that you had an over voltage this only means that you have good batteries and when fully charged they read over 50 volts , the next fault is the one that conserns me , it shows thermal cutback , this means that either you are climbing some extremly steep hills or the vehicle is being overloaded with weight . in the third test I cleared the fault codes and installed this controller on my test car .After several runs up and down hills I hooked the programmer back up and found no faults .I hate to say it but you have another problem with your car it is not the controller .
Please let me know what you find out I am curious .


I have tried to include everything I know about the cart and the problem.... ANY HELP is appreciated.

Have I mentioned that I HATE IQ CARTS, YET?
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Unread 07-29-2009, 07:55 PM   #2
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Default Re: '03 IQ is a still a Nightmare

scottyb,

1. Have you isolated the headlights/turn signals from the circuit and repeated a test run?

2. Is it possible that the 4 wheel brake system is providing enough resistance to cause a thermal error code on the controller?

Just brainstorming!
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Unread 07-29-2009, 10:01 PM   #3
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Default Re: '03 IQ is a still a Nightmare

I know nothing about this entire situation, so that is what this post will probably be worth. My first thought was a hidden governor. Second thought, a ghost. Third thought was also brake drag. My last thought is a weak ground connection anywhere in the system could be very hard to find.

Just hoping to provoke thoughts. Good luck with this mystery.

HS36
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Unread 07-29-2009, 11:45 PM   #4
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Default Re: '03 IQ is a still a Nightmare

Quote:
Originally Posted by Xact1 View Post
scottyb,

1. Have you isolated the headlights/turn signals from the circuit and repeated a test run?

2. Is it possible that the 4 wheel brake system is providing enough resistance to cause a thermal error code on the controller?

Just brainstorming!
on 1. yes initially we isolated all of the secondary....
And on 2. no. all of the brakes have been inspected, adjusted, and tested.....
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Unread 07-30-2009, 10:45 AM   #5
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Default Re: '03 IQ is a still a Nightmare

Dang ScottyB, what is left except the wiring.
And as you said most of it was cut or removed.
Is it passable a wire is crossed or mis-wired ?

The fact that it keeps happening at 5 mph and does not change one would think controller or motor, or wires crossed going to or from the controlled.

? what happens in Reverse ?
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Unread 07-30-2009, 01:09 PM   #6
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Default Re: '03 IQ is a still a Nightmare

Is there a possibility of incompatible part (mcor, obc, controller) ie. one part an 02 or 04 not being compatible with 03.
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Unread 07-30-2009, 02:01 PM   #7
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Default Re: '03 IQ is a still a Nightmare

I dunno?
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Unread 07-31-2009, 10:29 AM   #8
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Default Re: '03 IQ is a still a Nightmare

Not sure what system this cart has but if it is anything like my regen2 the motor may have 3 wires coming out of the back of it. I have figured, but do not know as fact, these wires have to be a tach feeb back type device. We use to have those on the 90 Volt DC motors on machines at work years ago. They send a signal back to the controller informing the controller what RPMs the motor is turning. I think on the carts that is how the controller decides if the cart is overspeeding and if it needs to slow the motor down or brake it. Anyway if my theory is rignt you may want to investigate that device. If it was messed up it could drive the controller crazy and really mess with the carts speed. Just a suggestion, again I am very new at these cart repairs.
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Unread 07-31-2009, 10:37 AM   #9
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Default Re: '03 IQ is a still a Nightmare

A very logical suspician.... alas we had 2 motors and 2 different speed reading plugs on them? But it has got to be something along those lines? Odd thing is it will get to full speed if you are gentle with the gas peddle? That makes me think it si something along the 'current draw' type of cut out? Also going too fast down hill makes it cut out until you stop and start over
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Unread 08-02-2009, 11:48 AM   #10
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Default Re: '03 IQ is a still a Nightmare

I am using the cart to go to the neighbors last night and I noticed if I stop at the bottom of the hill and step on the gas to full throttle the cart starts to drop out & catch up & drop out & catch again...The headlights dimmed each time it dropped out! Indicating a short?

Wieder yet... if I start slowly at the same hill it will build speed and let me floor it on the hill and rerach full speed at the top??


This has got to be the speed control device but again it has had the same problem with 2 motors and 3 controllers and 2 mcors?


ANYONE GOT ANY IDEA?
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