How to properly eliminate and remove an OBC???

anziosaint

Ok, I have a brand new DPI smart charger for a 2003 IQ club car DS I have been slowly working on in the garage.

I want to use the working OBC from that cart on another cart that I am having trouble with. The powerdrive charger on this other cart is not turning off and it appears the OBC has "kicked the bucket". Tonight I removed the working OBC from my build completely.

I have a few questions.

1-The black ground cable that runs through the OBC is attached to the controller along with another smaller gauge black wire that runs to a small black box with a lug. I am pointing to it in the picture. What is that box and do i still need it. I actually had a cable to run from the controller to the pack negative so i didn't have to mess wit the cable running through the OBC. I left the small gauge black wire connected to the controller and running to the lug on the small black box. Is that OK?

2- I now have the harness dangling that the OBC was connected to. What do I do with it? **See the second pic**

3- Aside from running a 10 gauge wire directly from the back of the charge receptacle to the pack negative, Is there anything else I need to do??

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BGW

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Phil_Billy

when I pull the 6 pin OBC out(what you have pictured), I connect the white and blue wires in the plug together. this by-passes the charger inhibit on the controller, which you will not not be present with the DPI charger.

Mooncarter

There is an entire detailed thread about this in the "Stickies."

Lot's of good info in there.

anziosaint

Should I assume the info is buried in the several page long "OBC bypass" thread? I looked at it some time ago and did not see the specifics of removing the OBC all together....... but i will look back through it. Any answers to my question #1 in the mean time would be greatly appreciated. Thanks so far.

yawood

Normally people just bypass it and leave it there but there is nothing stopping you from removing it altogether once it is bypassed.

mrgolf

That black block is a negative block it has a longer stud,made to hook negative cables to so that you don't have a lot of cables hooked to the negative on the controller. The one wire goes to the controller from there along with the main pack negative. That way you only have two cables on controller negative.

The other connector I just plugged a wire from blue to white wires and tapped it up. Never cut any wires in case anyone wanted to go back to obc system.

LabRat

Thank you heavenly Father for giving the Club Car engineers the ability to remove the OBC from their new carts. Gee Wiz what a really crazy idea that was, probably a Georgia Tech Grad that had never turned a wrench :)

Hunter450

Just a thought, you could cut the female connector from the dead OBC leaving just a few inches of the 2 wires that needs to be jumped and plug them back up. No tape and weather tight.

TahoeDawgZ71

This is how I recommend doing it if you're not going to ever use the OBC again.

1 - Put tow/run switch in TOW.
2 - Disconnect main positive and main negative battery terminals.
3 - Locate the 10 gauge black wire at the back of the OBC that comes from the charger receptacle. Cut this wire and crimp on a 5/16" 10 gauge ring terminal.
4 - Disconnect the grey wire with the fuse holder from the back of the OBC. Cut this wire off at the back of the charger receptacle, as it will not be used again. Cut the opposite end of the grey wire near the OBC and pull it out of the wire loom entirely, leaving only the 1- gauge black wire mentioned in the previous step. Discard the grey wire.
5 - Remove OBC from the vehicle
6 - Cut the 6-pin connector off of the OBC
7 - Dis-assemble the 6-pin connector that you removed from the OBC and de-pin it, leaving only the white wire and the blue wire in the connector. Put retaining clip and rubber gasket back on the plug
8 - Using a butt-connector or a solder joint, connect the white wire and the blue wire together.
9 - Plug the 6 pin connector back into the wire harness on the car.
10 - Connect the 10 gauge black wire from step 3 to either the B- post of the controller (or negative junction block on DS IQ), or to the main negative battery terminal
11 - Install a new 6 gauge cable from main battery negative to the controller B- terminal. This will replace the wire that was going through the hole in the OBC. You can re-use that same wire if you wish. You'll just have to cut the terminall off of it to pull it through the hole in the OBC and install a new terminal on it in order to re-use it.
12 - Connect positive and negative battery terminals
13 - Flip Tow/Run Switch to RUN.

anziosaint

TahoeDawg...... OUTSTANDING!!!!! Thank you. That is what I was Looking for.

Clear, concise, and everything I needed! I was pretty much thinking what you posted but just needed to hear it from someone in the “know”