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Old 03-31-2019, 05:58 AM   #1
rockfordpi
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Default 09 DS intermittent solenoid go/no go

09 DS 48v IQ Controller

Solenoid intermittent, sometimes it closes, sometimes not

Even when solenoid closed, cart does not always run

Pre-charge resistor getting very hot

Backstory. Previously, cart had stuck brush symptom, sometimes run, sometimes not, sometimes stutter when starting off. However, I could always make cart go within 10-15 seconds.

Put in a brand new set of batteries. Pulled motor, ALL FOUR brushes were seized, signs of moisture and heat in motor and commutator arcing. Lots of carbon, commutator/brushes grooved, otherwise brushes not really worn. Motor had been opened previously, guessing to replace brushes.

Un-seized the brushes, cleaned up brush holders and outside of brushes so they move freely. Cleaned carbon from (scraped out) grooves between commutator bars. Reinstalled.

Now cart is even more intermittent than before, pre-charge resistor getting hot, solenoid intermittent, sometimes runs, sometimes not, even with Sol. closed.
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Old 03-31-2019, 08:18 AM   #2
NoleFan4Ever
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Default Re: 09 DS intermittent solenoid go/no go

When it will not run, you need to test the output from the solenoid to verify it is closed (not just a "click"). If so, verify output from the controller to the motor. If so, there is more than likely a motor issue. If not, the controller has an issue or the a throttle output concern. Baring a lose cable or other unseen gremlin.

Once you verify the controller closed, here is how you test the controller output. With key switch On, Run/Tow switch in the Run position, Fwd/Rev rocker switch in the Fwd position (and also have the back jacked up off the ground). Get your DVM and place the black (–) probe at the motor A2 (white wire) and connect the red (+) probe at the motor A1 (green wire) and slowly depress the Go Pedal. When the MCOR closes (clicks), the voltage reading should increase from ~5vdc gradually going up to to approximately ~45-48vdc (could be higher) with the accelerator pedal fully pressed.

To test the throttle output. With the batteries connected, Tow/Run switch in Run; place the black (–) probe on packs main Negative post and the red (+) probe on the yellow wire at the 3-pin connector near the MCOR. (The reading should be approximately ~0.32vdc to ~0.5vdc with the pedal up). Slowly press the Go Pedal and the readings should increase until it reaches ~4.65vdc or more when the pedal is fully pressed. (Anything less than 4.60vdc and you are not reaching full throttle).
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