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Unread 10-12-2013, 07:30 PM   #1
Getting Wild
 
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Default Help Diagnosing No Run Condition - Club Car DS IQ Cart

I need some help diagnosing why my cart wont run.

Let me give you a brief history:

Cart came from Golf Course, Good Batteries and runs great just ugly as sin from the years of use and the stock color. Wife wants it pretty.

To recondition the cart, I dismantled everything, but kept all the wiring together, plugged into correct areas, etc.

Pressure washed the cart with all the electronics off the cart, everything.

(I am afraid I pushed water into the motor, transaxle, but that comes in later)

Did all the upgrades, painted the body and repaired the few things that needed it like bearing brackets on the accelerator pedal rod, brake pads, brake cables, etc.

Reassembled it. Cart looks great. We take it out for a spin. I notice that when underway the motor or transaxle is making a lot of noise compared to what it used to make before. The noise is a loud whirring sound, which increases in magnitude with the speed of the cart.

I figure that I have gotten water down into the motor or transaxle and so I decided to do a quick teardown to check the bearings for rust and for water in the transaxle.

I drained the trans fluid, looks ok, plenty in there, no water. I noticed a tiny bit of play in the input shaft bearing where the motor sits, but it is very very small amount of movement, almost not noticeable.

I take the motor apart and clean it with brake cleaner, there is a ton of dust inside, the bearing seams to be in good enough shape with no visible side to side or up and down play. I did notice that the armature has been worn down from the brushes, about a 1/32 to a 1/16" Id guess, and the brushes are chipped up a bit on the edges and grooved from the armature. There is some very light surface rust on the large round center section of the armature and some on the four curved plates inside the motor can. I lightly sanded this with 800 grit paper to try and relive any possibility that this was contacting.

I put everything back together with new trans oil, begin to put the wires back on the motor and when connecting the A1 and F1 wires to the terminal, I arced these two terminals! YIKES! The tow switch had somehow gotten back into Run and the negative cable was sitting on top of the negative post! CRAP!!

So anyway, the cart wont run now.

At first the battery light was coming on and staying on when I would attempt to run the cart. After taking the motor back out, making sure the brushes were seated and in place, etc etc, the light no longer stays on, but the motor does not run either. I get the loud click from what sounds like a relay, the motor makes a tiny bit of audible noise and feels like it is trying to turn but is stalled.

I tested the motor by first disconnecting everything, then jumping A1 to F1 and A2 to F2, then connected 12V to A1 and A2. The motor ran fine, but was very noisy as before all this fun began.

I reinstalled everything again and still no go, just a loud click, and a tiny bump bump bump and noise from the motor, but never runs.

I am at a loss, I figure I must have screwed something up accidently when I arced those A1 and F1 terminals during installation.

If you could please help me figure out what is wrong with it, I would greatly appreciate the help.

Sorry for such a long post.
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Unread 10-12-2013, 07:46 PM   #2
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Default Re: Help Diagnosing No Run Condition - Club Car DS IQ Cart

I just tried to reset the OBC. Not sure if it worked or not.

Nothing has changed. Still loud click, a little bit of noise and what sounds like a stalled motor that cant get going in, followed by the controller or something else clicking off as if it sees a high current or something.

I plugged the charger in to see if it will take a charge. Yep, that all seems to be working fine. Pack has plenty of voltage, charge stops and starts as normal.
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Unread 10-12-2013, 08:46 PM   #3
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Default Re: Help Diagnosing No Run Condition - Club Car DS IQ Cart

You got water in your motor. It also sounds like you've got some noise coming from the brushes in the motor. You've also taken out the controller when you made the arc on the motor post. FYI the tow/run switch doesn't kill power to the motor. The #6 gauge wires are still hot. The tow/run switch simply kills power to the control circuit. The power circuit must be physically unhooked from the battery pack to kill it.
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Unread 10-12-2013, 10:06 PM   #4
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Default Re: Help Diagnosing No Run Condition - Club Car DS IQ Cart

Thanks TahoeDawg. I appreciate you taking the time to help me out.

There is supposed to be a light that shines on the top of the controller right?

I don't see a light at all. So that couldn't be good.

That stinks. Now I need a motor and a controller.

Should I go ahead and convert to a series cart or repair this IQ stuff?

Thanks,
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Unread 10-13-2013, 11:53 AM   #5
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Default Re: Help Diagnosing No Run Condition - Club Car DS IQ Cart

Hi Matt
What motor do you have if it's the AMD (Black one), I know someone who will buy it and the controller off you including shipping. That might help take some of the STING out.
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Unread 10-13-2013, 02:30 PM   #6
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Default Re: Help Diagnosing No Run Condition - Club Car DS IQ Cart

Its a GE with the triangle shaped speed sensor plug and the controller is the 1510-5201 Curtis Controller 250 amps, or a split second arc from touching two motor poles whichever comes first!
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Unread 10-13-2013, 02:40 PM   #7
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Default Re: Help Diagnosing No Run Condition - Club Car DS IQ Cart

PM me you do not have private messages turned on
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Unread 10-13-2013, 04:08 PM   #8
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Default Re: Help Diagnosing No Run Condition - Club Car DS IQ Cart

I got a private message from you. I responded to it. Let me know if you didn't get it?
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