2003 IQ DS Lithium - additional parts and guidance

[TopDog69]

Originally Posted by InvalidUsername

Unplug that connector and jumper the blue and white wires together in the part with wires going to the controller, and see if your cart runs.

Good news, I did that and... the cart moved!

Next steps are to properly mount the batteries and see how she runs. After that, I'll mount the charger.

What do I do with the wires coming off the existing charge port?

[InvalidUsername]

Originally Posted by TopDog69

Good news, I did that and... the cart moved!

Next steps are to properly mount the batteries and see how she runs. After that, I'll mount the charger.

What do I do with the wires coming off the existing charge port?

If you're not using the charging port I'd just curl them up, secure it with cable ties and leave it tucked away somewhere. Or you could remove the wires by cutting or removing the pins in the connector

[TopDog69]

Thanks for the assistance! Made the difference.

I put a board in and properly mounted the two batteries, hooked them up, and I now have a running cart again!!!!!

Next steps are:
Put 2nd board in and install the on-board charger
Get a replacement standard three prong receptacle and install it
Install the 48v to 12v converter and try to get the accessories going
Clean up any leftover wiring etc.

[jasonojordan]

This is the one I like on my cart.

https://www.amazon.com/NOCO-GCP2-18-...s%2C141&sr=8-5

Has dual output so if you need 120v at the cart for anything while charging you have that opportunity.

They also make a single output version as well if you don't have a use for the extra output.

[TopDog69]

Originally Posted by jasonojordan

This is the one I like on my cart.

https://www.amazon.com/NOCO-GCP2-18-...s%2C141&sr=8-5

Has dual output so if you need 120v at the cart for anything while charging you have that opportunity.

They also make a single output version as well if you don't have a use for the extra output.

Ordered! Thanks for the info.

[TopDog69]

I'm a bit baffled at the 48v to 12v converter connections - well, one of them.

The two 48v wires go to the battery terminals. Managed to figure that out. :)

There is a single red wire going to the old fuse box that feeds the lights, wiper and horn - so that seems obvious - connect the red 12v wire to that.

But where do I connect the black 12v wire? There are three wires coming out of the fuse box and where they go I don't know specifically - and I don't know where they return to.

Do I just have to connect the 12v black wire on the converter to the ground strip by the charging port?

[TopDog69]

Been a while, here's a little update.

The cart has been running just fine on the 2 30AH Litime batteries.

I tested my 48v to 12v converter by connecting the 48v +ve to the +ve post on one battery, and the 48v -ve to the -ve on the other.

This produced 12v on the two 12v wires just as it should.

So I connected the red 12v +ve to the wire running to the existing fuse box and the -ve 12v to the -ve battery post.

The headlights work. The windshield wiper works. The tail lights work.

However, the turn signals, emergency signals and horn do not work. (These were all working before the conversion.)

So I still have some sleuthing to do. I have a manual switch to install as well, and a new fuse box which I may or may not use.

Should I be connecting the black 12v -ve to the B- post instead of the battery itself? (I take it that I should minimize the number of things connected directly to the battery.)

[simicrintz]

Do you have a flasher relay? I'd check that if so.

[TopDog69]

Update... I had quite a mental block about where to connect the 12v -ve from the 48v to 12v converter. Everyone said that I should just connect the returns from the accessories to it. Problem was, I wasn't sure where those were. Others suggested it should eventually connect to the 48v battery -ve.

I did a test where I did just that and some of the accessories worked. But the lights were very dim.

It all made sense when I learned 3 things. There's no voltage level in particular associated with the -ve. 12v -ve can connect to 48v -ve on the battery. The 12v and 48v -ves on the converter are connected anyway. And finally, the terminal strip near the charging port had to have the 12v -ve accessory returns connected to it, because the old 16v to 12v resistor/limiter/converter if you will was attached to it as well.

There was a 4th thing - that old converter was sucking down the 12v supply and causing the headlights to be dim, and preventing other accessories from working.

I removed the old converter and connected the 12v -ve wire from the new converter to the terminal block. (I also put in a new fuse block.)

And now everything works. Headlights, turn signals, horn, wiper, emergency flashers... haven't checked the brake light yet.

So I'm in pretty good shape. The two 30AH lithium cells are working well and staying balanced, and all my accessories are up and running.

The only things left to do are to replace the charging port, and maybe install a physical battery disconnect switch. I have it on hand, but not sure I trust it. The Amazon reviews show some scary failures. The batteries have bluetooth and I can turn the battery discharge off using the app. Maybe I'll just stick with that, although probably won't help in an emergency situation.

Thanks to all that helped.

I hope my sharing of my project will help someone else out.