Battery Cable upgrade/OBC bypass

Randy L · 02-25-2018, 11:13 AM

There are several threads addressing these topics and some really great information. So much information that I am really confused. My initial goal was to upgrade all my battery cables from 6 ga. to 2 ga. from the battery pack to the motor. I received the upgrade cables and I am ready to get started. I have a 2008 Club Car Precedent with six 8 volt batteries. Replacing the 5 battery pack cables is pretty basic. Here is where I need help.
1. Does the cable from negative battery 6 need to be upgraded to 2 ga. to keep the current flowing. I guess this is where the OBC bypass comes in. I see where this cable connects to the controller there are 2 pigtails that come off the connection. How do I address this issue.

2. A1 green going to the controller meets up with a yellow cable going to the selinoid. I assume this cable needs to be upgraded also along with the red cable going from the selinoid to the number 1 positive battery terminal.

3. Several of the 6 ga. cables have what I call pig tails coming off the terminal connections. These pig tails are lower ga. wires. Do I cut these wires and put on a ring connection to install on the battery terminal?

4. Unfortunately I did not get instructions with my upgrade kit. I know now that had I ordered from Scotty I would have received instructions on how to complete the installation. I did order the OBC stud from Scotty in case I do need it.

Thanks for looking and I hope I can get some help.

Sergio · 02-25-2018, 02:33 PM

You need to upgrade all 6ga cables to the larger 2ga.

If You are using the OBC for charging, You will need two separate 2ga cables to replace the old 6ga negative that went through the OBC.

You need a 5/16" brass stud through the OBC and a new 2ga cable for each side.

It is never a good idea to force a cable, lubricated or not, through the OBC.

If the toroidal concentrator inside the OBC does not get dislocated during the process, it can still happen later as the tight cable now acts as an axle and it can torque the concentrator free from the circuit board.

You will need some 5/16 ring connectors for the smaller gauges wires that were crimped together with any of the old 6ga on: the Batteries, Solenoid big post and OBC/pack negative cable.

You should have 11 total 2ga cables to replace all of the high current cables on a precedent with a working OBC and 6x8v batteries.

NoleFan4Ever · 02-25-2018, 02:53 PM

Quote:

Originally Posted by Randy L

There are several threads addressing these topics and some really great information. So much information that I am really confused. My initial goal was to upgrade all my battery cables from 6 ga. to 2 ga. from the battery pack to the motor. I received the upgrade cables and I am ready to get started. I have a 2008 Club Car Precedent with six 8 volt batteries. Replacing the 5 battery pack cables is pretty basic. Here is where I need help.
1. Does the cable from negative battery 6 need to be upgraded to 2 ga. to keep the current flowing. I guess this is where the OBC bypass comes in. I see where this cable connects to the controller there are 2 pigtails that come off the connection. How do I address this issue. Yes, that one will run "through" your OBC and to the controller. Hopefully the lug is not installed or you will need to cut and replace it. You can use the Stud kit too, I just hate multiple termination points and prefer the cable to go through the OBC (and you will not be bypassing your OBC at all unless you are replacing ur OEM charger with a smart charger)

2. A1 green going to the controller meets up with a yellow cable going to the selinoid. I assume this cable needs to be upgraded also along with the red cable going from the selinoid to the number 1 positive battery terminal.I am not sure who you got the kit from, but the needed cables should be in there and would replace the battery to solenoid.

3. Several of the 6 ga. cables have what I call pig tails coming off the terminal connections. These pig tails are lower ga. wires. Do I cut these wires and put on a ring connection to install on the battery terminal?I am not sure if those are for your add-ons or OEM stuff. Trace them out to be sure. If they are needed, you can use them or if they are for add-ons, run them to a voltage reduces and away from the batteries.

4. Unfortunately I did not get instructions with my upgrade kit. I know now that had I ordered from Scotty I would have received instructions on how to complete the installation. I did order the OBC stud from Scotty in case I do need it. Watch some of those cheap sets - they are garbage out the box! I make my own and if you buy, then buy from one of the sponsors like scottyb or someone that makes durable custom sets.

Thanks for looking and I hope I can get some help.

