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Unread 05-21-2014, 07:15 PM   #1
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Default 03 DS IQ 48 volt, intermittant startup issues

I have a 03 (I guess) DS 48 volt IQ, I replaced the solenoid already, and I though that solved the problem, but it started to act up again, it wont start up, we keep on flipping the switch back and forth, and after a while it starts to work normal again, we also replace the forward/reverse switch also. Is this a controller issue?
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Unread 05-21-2014, 07:44 PM   #2
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Default Re: 03 DS IQ 48 volt, intermittant startup issues

I found out something about a solenoid drop out harness for 2003s, cart might be a 02, anybody hear of this?
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Unread 05-21-2014, 08:52 PM   #3
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Default Re: 03 DS IQ 48 volt, intermittant startup issues

Can you post your serial number, that'll help us determine exactly what type of cart and year you've got.

Serial tag should be under the dash above the footwell area, and slightly off center to the right of the cart.
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Unread 05-21-2014, 09:54 PM   #4
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Default Re: 03 DS IQ 48 volt, intermittant startup issues

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Unread 05-21-2014, 10:12 PM   #5
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Default Re: 03 DS IQ 48 volt, intermittant startup issues

It's an 02 DS IQ, made in the 33rd week of production for the 02s.

Can't help you out much with the problem you're having, but someone who can should be along before too long. Knowing for sure the year helps to narrow down some possible problems and troubleshooting advice.
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Unread 05-21-2014, 10:14 PM   #6
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Default Re: 03 DS IQ 48 volt, intermittant startup issues

Thanks, I think the solution to the problem is that solenoid dropout harness, hopefully somebody comes along and agrees with me!
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Unread 05-22-2014, 06:45 AM   #7
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Default Re: 03 DS IQ 48 volt, intermittant startup issues

You may need a solenoid dropout harness, but as I understand it that problem occurs when You are driving the cart. It is triggered by the change in current from normal driving (battery->motor) to regen (motor->battery). The diode in the dropout harness keeps the controller from getting a false main dropout fault.

What You describe could be the micro-switch in the MCOR not working every time you press the pedal. You can remove the 2-pin connector from the MCOR and jump the connector with a paper-clip. If the cart runs every time with the paper clip in place, it is time to replace the MCOR.
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Unread 05-22-2014, 08:12 AM   #8
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Default Re: 03 DS IQ 48 volt, intermittant startup issues

Can u explaine what the mcor is? The problem only occurs at startup, when the cart is under power it runs fine
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Unread 05-22-2014, 09:16 AM   #9
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Default Re: 03 DS IQ 48 volt, intermittant startup issues

The MCOR is mechanically attached to the pedal. It serves 2 functions:
1) 2-Pin Connector: When you first step on the pedal, a ON-OFF switch closes and sends a signal to the controller that you are about to move.
2) 3-Pin Connector: It provides a variable voltage from 0-5v that is proportional to the amount of pedal travel. The controller uses this signal to provide from 0-100% power to the motor.


Look at the sticky section for more information and pictures of the the MCOR
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Unread 05-22-2014, 11:56 AM   #10
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Default Re: 03 DS IQ 48 volt, intermittant startup issues

Thank you Sergio! I'm picking up a mcor today, but I'm going to jump it first and see if that cures the problem!
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