2002 Club Car 48V/Regen/Curtis IQ will not move

nate0427

Hello All,

I come to you today as most do looking for your expertise on a cart that I just picked up.
First let me start by thanking anyone for taking time to help me.
The cart is a 2002 Club Car 48V with Regen and Curtis IQ.

The cart was advertised as needing new batteries and otherwise ok.
Old batteries were completely depleted/swollen and battery cables were different gauges.

I first started with replacing the batteries and all battery cables with 4 gauge.

Now I have 50.4V with ignition on and run/tow switch in the run position.

All the cart will do is click from the MCOR.
So the first thing I did was verify all connections are correct and tight then obtained a proper wiring diagram.

First started with the F/R switch and checked for continuity and made sure power is being switched. All is ok and 50.4V were measured in the forward and reverse position at the switch.

Next on to the MCOR. I verified power from the ignition switch (blue wire) and have 50.4V. Next measured the same on pin 6 at the controller with the pedal down.
I also verified I have resistance that fluctuates with pedal position on the 3 wire connector plugging into the MCOR.

On to the controller....
I have 50.4V on pin 8 with the F/R in the forward position, 50.4V on pins 9 & 10 with ignition in run.
Pins 1-3 have continuity back to the MCOR.

FOUND A PROBLEM!
Pin 5 should have +48V in run position and I have 0V.
This is a light blue wire that travels to the OBC only and nowhere else.

Here is where I need help...
Should the +48V come from the controller to the OBC?
Or the OBC to the controller?
Forgot to mention I have no reverse buzzer when switched to reverse??

For lack of options I center stripped that circuit and added a fused jumper battery feed (50.4V) to see what would happen?

All works! I have forward and reverse with buzzer!

So my main question is what part is causing no power to pin 5 (blue wire)?
OBC or Controller?

Also now for some reason the cart seems really fast with no limit or cut off in reverse and seems normal in forward that will cut the speed around 10mph?

Thank you for any and all help.

Here are the diagrams I used, black and white diagram matches cart identical and color was used for MCOR only.

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

nate0427

pix.sfly.com/tdyd-G

jjance

The circuit that you bypassed was the charging interlock. It prevents you from moving the cart while charging it. As long as you remember to unplug the charger you'll be ok. How does your charger do. Does it charge the batteries OK?

nate0427

Hi Jjance,

Thanks for the quick reply.
I'm not sure if the charger works?
I plugged it in and nothing happened? Honestly I figured it wouldn't charge since the batteries are new and over 48V??
I didn't try to charge it with pin 5 jumped.

nate0427

Update on the fast in reverse situation.
Found the S1/S2 circuits at the controller were not in the correct location.
I swapped the two and all is ok with forward/reverse.

jjance

Sounds like you may have a bad OBC. Check all of the wiring. Start by making sure the #4 Gauge wire is still going through the hole in the OBC to the battery main negative. Then try the obligatory OBC reset.

nate0427

I'm going to go over all the wiring and measure resistance end to end on all wires.
The 4 AWG battery ground is routed through the OBC.
I tried performing an OBC reset several times but the reverse buzzer never made a sound?
Not sure why? I followed the reset to spec.
Thank you for all your help, it sure does seem like a bad OBC like you said.

mrgolf

Obc reset on your cart is unhook main negative cable for ten minutes. You are just allowing the capacitors to bleed off to reset anyway.

jjance

If the OBC is bad it would be better to go with a DPI charger and do away with the OBC. There is not much difference price wise. Also be sure to check the black wire from the charger plug. It has a habit of coming loose at the controller.