See above

Randy L · 02-25-2018, 03:24 PM

Thank you Sergio and NoteFan4Ever for the quick response. That really helps and this project doesn't appear to be so daunting anymore. Now to be sure I understand this OBC situation I have a few more questions. I have the charger that came with the cart, and following the directions for using the brass stud will that bypass the OBC? Is there an advantage to bypassing the OBC? And finally, the two smaller ga cables attached to the negative pack cable will need the 5/16 ring connections? Thanks again for your help!

NoleFan4Ever · 02-25-2018, 04:05 PM

No, the brass stud kit will just allow you to connect on both sides of the OBC with a cable which still allows it to read/register the current flow being used. Bypassing the OBC is when you basically remove it electrically from the system, which your OEM charger will not work automatically anymore but when the OBC is bypassed as per the thread in the sticky's, it will run and charge, but only by manual means and will not cut off by itself or use any certain algorithms.

People usually only do that when it has failed and they are going to soon replace it or start using a smart type charger that does not need an OBC to operate, as does your OEM style.

Yes on the 5/16" and remember to always place the heaviest load carrying connections on the bottom. (that being the larger cable)

Randy L · 02-25-2018, 09:52 PM

Thank you NoleFan4Ever! Tomorrow I will pick up some 5/16 ring connections and hope Scotty's OBC Stud arrives soon. I really do appreciate your help and thanks to Sergio also. I would not have tried doing this if it wasn't for this forum. This is pretty neat place to hang out!!

NoleFan4Ever · 02-26-2018, 12:01 AM

And if you have crimper and a piece of good heat shrink (a 2 awg lug you can pick one up at any welding or electrical shop) then just remove the lug and pull it through the OBC and then re-install it. If you do go forward with the stud kit, just be gentle when tightening it as you do not want to over-tighten it and damage the OBC.

Randy L · 02-27-2018, 08:06 PM

Done with the cable conversion, thought it went well...until I tried to turn things on. Nothing...the reverse buzzer does not buzz, the head lights flashed on for a spilt second and then off. The batteries all test out great. From one positive to 6 negative 51volts. I did hook up the charger and it waited a few seconds then started charging. I've kept an eye on it and it is gradually reducing the voltage. I need some help troubleshooting. Any ideas? Please!

Sergio · 02-27-2018, 08:52 PM

You would get those symptoms if the 15 amp fuse behind the Tow/Run switch is blown.

It looks like You may have a wire in the wrong place.

When did You see the head lights flash briefly, when the key switch was turned ON or when the light switch was turned ON?

Randy L · 02-27-2018, 09:45 PM

The lights flashed when I turned the lights on, not sure if I had the key switch turned on or not. Are there any connections I need to check with the volt meter. Since the battery pack it charging the way it should would that rule out the OBC?

02-25-2018, 11:13 AM	#1
Randy L Not Yet Wild Join Date: Jan 2010 Location: Kansas Posts: 38	Battery Cable upgrade/OBC bypass There are several threads addressing these topics and some really great information. So much information that I am really confused. My initial goal was to upgrade all my battery cables from 6 ga. to 2 ga. from the battery pack to the motor. I received the upgrade cables and I am ready to get started. I have a 2008 Club Car Precedent with six 8 volt batteries. Replacing the 5 battery pack cables is pretty basic. Here is where I need help. 1. Does the cable from negative battery 6 need to be upgraded to 2 ga. to keep the current flowing. I guess this is where the OBC bypass comes in. I see where this cable connects to the controller there are 2 pigtails that come off the connection. How do I address this issue. 2. A1 green going to the controller meets up with a yellow cable going to the selinoid. I assume this cable needs to be upgraded also along with the red cable going from the selinoid to the number 1 positive battery terminal. 3. Several of the 6 ga. cables have what I call pig tails coming off the terminal connections. These pig tails are lower ga. wires. Do I cut these wires and put on a ring connection to install on the battery terminal? 4. Unfortunately I did not get instructions with my upgrade kit. I know now that had I ordered from Scotty I would have received instructions on how to complete the installation. I did order the OBC stud from Scotty in case I do need it. Thanks for looking and I hope I can get some help.

