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Old 12-30-2020, 03:30 PM   #1
sefrlw
Not Yet Wild
Club Car
 
Join Date: Dec 2020
Location: NC
Posts: 17
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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