Help make 1 running cart from 2 dead ones 1-36v 1-48v

[mikeward]

I need some advice for the experienced guys here. I'm trying to put a cart together for the grandkids when they come over from 2 non working carts
I have 3 Club Carts
2 - 48 volt IQ 2004 and 2003
1 - 36 volt DS was working till battery fail.
The 03 IQ I got for my Mom and after several years I just replaced the batteries with Trojans. This is the cart that works well. I gave the batteries from the 36v cart as cores. My heart jumped at the $950 dollar price. Ouch, but I had a plan

The old Trojans still have usable pack voltage.
I put then in the 04 IQ
And charged them everything seemed OK charger shut off after overnight charge
Reverse buzzer works but no movement. Tried the charger again and now it won't turn on. Guess OBC is shot now too
Looked at the selonoid and the red cable had some lumpy solder on it. huh?
Wiggled it and it came off. The solder was attaching it to the terminal end which was bolted to the selonoid. wire was sitting on top of end piece not clamped in it.
Took off cable cleaned it up and crimped it in and reattached to selonoid.
Then I notices the green wire going to the other big solenoid terminal was wrapped in duct tape. Not really wrapped but shoved around it. See pic.
Took it off re crimped end and reattached.
No difference in cart reverse buzzer but no movement

Jacked and blocked rear end and jumped red and green wires on selonoid - nothing.

I've looked at wiring diagrams here and can only find red and yellow wires to solenoid.

So I'm thinking I need a controller and a selonoid to make the 04 IQ work at minimum.
Now I'm thinking a controller and a selonoid could be put in the 36v DS with the 48 volt batteries. And that art would really go. I'm thinking of Scotties conversion kit here.
I'm pretty sure the 36v motor is not compatible with the IQ system so I can't move the motor to the 48v cart.

I'd like to get one working cart out of these 2

I need to keep the older batteries charged in the 04 cart
I have a DPI charger for my 03 IQ cart. Can I do the same OBC bypass on the 04 IQ
That I did on my 03 IQ cart? This would keep the batteries till I finish getting something done.

Right now I'm thinking of making a runner out of 36v Ds
Comments Advice please...

[mikeward]

Pics of the 2 carts

yes you can do the obc by pass on the 04 iq

if it were me ...
i would fix the 36v for the kids
you can use the motor with 48v so you would just need scotty's conversion kit
you have the dpi charger for 48v just change the charger plug

[Aflyer]

With the bad cables you did find on the 2004, I think I would take every connection apart, check it and clean it and make sure there is no corrosion inside the terminals.

Then I would check the water level in each cell, and the voltage on each battery, plus the total pack and see what you have, if they are real low that could prevent the charger from charging.

Try charging the really low ones with a regular battery charger for 10 minutes, then try the charger again.

After you know if you have good batteries and connections, then we can help you test the OBC, and the Controller.

How long has this been sitting, I am not sure if I missed that in your post?

Aflyer

[Golferdave]

Old Trojans ? How old ?
Pack voltage ? Individual batt volts ?

Charger worked, & now don't, :
Bad OBC might be right,
or
Like Aflyer said:
Might be more bad wires/cables/connections, a bad battery or charger issues.

Solenoid click ?

[mikeward]

The problem is not the batteries. They re older Trojans pack voltage is 49
They would be ok for kids to drive cart
I was thinking of getting the 04 DS running. I bought it for $500 with charger and 8 extra tires. Thought if I put old batteries in it and it worked kids could use it.
But after batteries put in, no go. Someone messed with this cart and if controller,solenoid and OBC are bad I might as well get an upgrade kit pared up with the 36 v cart. Bodies on both are v good. The 36 v cart should really move with 48 volts.
I will just get rid of the 04 cart, 36v charger, and 2 48v chargers.

If I could good used controller, solenoid and OBC for cheap then the 04 cart could be fixed . Don't know if it's worth it to me.
I still have to get a rebuilt engine for my second Turf 2 carryall and put it in.
My wife thinks I've lost my mind
2 turf 2 carryalls
1 good working 48v DS
Then the 2 parts carts I'd like to make one of

[Aflyer]

mikeward,
Tell us more about the 04 that didn't run after you put the battery pack in it?

Solenoid clicks, reverse buzzer, roll test for buzzer beeps indicating communication with the controller, and will it take a charge?

Aflyer

[mikeward]

after putting in battery pack I hooked it up to charger and started charging but reverse buzzer was not working.
Kept checking every few hours and finally Left it to charge overnight.charger was off in morning.
In the morning I unplugged charger waited a few hours and then put the charger on it again. Charger would not go on. Got my other club car charger and the same would not go on. Both chargers are good.

But reverse buzzer worked.
Tried the next day same result
Today turned key on put in F pushed it and no beeping same with reverse.
BUT put charger on and now it's charging ?

The F/R switch was replaced. I guess I should check it. I ok
Now it's hooked up to batteries correctly.
The solenoid with gas pedal pushed, reads 48 volts on both large terminals and both small ones. Jumped both large solenoid terminals with wheels off ground and wheels didn't turn maybe I should do it again
No click at solenoid
Oh and the solenoid has a thick red wire from controller and the other is a thick green wire from controller. Every wiring diagram I've seen has a yellow not green. Have not opened up controller. I guess I could check that too.
I'm really learning a lot here
Is there a way to check controller?

[Aflyer]

I did a quick search for Testing Controller, and below I pasted a link to a long but informative thread. Your car is an AQ04, so that means it is an IQ cart for testing purposes.

http://www.buggiesgonewild.com/elect...da-long-4.html

Others will chime in with more direct answers, but this should get you started.

Good luck with your testing,
Aflyer

[mikeward]

Thanks will check it out
Just went out and unplugged power drive 2 charger.
Reverse buzzer now works but still no beeping when cart is pushed.
Took the power drive 3 charger which came with cart and plugged it in and that is working now also.
Neither of them worked the last few days. The only thing I did was check pack voltage and and power to each terminal on solenoid.