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Unread 05-19-2007, 05:05 PM   #1
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Default Everything worked this morning but nothing works now???

Sorry for the long post but here is a rundown of what has happened today. Can anyone please help me figure out what to do next??? These are posts I have made today on another forum all combined. I really appreciate anyone taking the time read this and help out!

* I have an 03 IQ and read something on the forum about cutting the green wire that comes out of the motor and it would eliminate the regen braking. Great idea! I unfortunately decided to do this and didn't unhook the batteries. When I had my wrench under near the motor I saw a spark that looked like it came from accidentally jumping the pos. to the neg. on the motor??? The big wires! I'm not sure. I ended up cutting the little green wire that comes out of the 3 wire connector and when I went to put it in reverse I heard the buzzer and the solonoid click but it wasn't moving! Leave it to me to do something minor and screw it all up! We'll I checked the forum to see if I could get any ideas as to what it may be but had to run. I figured I would take the golf cart out and fix reverse later in the day. I started driving up the hill and all the sudden it felt like someone put it in nuetral. I checked the switch and it was still in forward. When I pushed the gas again, it went fine but if it started to get a load, same thing! I turned around to go back home and thankfully I realized that cutting the wire has eliminated my regen but unfortunately I have bigger problems now. Any ideas where to start. Batteries should be fine, I think from checking around I may have fried my F/R switch???
* It does run but only until it gets too much of a load on it. If I let off the accellerator and then back on it it runs until it gets a little load on it again.
* hooked it all back up and nothing has changed, except, I think the regen braking is working again but still have all the same other problems. No reverse and the cart will just cut off all power when under a load, then let off the gas and press the gas again and off I go until it gets too much of a load on it. When I say load I mean climbing a slow gradual hill on pavement. Not steep in any way. Feels like I have full power until it gets to that point where it's just too much!
* after hooking up the green wire again I decided to go out and take off the F/R switch and see if I could see anything that looked like it was fried etc. I took the switch bolts off and disconnected the harnesses attached. I had the switch in my hand and took that out of the side clips also so that the rocker switch assembly came apart as well. I didn't know what to look for but wanted to see if anything didn't look right. Didn't see anything that looked funny so I put it back together and made sure the rocker assembly worked properly and it did. I attached the switch back to the body, screwed the bolts in and flipped the switch back to run from Tow. I put the key in, put my baby in reverse AND, nothing.... Now I don't even hear the buzzer or the solonoid. Doesn't go forward or backwards! My problem is worsening by the minute! I like to get help but also want to see if I can figure this thing out on my own and it is taking me into a deep dark hole!!! Because of my day so far, I am not working on this thing again until I have some help so I don't screw it up anymore than I already have! Please help! She's wounded and I can't watch her suffer any more!
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Unread 05-19-2007, 05:33 PM   #2
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I'm an idiot! I never switched it back from TOW to RUN. I still do have a problem though!

No reverse, solonoid clicks and buzzer sounds
All power loss under a load, (going up a hill). Take my foot off the accellerator and put it back on and away I go again until the load builds up again.
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Unread 05-19-2007, 05:58 PM   #3
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I would clean all connections on the batteries with a wire brush and put them back tight. I would take it to a respectable shop and tell them your story, because I'm pretty sure your problem lies in the motor or controller, or wiring in between. Take a 200% look at EVERYTHING, even things that you find pointless, and make sure everything looks ok on the outside. I'm leaning toward a motor/controller problem though.
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Unread 05-19-2007, 07:15 PM   #4
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Everything was checked and cleaned. I looked at all the wires fom the motor to the controller and everything feels tight and looks clean! As far as a motor or controller problem, it goes forward??? Shouldn't that eliminate that as a possibility?
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Unread 05-19-2007, 07:27 PM   #5
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I'll say this and be done, because I'm not an electric guy in any way, shape, or form:

There are basically three things that could have taken the brunt of the short caused by the wrench:

1. Motor
2. Controller
3. F-N-R switch

I would definitely have it taken to a shop though, unless you're highly electrically inclined.

Car53WhereRU has a similar cart, maybe he will jump in tonight and help you out some.
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Unread 05-19-2007, 09:22 PM   #6
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More than likely, you have blown the controller. The controller and the computer (obc) are the most sensitive items on your cart and the first to blow from a "short" or removing a wire the wrong way.

The first thing you do before working on ANYTHING under the seat is <1>flip the tow/run switch to TOW <2> Disconnect the MAIN Positive and the MAIN Negative. If you didn't do this, Count on the controller being bad since you shorted out the wires on the motor. They go to the controller.

It sounds like a component in the controller is getting too hot and craping out by what you describe.

I'm hoping I'm wrong in my diagnostics and for your sake it's not the controller. I hope it's a simple thing like a melted wire or something.

See what some of the other guy's say. I hate guessing games when it comes to troubleshooting. We all do.
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Unread 05-19-2007, 10:26 PM   #7
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Just sent you a loooong PM....Car53
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Unread 05-21-2007, 07:34 AM   #8
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Check Roady's "sticky" wiring diagrams...


The 88-03 48V with the OBC (On-Board-Computer)

I noticed there are in-line fuses in alot more places then my regen (w/o IQ)...

Back in the day, When I used to work on my own cars, and I "sparked" something... first place I would look is the FUSES!
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Unread 05-09-2014, 10:06 PM   #9
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Default Re: Everything worked this morning but nothing works now???

#1 stop working on your cart
#2 you can not cut the green wire on an IQ Cart, you go into limp mode
This may be your load problem
#3 when it sparked you touched one of the smaller motor wires, if so you blew out the forward reverse switching transistors in the controller. There shorted in one direction.
#4 most likely need a new switch now.
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Unread 05-09-2014, 10:16 PM   #10
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Default Re: Everything worked this morning but nothing works now???

Quote:
Originally Posted by greg-g View Post
#1 stop working on your cart
#2 you can not cut the green wire on an IQ Cart, you go into limp mode
This may be your load problem
#3 when it sparked you touched one of the smaller motor wires, if so you blew out the forward reverse switching transistors in the controller. There shorted in one direction.
#4 most likely need a new switch now.
You know this is a REALLY old thread, right?
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