Unknown 'cluster'

BigOL3

This cluster is behind OBC above rear axle. It appears someone did some "rigging". Of the many wires that are connected, there are only 2 that I know for sure what they are for( have not traced the rest down). The big black wire runs through obc and connects to neg on pack. It appears someone upgraded the black wire (but left it) with the red cable that also connects to neg on pack. I have received some components (including #2 cables) from David, RevCarts, to replace those.

My question ...... this cluster appears to be working, and I have no idea how the original connection setup was made ..... what would be the best suggestion?

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BGW

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Roxyflash

There using it for ground connection ugly but works

NoleFan4Ever

That's a "Redneck" terminal Bolt!

BigOL3

Bought what I thought too. I guess I need to remove both the black wire thru OBC and red cable going around it, both are connected to pack ground. Then install the new replacement 2ga. cable I got from David, thru OBC.

NoleFan4Ever

That would be correct.

Fairtax4me

That red cable is a major problem, and could be why the OBC was “bypassed” before. The OBC has to monitor all current via the negative battery cable passing through the center of the inductive pickup sensor in the middle of it. It can’t do that if the cable does not go through the OBC. Having a second path around, and a possibly damaged or deteriorated wire going through the OBC, It’s likely the OBC is not measuring any current at all, and will not charge the battery pack properly because of that.

The red cable needs to be removed completely, and the black cable probably needs to be replaced with a new (larger) cable that runs through the OBC center hole. Everything is bolted together there because the original controller had its B- terminal on that side. Those wires would have all been bolted together at the B- terminal on the controller. Someone upgraded to an Alltrax at some point, and just didn’t feel like making new cables so that everything would reach to the B- on the Alltrax.

Htownblue

Looks like an Alltrax install given the blue controller on right side of photo. Whoever did that install made a common ground bolt and likely ran that bundle via wire to the B- on the controller.

BigOL3

Yes, I already have the 2ga cable to replace going thru OBC.

yawood

2ga is probably too big to go through the hole in the OBC. DO NOT be tempted to drill out the hole to make it bigger - you WILL ruin the OBC.

There is a stud that you can buy from David (Revolution) that goes through the OBC and allows you to connect the larger cable either side.

NoleFan4Ever

But be sure to try it first. As Yawood stated, it ~may not work, but many times it does. I always use 2 awg Excelene welding cable and it fits nicely thru the Hall sensor. I just rub a little lubricant on it and there she goes....