AQ03 Model

[Andy4639]

I have a customers IQ cart which by the number it's a 03 DS model.

Batteries reading 52 volts.
Micrometer disconnected under the cart micro switch 2 wire plug with jumper wire installed. Cart in either direction key on, run switch in run position and hit the gas I get nothing at all. No clicking nothing! Backup Buzzer not working either and it's hooked up. It looks like everything is stock wiring no mods are BS done to wiring.


Take and put jumper on - side small terminal of solenoid to battery ground and do the same thing I get the solenoid to click. If I add a jumper to the 2 big terminals it doesn't do anything.

Battery charger is working also but not sure if it's going to shut off. I let it charge all night and it was still at 13 amps this morning. Batteries have been un charged since this past summer he says. Yesterday when I picked the cart up I measured 42 volts on the pack. Can some one point me into the right direction maybe a trouble shooting procedure to help determine the problem.


Would it be the OBC are controller I should be looking at since I have no ground on the selonoid I would think OBC but not sure.

[Sergio]

In the IQ system, the negative side of the solenoid coil is provided by the controller, so you have verified the positive side is getting power from the key switch.

To by-pass the OBC lockout on that system, disconnect the OBC 6 pin plug and put a jumper between the red and blue wires on the harness side.

If that works, then the OBC is holding the controller into lockout mode.

[Andy4639]

Ok thanks. I'll go try it.

What will I need to do if that gets it running?

Nothing happened. I left the connection unplugged with the jumper installed is this correct are do I need to plug it back together and jump them?

[Sergio]

Two options:

1. Buy a new OBC.
2. Make the by-pass permanent and buy a DPI charger.

[Andy4639]

Sergio
Nothing happened. I had to keep the negative jumper in place to get the solenoid to activate.

[Sergio]

Leave the by-pass in place for now so that is off the equation.

Make sure the pedal micro-switch in closing properly.

Disconnect the 2 pin plug at the MCOR, You should have +48v on the blue wire when the key switch is turned on, if so, put a paper click to jump the 2 pins on the MCOR.

See if it runs.

[Andy4639]

No that's how I had it last night and to begin with. I plug the 2 wire connection back in and it's the same either way. With are without the jumper for micro switch.

[Sergio]

Are you getting +48v on the blue wire?

[Andy4639]

No only 37 volts on blue wire in harness. This is with the micro switch in stalled are jumped.

[Sergio]

You need to measure the voltage without it being plugged in, otherwise you are measuring the voltage drop across the controller.

With the blue wire not connected to anything, you should get +48v (or your current pack voltage) when the key switch is turned on.

IF not, look for the sonic weld where the power splits from the key switch to the MCOR.