02-25-2018, 02:33 PM	#2
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Battery Cable upgrade/OBC bypass You need to upgrade all 6ga cables to the larger 2ga. If You are using the OBC for charging, You will need two separate 2ga cables to replace the old 6ga negative that went through the OBC. You need a 5/16" brass stud through the OBC and a new 2ga cable for each side. It is never a good idea to force a cable, lubricated or not, through the OBC. If the toroidal concentrator inside the OBC does not get dislocated during the process, it can still happen later as the tight cable now acts as an axle and it can torque the concentrator free from the circuit board. You will need some 5/16 ring connectors for the smaller gauges wires that were crimped together with any of the old 6ga on: the Batteries, Solenoid big post and OBC/pack negative cable. You should have 11 total 2ga cables to replace all of the high current cables on a precedent with a working OBC and 6x8v batteries.

02-25-2018, 03:24 PM	#4
Randy L Not Yet Wild Join Date: Jan 2010 Location: Kansas Posts: 38	Re: Battery Cable upgrade/OBC bypass Thank you Sergio and NoteFan4Ever for the quick response. That really helps and this project doesn't appear to be so daunting anymore. Now to be sure I understand this OBC situation I have a few more questions. I have the charger that came with the cart, and following the directions for using the brass stud will that bypass the OBC? Is there an advantage to bypassing the OBC? And finally, the two smaller ga cables attached to the negative pack cable will need the 5/16 ring connections? Thanks again for your help!

02-25-2018, 04:05 PM	#5
NoleFan4Ever MOD of all BS! Join Date: Sep 2011 Location: Florida Posts: 17,477	Re: Battery Cable upgrade/OBC bypass No, the brass stud kit will just allow you to connect on both sides of the OBC with a cable which still allows it to read/register the current flow being used. Bypassing the OBC is when you basically remove it electrically from the system, which your OEM charger will not work automatically anymore but when the OBC is bypassed as per the thread in the sticky's, it will run and charge, but only by manual means and will not cut off by itself or use any certain algorithms. People usually only do that when it has failed and they are going to soon replace it or start using a smart type charger that does not need an OBC to operate, as does your OEM style. Yes on the 5/16" and remember to always place the heaviest load carrying connections on the bottom. (that being the larger cable)

02-25-2018, 09:52 PM	#6
Randy L Not Yet Wild Join Date: Jan 2010 Location: Kansas Posts: 38	Re: Battery Cable upgrade/OBC bypass Thank you NoleFan4Ever! Tomorrow I will pick up some 5/16 ring connections and hope Scotty's OBC Stud arrives soon. I really do appreciate your help and thanks to Sergio also. I would not have tried doing this if it wasn't for this forum. This is pretty neat place to hang out!!

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02-26-2018, 12:01 AM	#7
NoleFan4Ever MOD of all BS! Join Date: Sep 2011 Location: Florida Posts: 17,477	Re: Battery Cable upgrade/OBC bypass And if you have crimper and a piece of good heat shrink (a 2 awg lug you can pick one up at any welding or electrical shop) then just remove the lug and pull it through the OBC and then re-install it. If you do go forward with the stud kit, just be gentle when tightening it as you do not want to over-tighten it and damage the OBC.

02-27-2018, 08:06 PM	#8
Randy L Not Yet Wild Join Date: Jan 2010 Location: Kansas Posts: 38	Re: Battery Cable upgrade/OBC bypass Done with the cable conversion, thought it went well...until I tried to turn things on. Nothing...the reverse buzzer does not buzz, the head lights flashed on for a spilt second and then off. The batteries all test out great. From one positive to 6 negative 51volts. I did hook up the charger and it waited a few seconds then started charging. I've kept an eye on it and it is gradually reducing the voltage. I need some help troubleshooting. Any ideas? Please!

02-27-2018, 08:52 PM	#9
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Battery Cable upgrade/OBC bypass You would get those symptoms if the 15 amp fuse behind the Tow/Run switch is blown. It looks like You may have a wire in the wrong place. When did You see the head lights flash briefly, when the key switch was turned ON or when the light switch was turned ON?

02-27-2018, 09:45 PM	#10
Randy L Not Yet Wild Join Date: Jan 2010 Location: Kansas Posts: 38	Re: Battery Cable upgrade/OBC bypass The lights flashed when I turned the lights on, not sure if I had the key switch turned on or not. Are there any connections I need to check with the volt meter. Since the battery pack it charging the way it should would that rule out the OBC?

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