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Unread 12-04-2013, 03:42 PM   #1
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Default 2002 club car help

Ok I replaced solonoid replaced controller took motor apart cleaned and inspected it put new brushes put new magnet on end of motor all as per stock except for magnet. Took pictures of wireing so I know it's all back like it should be batterys charged . Turn key on press pedal down all I get is click and seconds later another click what am I missing
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Unread 12-04-2013, 04:07 PM   #2
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Default Re: 2002 club car help

It's a 48 volt 2002 club car AQ 02
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Unread 12-05-2013, 07:06 AM   #3
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Default Re: 2002 club car help

I know it's a sealed unit but maybe when the cart was submerged the Mcor got water in it?
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Unread 04-27-2014, 05:05 PM   #4
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Default Re: 2002 club car help

Ok replaced mcor still same . Push pedal down hear solonoid click once then again. No thing
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Unread 04-27-2014, 05:10 PM   #5
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Default Re: 2002 club car help

So far I have charged and checked batterys. They appear good replaced motor controller with another Curtis wright. Replaced solonoid with exact match replaced mcor with new one took motor out inspected it replaced brushes. Cleaned thoroughly new bearing. New high speed magnet. Drained oil in rear end and replaced checked all fuses cleaned brakes. Still all I get is push pedal down click. Wait few seconds click. Then nothing
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Unread 04-27-2014, 08:04 PM   #6
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Default Re: 2002 club car help

Could this be the 2002 IQ "solenoid dropout"?
You have pretty much replaced every part on the cart. All the wires look ok and aren't corroded, broken, etc?
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Unread 04-27-2014, 08:45 PM   #7
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Default Re: 2002 club car help

No all wires look very good
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Unread 04-27-2014, 08:52 PM   #8
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Default Re: 2002 club car help

What is solenoid dropout
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Unread 04-27-2014, 10:33 PM   #9
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Default Re: 2002 club car help

This explains it; it's all I can think of with your cart since you have replaced everything...

Quote:
Originally Posted by TahoeDawgZ71 View Post
Sounds like a Solenoid dropout to me. IQ cars are hard to work on unless you've got the scanner because there's so many different things that can cause the same symptom. Speed sensors are typical problems and can cause the car to go into limp mode but that's not what is happening here. Something is causing the solenoid to drop out. No doubt about that. When the controller detects a solenoid dropout it slows the cart to a crawl. If the speed sensor wasn't working it wouldn't be able to monitor it's own speed and bring itself to a crawl. The beep beep beep you are hearing is an indication that the speed sensor works perfectly. Anybody with an IQ car can mimic this scenario by getting it up to speed, slamming on brakes and locking the tires down until the solenoid drops out, then releasing the brake while the car is still rolling. It's going to do the same thing your car is doing. It'll beep and slow itself. You may have a bad solenoid. You'll need to monitor the voltage to the two small posts on the solenoid. Attach a multimeter to them. You should see full battery voltage when solenoid is closed. When car drops out, look and see if this voltage is falling off or staying strong. If it's staying strong, replace the solenoid. If it's dropping to zero you've got another problem. The controller is telling the solenoid to open. Now, with that being said it opens up a whole realm of possibilities as to what the issue is. If you've got an intermittent internal microswitch in your mcor it'll cause it. Also, on some but not all early IQ models such as this, there needs to be a diode in the wire harness behind the Tow/Run switch. This can't be seen without destroying the wire harness. However, there is an IQ Dropout harness available that will correct this problem. It just snaps into the existing deutsch connectors behind the tow/run switch. This is cheap insurance and I recommend it on all 2002-2003 DS IQ cars. 102355201 is the part number for the harness. If you're going to buy and sell IQ cars, please do yourself a favor and buy an IQDM scanner. It'll turn the most complicated Club Car you've ever seen into the easiest thing you've ever worked on.
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Unread 04-28-2014, 11:31 AM   #10
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Default Re: 2002 club car help

Man I sure could use some help I don't want to have to take this cart to a dealer I'm sure they will charge me arm and leg
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