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Old 12-30-2020, 03:30 PM   #1
sefrlw
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Default 2003 DS IQ restoration

I have been out of the carting world for quite sometime as I simply had other priorities. Well I am getting back in. I have a 2003 DS IQ and am in the process of reviving it. The batteries were toast They were dry for 5-7 years and have been replaced. The MCOR was also on the way out and has been replaced and updated to a series 4 version. The cart drives and functions but is very slow from what I remember. This is hopefully due to the batteries have not yet been through a full charge cycle. Which is where I am going with this.

The charger will not start. I have read through the charging troubleshooting section and have the following suspicion. The OBC charging circuit is likely toast on the OBC. I have done the following

Gray signal wire is fine to the charging port. tested with continuity from the fuse yellow fuse connector to the pin on the female side of the charging port.

The signal fuse is good

The windowed fuse is good after being test with continuity

The relay in the charger does not get pack voltage when the blue and red wires are pulled off the relay and probed with a multimeter.

Pack voltage is 50 +/- .2 Volts

So I am now at the point of bypass testing the OBC for charging and am slightly confused about jumping to do this. As I understand I should jump the Gray wire, from the charging port side to the negative of the pack. and then I need to jump the negative from the charging port to the same negative of the pack. Where do I connect the negative on the charging port side? Either one of the posts on the fuse?

Do I leave the black wire that goes back through the OBC connected to the pack or leave it off?

All I want to do is verify the charger works or not and if it does I should assume the OBC is bad.

If the OBC charging is bad then the question comes up as I have seen lots of comments about just doing a smart charger. Why would I do this other than cost? It appears to me the OBC and smart charger are roughly the same cost either way. Do I need to have anything programmed or setup if I replace the OBC or is it just plug and go?

Thanks for any help you all can provide!
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Old 12-30-2020, 03:37 PM   #2
kgsc
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Default Re: 2003 DS IQ restoration

Try this.. Search function is your friend

https://www.buggiesgonewild.com/showthread.php?t=122916
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Old 12-30-2020, 03:58 PM   #3
sefrlw
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Default Re: 2003 DS IQ restoration

Thanks this is twhat I read through to get where I am. I read through that thread again. OBC side of window fuse answers one of my questions.4
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Old 12-30-2020, 06:18 PM   #4
sefrlw
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Default Re: 2003 DS IQ restoration

Well reread made all the difference. ID10T in my initial testing. Looks like the relay in the charger is bad. When I retest with the charger plugged into the cart and not into power I got pack voltage. So I have a relay on the way.

Also I have to apologize My initial reply. Apparently I typod what to twhat which was also a misspelling, but in any case I was not calling you a twat!

Thanks for the help and refocus on my tests!
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Old 12-30-2020, 06:49 PM   #5
simicrintz
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Default Re: 2003 DS IQ restoration

Quote:
Originally Posted by sefrlw View Post
ID10T
Where are you located? I've only heard one other guy use that before
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Old 12-30-2020, 09:37 PM   #6
sefrlw
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Default Re: 2003 DS IQ restoration

Quote:
Originally Posted by simicrintz View Post
Where are you located? I've only heard one other guy use that before
NC It is a what you do more than where you are from thing.... ID10T is synonymous with PEBKAC....
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Old 12-31-2020, 10:58 AM   #7
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Default Re: 2003 DS IQ restoration

I buy gensets from a guy named Mike out that way; any chance you are him?!

Now I gotta go look up PEBKAC.......
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Old 12-31-2020, 11:44 AM   #8
Wakko47
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Default Re: 2003 DS IQ restoration

Quote:
Originally Posted by simicrintz View Post
Where are you located? I've only heard one other guy use that before
I use that with my FNGs at work. Usually the military ones get it right away.
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Old 12-31-2020, 01:00 PM   #9
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Default Re: 2003 DS IQ restoration

Problem exists between keyboard and chair?
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Old 12-31-2020, 07:25 PM   #10
_ogre
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Default Re: 2003 DS IQ restoration

i did maintenance on cnc milling centers back in the 80s & 90s, we'd go out to a machine for the 3rd time for the same nonexistent problem and write 'IO error' on the work order. idiot operator error, we all new the term
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