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Old 06-17-2017, 01:01 PM   #1
batlbot
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Unhappy 2005 DS (IQ) won't go, solenoid clicks on then off

My cart is a 2005 DS 48V IQ. It has good newish batteries charged to about 49-50v right now. Everything is stock (except the new Solenoid, read on).
I use it to pull a trailer around my yard.

Here is my story:
Recently it just kinda stopped moving abruptly. I dismantled it and did some basic troubleshooting and it seemed like the Solenoid was not working. So I got a new one from Scottyb. Installed it and while I had all the stuff off, took it for a test drive around the block. It worked great. Took it for a reverse spin, worked great.

Pulled it back in the garage and the next day I reassembled everything (back seat frame, etc) and went to drive it and it won't move!
The solenoid clicks nice and solid and then about 1-2 seconds later it clicks off. But no movement.
I jacked up the back and occasionally, when I try it the wheels will spin for a second or two but still the solenoid clicks off. Sometimes, the motor sounds like it is trying, kinda "vibrating", before the solenoid clicks off.
I have tried various troubleshooting steps outlined in various posts here on BGW, but to no avail.

Anyway, I sorta suspect the controller but hoping for some guidance. I would hate to buy a $4-500 controller to find out that's not the problem!

Any help would be appreciated!
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Old 06-17-2017, 01:39 PM   #2
Muddog
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Default Re: 2005 DS (IQ) won't go, solenoid clicks on then off

It sounds to me either cables or MCOR.
More like a connection problem.
When you removed the body you could have taken some stress off of your cables, allowing for a connection. When you replaced the body the cables moved back to shorted position.
Look at cables on batteries, motor and controller, ensure all connections are tight and clean.
Inspect your cables for missing insulation, corrosion and breakage.
If your problem is not the cables, test your MCOR, there's a microswitch in it that activates the solenoid when you press the pedal. It could be bad.
Use site search in blue bar near top of page, you'll find info on MCOR testing.
MCOR failure is more common than controller failure.
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Old 06-17-2017, 01:55 PM   #3
batlbot
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Default Re: 2005 DS (IQ) won't go, solenoid clicks on then off

Hey Muddog, thanks for the reply.

I forgot to mention, all the battery cables are brand new as well. I also removed and cleaned tightened all the other cables I could find, on the motor, on the controller, etc.

Since the solenoid does click on with a resounding clack, I don't think the switch on the MCOR should be the problem, right? It could be the MCOR itself I guess, I have not really ruled it out because I am not sure the troubleshooting process for it. I have seen may posts but never sure which ones apply to my cart. :(
I tried measuring the resistance from it but get very strange readings (nothing like 0- 5k) so maybe I am doing it wrong or reading from the wrong place...
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Old 06-17-2017, 02:43 PM   #4
batlbot
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Default Re: 2005 DS (IQ) won't go, solenoid clicks on then off

Following up on the MCOR suggestion. I THINK it's OK although the readings I get are not exactly what the test procedure I found seem to indicate.

The ohms between yellow and purple/white go between 1200 to 7600 (fully depressed).

Between yellow and white the reading is from 8500 to 2500.

Anyway, no idea what they should be exactly but it seems that the resistance changes fairly regularly between off and fully on. If the function of the MCOR is to provide varying resistance to the controller, it seems to do that.
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Old 06-17-2017, 02:46 PM   #5
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Default Re: 2005 DS (IQ) won't go, solenoid clicks on then off

Found on site search. Little blue bar near top of page.
How to test stuff.
http://www.buggiesgonewild.com/elect...ce-please.html
3rd post, look at attachment.
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Old 06-17-2017, 03:00 PM   #6
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Default Re: 2005 DS (IQ) won't go, solenoid clicks on then off

Yellow & purple/white test resistance.
Red & - test voltage
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Old 06-17-2017, 04:05 PM   #7
medicaid832
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Default Re: 2005 DS (IQ) won't go, solenoid clicks on then off

Any chance you could have gotten a defective solenoid?

Sent from my SAMSUNG-SM-G891A using Tapatalk
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Old 06-17-2017, 04:41 PM   #8
batlbot
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Default Re: 2005 DS (IQ) won't go, solenoid clicks on then off

Muddog, I found a similar test procedure via search and went through it. Like I said, the numbers don't exactly match up, but seem to indicate it's at least doing near to what it should.

Medicaid, I don't think it's a bad solenoid. I guess I could bypass it and see.
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Old 06-17-2017, 06:07 PM   #9
mrgolf
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Default Re: 2005 DS (IQ) won't go, solenoid clicks on then off

Sounds to me like you may have let the smoke out of the controller. I'm guessing when you were replacing the parts you got a spark somewhere. That's all it takes to kill the controller.
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Old 06-17-2017, 11:34 PM   #10
NoleFan4Ever
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Default Re: 2005 DS (IQ) won't go, solenoid clicks on then off

Quote:
Originally Posted by mrgolf View Post
Sounds to me like you may have let the smoke out of the controller. I'm guessing when you were replacing the parts you got a spark somewhere. That's all it takes to kill the controller.
Yes, I am thinking the same thing.

We need to ask Sergio and/or David (or anyone else that can) to supply us a test procedure for Series, IQ, and Excel controllers (if there is such a thing) and then make it a sticky so everyone can utilize it for troubleshooting...
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