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-   -   OBC Bypassing (http://www.buggiesgonewild.com/electric-club-car/114227-obc-bypassing.html)

Sergio 01-21-2016 07:01 AM

OBC Bypassing
I think the White and Blue work better for all years IQ and Excel carts.

For the Regen-2 and other Model Years where the Blue wire was connected to the harness instead of the controller, the OBC provided power directly to the electrical system.
If the White and the Red/White wires going to the OBC are the same gauge, I would still use the White wire, but add a 10 amp inline fuse.

If the Red/White wire is a larger gauge, then use the Red/White on the OBC side of the connector and keep the fuse.

I like the idea of not having any power going to the Controller connector when the Tow/Run is on Tow (which is how the OBC works).

Using the Red wire would also provide non-fused 48v power at the controller connector.

The above information is for Sepex only systems.

All model years of the Series carts, the OBC provided the negative side of the Solenoid on the Yellow wire.

For the Series carts You just have to disconnect the Yellow wire from the OBC and run it directly from Solenoid to controller B- (or other negative source like pack negative).

TahoeDawgZ71 01-21-2016 06:17 PM

re: OBC Bypass ~ Technnical Tips
I'll add a little tip for those people who want to make this modification. I've often been asked what procedure is best used to make this modification. The OBC that is being bypassed has usually failed, creating the need to bypass it and use a standalone charger. Before you throw it in the trash, cut the 6 pin plug off of the old OBC, disassemble it and remove all of the unnecessary wires (Everything except the white and blue wires). Make a connection between the white and blue wires of the 6 pin plug. Butt connectors will work, but I prefer solder and heat shrink tubing. Plug the 6 pin connector back into the wire harness.

Sergio 01-21-2016 08:40 PM

re: OBC Bypass ~ Technnical Tips
3 Attachment(s)
I did not know this was going to be a sticky, so let me add a little more detail.

You also need to by-pass the OBC charging current control SCR by running the negative 10ga wire from the back of the charger receptacle directly to B- or pack negative.

The fuse is only needed on the Older Regen carts.

The IQ and Excel carts already have a fuse on the white wire before the Tow/Run switch.

I took a few pictures to illustrate David's comments about removing the unused pins from the 6-pin OBC connector.

Picture 1:
This is the Tab that locks the pins in place inside the OBC 6-pin connector, note the opening on the side of the Tab.
Picture 2:
To remove the Tab use a "pick" or a small screwdriver to slide under the opening and pull the Tab OFF the connector.
Picture 3:
Use a small screwdriver to move the individual pin locking tab to the side and pull the wire from the back to remove the pin OFF the connector.

lockman1 01-21-2016 09:44 PM

re: OBC Bypass ~ Technnical Tips

Originally Posted by Sergio (Post 1235244)
I did not know this was going to be a sticky...

Yeah, well... Scotty felt it was pertinent information, and I felt that the info you provide to BGW is well worth the sticky!

Carry on!


scooterman 01-25-2016 01:26 PM

re: OBC Bypass ~ Technnical Tips
The sticky may simplify the process when you get a 100 post from 100 different users wanting the same information. It is a handy tool commonly used in many forums for the same reasoning.

jakesnake27 02-29-2016 11:27 AM

re: OBC Bypass ~ Technnical Tips
Should we change the title to "Bypassing Club Car IQ/Excel OBC"?

TahoeDawgZ71 02-29-2016 02:07 PM

re: OBC Bypass ~ Technnical Tips

Originally Posted by jakesnake27 (Post 1247856)
Should we change the title to "Bypassing Club Car IQ/Excel OBC"?

It would definitely apply, the procedure is the same.

lockman1 03-01-2016 08:33 AM

re: OBC Bypass ~ Technnical Tips
:wink: :mrgreen:

jakesnake27 03-01-2016 08:59 AM

re: OBC Bypass ~ Technnical Tips
Thanks Don!

scottyb 03-01-2016 10:18 AM

re: OBC Bypass ~ Technnical Tips
Customer sent me a DIY video which is circulating the internet regarding OBC bypass. This video suggest connecting the 10g black charge lead directly to the Main neg battery terminal. Which is correct. Then they button the cart up without making any small wire alterations!??? Aren't they missing a critical part of the OBC bypass in this popular video?

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