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Unread 03-03-2010, 08:42 AM   #1
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Default 2004 IQ 48v charging problem

Heya guys, I've been having a problem with one of our club cars for a week or so now. I've tried to read as much as I can and feel like I know a lot more than I did before I found your site. I'm sure this means I know 1% of what I need to know. I work for a golf course maintenance department. A few years ago the golf guys switched from club car to Yamaha and we kept a few of the old cc's to use for setup and what not. Things are real tight right now so I don't want to call in cc if it can be avoided.

My cart is a 2004 Electric IQ 48v with regen. I pulled this -AQ0434 and I think it has regen because it seems to brake when pressure is removed from the pedal. The cart is pretty much stock with no modifications. The cart runs no problem, forward/reverse all seems good.
When I plug the cart into the charger (We have four, same issue with all chargers and the other three carts charge fine) the relay kicks on but the meter only barely moves to 0 and the cart does not charge. When the issue started the battery pack read 50v and all the batteries were right around 8v. I originally thought I hadn't run the cart enough to warrant a charge so I ran it for most of the day and the same thing happened. It's not dead, I can still run it but I can tell it needs a charge now. Battery pack reads 46.5v and all the batteries are in the 7.5 to 7.7v range. All the batteries are less than 1.5 years old.

Things I've done-
Checked the fuse behind the charge receptacle from wire to wire and it's good.
Checked the grey wire fuse and it's good. Checked continuity (grey wire) from the back of the receptacle to as close to the obc as I can and that's also good.
Checked all my battery connections. Cleaned all the posts, and replaced one wire that had a little corrosion. Cart had no problem running before and still runs now so I think they are good.
Plugged the cart into the charger, waited for the relay to kick in, pressed the power pedal and the cart did not move.
Jumped from the receptacle side of the grey wire to the negative terminal of battery 1 and the relay kicks in but the meter still doesn't move. Charger sounds the same jumped or just a regular plug in.

I have no clue what to do now. Any thoughts or suggestions? I'm starting to wonder if maybe there is a problem with the receptacle but I don't know how to go about troubleshooting that part of the system. Thanks for reading my post and I appreciate any thoughts on my problem.
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Unread 03-03-2010, 08:55 AM   #2
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Default Re: 2004 IQ 48v charging problem

You can check the connection between battery pack and recepticle with a voltmeter at the receptacle. Have you tried using a few other chargers you have there? If so and they do not work either, likely you have an OBC problem.
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Unread 03-03-2010, 09:25 AM   #3
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Default Re: 2004 IQ 48v charging problem

Thanks Scottyb, I checked the receptacle and got battery pack voltage from the red pin to the grey pin.
Did you mean try to charge the cart on the other chargers or try bypassing the obc on the other chargers? I tried to charge the cart on all four chargers with the same results, but I only did the bypass with one charger. Is there another way to check the obc or do I need to bite the bullet and call CC? I'm willing to try anything, time I've got...$$ I don't.
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Unread 03-03-2010, 09:29 AM   #4
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Default Re: 2004 IQ 48v charging problem

If the chargers work on other carts then the problem i sin the cart. If you bypass the obc and the charger works likely the obc is bad.
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Unread 03-03-2010, 12:33 PM   #5
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Default Re: 2004 IQ 48v charging problem

When I bypass the obc and the charger clicks should the meter kick over to full charge or 15 amps? It doesn't seem to do anything different when I bypass the obc (that I can tell). The meter barely moves and I don't see a change in the battery pack voltage when the charger relay clicks. Am I not correct in thinking the cart should charge when I bypass the obc?
I'm considering switching out the obc from the bad cart and using one of the good carts obc just to see if that will change my symptoms. I think I read where that may not be a good idea? The carts are all 2004 iq 48v, should the obc be interchangeable?
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Unread 03-07-2010, 11:20 AM   #6
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Default Re: 2004 IQ 48v charging problem

The carts are all 2004 iq 48v, should the obc be interchangeable YES

Can U describe how U are bypassing the OBC ?
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Unread 03-08-2010, 07:54 AM   #7
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Default Re: 2004 IQ 48v charging problem

To bypass the obc I placed a jumper between the grey wire at the receptacle and the negative post of the #1 battery. The relay on the charger kicked in but the meter only reads 0 on the charger. I get the same thing without the obc bypassed.. relay kicks in but 0 meter reading on the charger. The charger works with other carts no problem. I've got 4 carts and 4 chargers. The cart will not charge on any charger that I have but the other carts all charge with all 4 chargers.
I tried to reset the obc but I never hear the buzzer when I press the pedal in reverse. I don't know if I'm doing it right, but I'm pretty sure I followed the guide correctly.
I'm probably going to call CC today and ask them to come out and check the obc and bring a replacement. When my mechanic gets here today I'll find out if he switched out the obc with one of the known good ones. Whatever happens I'll post here to let you guys know what ended up resolving my problem. Thanks for the help!
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Unread 03-08-2010, 04:42 PM   #8
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Default Re: 2004 IQ 48v charging problem

Quote:
Originally Posted by Wescott View Post
To bypass the obc I placed a jumper between the grey wire at the receptacle and the negative post of the #1 battery. The relay on the charger kicked in but the meter only reads 0 on the charger. I get the same thing without the obc bypassed.. relay kicks in but 0 meter reading on the charger. The charger works with other carts no problem. I've got 4 carts and 4 chargers. The cart will not charge on any charger that I have but the other carts all charge with all 4 chargers.
I tried to reset the obc but I never hear the buzzer when I press the pedal in reverse. I don't know if I'm doing it right, but I'm pretty sure I followed the guide correctly.
I'm probably going to call CC today and ask them to come out and check the obc and bring a replacement. When my mechanic gets here today I'll find out if he switched out the obc with one of the known good ones. Whatever happens I'll post here to let you guys know what ended up resolving my problem. Thanks for the help!

great
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Unread 03-09-2010, 07:11 AM   #9
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Default Re: 2004 IQ 48v charging problem

Ok, so we swapped the obc with a known good one from another cart and the problem cart charged. Bad obc, bad, bad, bad! Got another one on order from the local CC fellas. $125 isn't bad, about the price of a new battery. Thanks for your help, this problem would have cost me far more than it did without this website.
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Unread 03-09-2010, 10:29 AM   #10
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Default Re: 2004 IQ 48v charging problem

Quote:
Originally Posted by Wescott View Post
Ok, so we swapped the obc with a known good one from another cart and the problem cart charged. Bad obc, bad, bad, bad! Got another one on order from the local CC fellas. $125 isn't bad, about the price of a new battery. Thanks for your help, this problem would have cost me far more than it did without this website.
Thanks

That being said , this makes %0 sense to me , if the OBC was truly bypassed during the test , it should have charged.
This is partially my fault I meant to ask scuba or scotty to post the OBC bypass PIC , which shows U to jump the relay at the charger , it is easier and
fool Proof . Oh well , missed opportunity !

later
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