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Unread 08-04-2015, 02:19 PM   #11
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Default Re: 2004 CC DS Bypass OBC to use New Charger

Ok it's a 2003. AQ03--------
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Unread 08-04-2015, 02:28 PM   #12
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Default Re: 2004 CC DS Bypass OBC to use New Charger

It's a 2003.
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Unread 08-04-2015, 02:35 PM   #13
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Default Re: 2004 CC DS Bypass OBC to use New Charger

Sorry I may have replied several times...new to the forum. My cart is a 2003.
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Unread 08-04-2015, 02:40 PM   #14
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Default Re: 2004 CC DS Bypass OBC to use New Charger

The IQ carts use a low current signal from the OBC to the controller to lockout, so the procedure is:

To By-pass the OBC "charging current control" function:
Run a 10ga wire from the back of the charger receptacle negative pin directly to pack negative.
To by-pass the OBC "cart lockout" function:
Disconnected the 6-pin plug from the OBC and jump the White with the Blue wires in the harness side connector.
You can just disconnect the Gray sense wire since it has no purpose with the new charger.

Also, keep in mind that after the by-pass it will be possible to drive the cart while the charger is still plugged in.

If the OBC is still working, You can sell it at the parts for sale section. You will need a new cable to go from pack negative to controller B- if You decide to do so.
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Unread 08-04-2015, 02:54 PM   #15
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Default Re: 2004 CC DS Bypass OBC to use New Charger

Quote:
Originally Posted by tlove007 View Post
Ok it's a 2003. AQ03--------
Then it's supposed to have the black IQ controller in it. AQ - IQ system
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Unread 08-04-2015, 03:21 PM   #16
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Default Re: 2004 CC DS Bypass OBC to use New Charger

O.K. I've jumpered from the receptacle side of the big yellow fuse holder on what I am assuming is the negative pin on the charger receptacle to the #6 battery negative post. If I'm understanding right, this bypasses the OBC charging current control (which should allow the new integrated charger to work)?? Is there a particular reason I would need to bypass the "cart lockout" function?
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Unread 08-04-2015, 03:23 PM   #17
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Default Re: 2004 CC DS Bypass OBC to use New Charger

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Originally Posted by CCFanatic View Post
Then it's supposed to have the black IQ controller in it. AQ - IQ system
You're exactly right. The controller has a grey housing over it and I was attempting to look at it through a pin hole rather than remove the bag well access panel. Once I removed it I could tell it was just a plastic cover over the "black" controller.

Thanks for the help.
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Unread 08-04-2015, 03:26 PM   #18
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Default Re: 2004 CC DS Bypass OBC to use New Charger

Quote:
Originally Posted by Sergio View Post
The IQ carts use a low current signal from the OBC to the controller to lockout, so the procedure is:

To By-pass the OBC "charging current control" function:
Run a 10ga wire from the back of the charger receptacle negative pin directly to pack negative.
To by-pass the OBC "cart lockout" function:
Disconnected the 6-pin plug from the OBC and jump the White with the Blue wires in the harness side connector.
You can just disconnect the Gray sense wire since it has no purpose with the new charger.

Also, keep in mind that after the by-pass it will be possible to drive the cart while the charger is still plugged in.

If the OBC is still working, You can sell it at the parts for sale section. You will need a new cable to go from pack negative to controller B- if You decide to do so.
Is the "harness side connector" the grey, square connector on the OBC that has an orange rubber insert where the pins connect? How would you suggest I jumper the blue and white wires? And finally, what grey sense wire?

Sorry, first time trying anything like this...really appreciate the help.
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Unread 08-04-2015, 03:35 PM   #19
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Default Re: 2004 CC DS Bypass OBC to use New Charger

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Originally Posted by CCFanatic View Post
Then it's supposed to have the black IQ controller in it. AQ - IQ system
I do still think it's a Regen 2 however, according to the image you sent earlier it states only the Regen 2 has the run/tow switch... which mine does.
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Unread 08-04-2015, 03:54 PM   #20
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Default Re: 2004 CC DS Bypass OBC to use New Charger

The "sense" wire is the one in the yellow fuse holder, it is no longer needed and You should remove the fuse and leave the wire disconnected.

The negative wire is a 10ga wire that goes to the OBC now, it needs to go directly to pack negative.

Yes, the 6-pin square gray connector in the cart harness, not the OBC.

If the OBC is bad, You can just cut the wires off on the OBC side and twist those 2 wires together. Put tape on the other ones individually.

You can also cut the wires off on the harness side since you are not likely to put another OBC in the cart.

If You don't by-pass the cart lockout feature the OBC will eventually prevent the cart from running as it will no longer sense the pack being charged.

Make sure you have the Tow/Run on Tow and batteries disconnected when doing all this re-wiring.
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