04 DS IQ Dead New Batteries,controller,obc

[TwistedLizard]

04 Club Car DS IQ i have installed new batteries new controller(upgraded to 350amp) new on board computer checked the MCOR (seems to be workin) no click from solenoid does have power on both sides and on the small front conacts as well.

Now it has been a while since ive played with a stock controller setup with the IQ or even the mcor. i am more a custom to the Alltrax SPM controller

so i need a little help getting to the problem with this cart. I have a meter and can use it just need to know where and what i should be reading

I would be very greatful for any help THanks

[Sergio]

2004 Club Car IQ tests for Solenoid not activating:

Use this wiring diagram for Reference

Setup for Cart:

• Lift one rear wheel OFF the ground.
• Turn Key switch ON.
• Put FNR in forward.

Set Your meter to 200vDC.

All references to +48v are nominal voltages and mean actual pack voltage.


Testing the Solenoid Activation:

• Pack Negative to positive side of solenoid coil (light blue): Always +48v
  
  
• Pack Positive to negative side of solenoid coil (blue/white): 0v Pedal Up and +48v pedal down.

IF the Solenoid is not activating and first reading is +48v, the entire troubleshooting needs to focus on the Controller getting the correct input signals it needs before it activates the solenoid.


Take all readings on the back of the controller connector in reference to pack negative.

Pin #6 - Green Wire (pedal microswitch) +48v once You press the pedal.

pin #5 - Light Blue wire (OBC lockout) +48v.

Pin #10 - Tan Wire (key switch) +48v once Key switch is ON

Pin #9 - Gray wire (RUN Mode) +48v if tow/run switch is on Run

Pin #16 - Blue (Forward direction) +48v when FNR is on Forward.

Pin #2 - Yellow (MCOR wiper) Pedal up to pedal down should go from 0.35v to 4.65v (approximately).

IF Controller Pin #6 is not getting +48 with Pedal down, by-pass the MCOR micro switch:

Remove the 2-pin connector from the MCOR and insert a large paper-clip jumping the 2 wires together.

Measure the voltage from pack negative to the paper clip to make sure You get +48v.

Tape the connector to avoid shorting the circuit.

Test if the cart works.

IF the MCOR wiper signal (Voltage range on Controller Pin #2) is not right, test the MCOR:

Measurements are taken with MCOR 3-pin connector disconnected:

1) Controller power to MCOR (measured at the harness):

Pack positive to Purple/White wire: +48v

White wire to Pack negative: +5v

2) MCOR resistance (meter set to 20kΩ, measured at the MCOR pins):

Yellow to Purple/White (pedal up to pedal down): 1kΩ to 7kΩ

Yellow to White (pedal up to pedal down): 7kΩ to 1kΩ

White to Purple/White (pedal up to pedal down): constant 6k

The 1kΩ, 6kΩ and 7kΩ are nominal readings, You can post your actual readings, but they should be around that range of values.

Good Luck

[TwistedLizard]

Thanks will go after it when i get back and post what the readings are
Just what i needed

[glassk]

Our 03 IQ doesn't have an audible click from the solenoid, ... Just sayin'

[mrgolf]

Mine has a very faint click, almost sounds like a large micro switch.

[Cruise Master]

Bump, so I can find thread.

[TwistedLizard]

Ok cart running as long as i keep the paperclip in the MCOR what i dont understand is that i had tried that before and it wouldnt run, but after taking all the readings and got to the part about checking voltage on the paperclip the test cart the cart ran and runs in both directions it does seem to be bumping a governor of some sort going forward. but other than that it runs so am i to assume (and we no where that could go) that the MCOR is the problem ?

[Sergio]

Yes the MCOR is bad since the micro switch inside has failed.

There is actually a sticky on how to replace that micro switch if You like that kind of project.

The reason to take that voltage reading at the paper clip is just to make sure there is not a rare failure on the sonic weld and there was no power available at the MCOR.

You may also have a speed sensor problem if that "governor" comment is referring to speeds above 8 mph.

[TwistedLizard]

I will check out the sticky and just in case I have already ordered a MCOR . Any way to beat a speed sensor ?

[Sergio]

David from RevolutionGolfCars.com wrote a good sticky on how to test the speed sensor and the different sensor part #'s depending on motor type:

http://www.buggiesgonewild.com/elect...nsor-test.html