2004 DS IQ - suddenly stopped working no solenoid click

[MauiMarcus]

Purchased this 48v 2004 DS IQ a month ago. Have spent this quarantine working on it. Purchased 6 new interstate batteries 4/1/20. Purchased and installed myself an Admiral A4, XCT500IQ, MZJ400A solenoid and 2g wires from Scotty at Carts Unlimited 4/23/20. Carts been running like a champ for 10 days.

Today, after a 15 min ride in my hilly neighborhood I pulled into my driveway and stopped. When I went to move it into the carport, it would not move forward or backwards. Buzzer comes on in reverse and also buzzes when I push it, but no movement or power when I press the accelerator. Cart only makes slight jerky movements both forward and backwards- like a wire is loose or something.

After doing this for a few minutes I realize the solenoid was not clicking when I step on the accelerator - which it used to do loudly for the last 10 days. So the solenoid does not seem to be engaging.

In dash voltmeter shows 51.8v. I did not (yet) remove the back seat and access cover (it's nighttime here). I did look at the motor, speed controller and solenoid through the passenger wheelwell and all wires appear to be connected and nothing was overly hot. The controller's fan would come on for a second when I flip the run/tow switch.

I am a newbie with no golf cart experience, but I have time, am a tinkerer and with this forum and youtube I was able to do all of the current mods myself.

I can send photos, etc., any help would be greatly appreciated. FYI I also emailed Scotty (who is always super responsive), but its the weekend and I'd like to fix it so I can drive it again ASAP.

thanks from Maui,

Marcus

[Mooncarter]

Best thing to do right now is get a diagram of your wiring and trace the activation circuit for your solenoid.

But it sounds to me like your solenoid has failed.

[MauiMarcus]

It worked fine for 10 days, and I sent photos to Scotty while installing. It seems something has failed. I am researching how to troubleshoot the accelerator pedal assembly and microswitches.



I read your build thread...very cool!

[MauiMarcus]

I just went outside to turn off the garage light (it’s 1am here) and I decided to try to move the Cart to see if it miraculously fixed itself...

...and it did! Was able to park it. Still want to fix the issue- I don’t want to get stuck miles from home.

So now the problem is intermittent.

[skippyjasper]

Sounds like the solenoid is running too hot. It worked after cooling down. Is it properly sized for your system?
Might be worth the time to check the connections. Can you access the contacts and check for arcing/deposits?

Skippy


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[Mooncarter]

Originally Posted by MauiMarcus

It worked fine for 10 days, and I sent photos to Scotty while installing. It seems something has failed. I am researching how to troubleshoot the accelerator pedal assembly and microswitches.



I read your build thread...very cool!

Thank you. It was a fun challenge.

[MauiMarcus]

Mornin Skippy

The solenoid is brand new and purchased as a “kit” from Carts Unlimited 3 weeks ago. It should be appropriately sized: Admiral A4 motor, Altres XTC500IQ controller, MZJ400A solenoid.

I’ll be looking closer today- but a quick investigation last night showed all connections good and nothing under there was hot at all...

Thanks for reading/helping!

[Hkspwrsche]

Originally Posted by MauiMarcus

Purchased this 48v 2004 DS IQ a month ago. Have spent this quarantine working on it. Purchased 6 new interstate batteries 4/1/20. Purchased and installed myself an Admiral A4, XCT500IQ, MZJ400A solenoid and 2g wires from Scotty at Carts Unlimited 4/23/20. Carts been running like a champ for 10 days.

Today, after a 15 min ride in my hilly neighborhood I pulled into my driveway and stopped. When I went to move it into the carport, it would not move forward or backwards. Buzzer comes on in reverse and also buzzes when I push it, but no movement or power when I press the accelerator. Cart only makes slight jerky movements both forward and backwards- like a wire is loose or something.

Mcor? Is yours original? Mine was doing that jerky movement randomly. A week after I got it is when it happened the first time when my wife took it out with my daughter. Then it did it again with me and started happening about every other ride. Mine was original and getting worse. I did the mcor4 upgrade and it’s 100% now. Smooth and works fine.

As a coincidence, I’ve had my 04 DS IQ about a month and I would guess the seller thought something expensive was going bad and that was some of the motivation to move it on.