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Unread 11-27-2012, 11:37 AM   #1
Not Yet Wild
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Default Club Car OBC issues with readapting to fit my build

Let me start with saying hello. I've been reading on here a while but have yet to have much expertise to share with the community that hasn't already been posted.

Have a Club Car DS powerdrive i built up with the following specs several years ago. I removed the OBC when I did the build, and have been borrowing a buddies Lester auto charger for a while to charge it but recently had to give it back. Now I am attempting to rewire the original working OBC so I can use my powerdrive charger.

1995 Club car DS
Alltrax axe 650
HD FNR
HD Solenoid
1/0 wires
Beast motor
MCOR throttle upgrade

My OBC# 101956103

I bought an OBC stud from ScottyB and hooked my Neg cable up with the controller end on the metal backing side of the obc, and the plastic side going to battery pack neg
black wires - one to neg side of batter pack and one to black wire coming out of charge receptacle
red wire - fused going to positive side of pack
grey wire - going to charge receptacle
unconnected are brown, yellow, and green

Currently when you plug the charger in there is a small hesitation and the charger kicks on. No amperage is shown on charger though. I'm reading 60ish volts at the charge receptacle but only 49ish on my battery pack. From what I can understand the OBC controls the negative flow via the two black wires. Apparently its kicking the charger on but not allowing any juice through.

I am trying my best to avoid buying an auto charger if I don't have to since I have working parts laying around. Any of you OBC Experts have any opinions? I've read plenty of OBC threads but haven't seen anyone do this.
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Unread 11-28-2012, 04:23 AM   #2
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Default Re: Club Car OBC issues with readapting to fit my build

You may have OBC put in backwards but not sure, my cart is 60 miles away in winter storage.
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Unread 11-28-2012, 06:15 AM   #3
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Default Re: Club Car OBC issues with readapting to fit my build

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Originally Posted by Fishing Dude View Post
You may have OBC put in backwards but not sure, my cart is 60 miles away in winter storage.
. . . agree . . .

. . . should also have a red wire going to charge receptacle from main pos terminal of pack . . .
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Unread 11-28-2012, 08:09 AM   #4
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Default Re: Club Car OBC issues with readapting to fit my build

your charger receptical has 3 wires a red 10 gage that goes to pos of #1 battery.......a 10 gage black that goes to B- of controller and your grey wire, there is a fuse in grey wire and a fuse on top of receptical..........your #6 neg battery cable has to go thur the OBC not around it.......if you bought the kit from scotty that stud goes thur the hole in OBC with your neg cable from #6 battery bolted to front part of it and the back end that cable bolts to it and then to B- of controller along with the 10 gage wire from receptical..................................
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Unread 11-28-2012, 10:27 AM   #5
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Default Re: Club Car OBC issues with readapting to fit my build

I forgot to mention it but the red wire from the controller is hooked up correctly. Also the "#6" wire is hooked up like you mention.

Shadowman- so you're saying the black wire from the charge receptacle goes directly to the B-? All the diagrams I look at show that wire going to OBC and then the other black wire coming from OBC going to B-
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Unread 11-28-2012, 10:52 AM   #6
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Default Re: Club Car OBC issues with readapting to fit my build

Quote:
Originally Posted by Hustamuff View Post
I forgot to mention it but the red wire from the controller is hooked up correctly. Also the "#6" wire is hooked up like you mention.

Shadowman- so you're saying the black wire from the charge receptacle goes directly to the B-? All the diagrams I look at show that wire going to OBC and then the other black wire coming from OBC going to B-
. . . I believe a #10 black wire from OBC (along with #6 black from NEG terminal, passing thru OBC) go to B- on controller . . .

. . . possibly the #10 black wire from receptacle goes to OBC (via harness) that ultimately is same #10 black wire from OBC to controller's B-?

. . . I am looking at a diagram for a 97 CC DS . . .
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Unread 11-29-2012, 09:50 AM   #7
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Default Re: Club Car OBC issues with readapting to fit my build

well I did some investigating yesterday. The two #10 black wire are not common, ie they arent' connected internally. I cut the one going to the charge receptacle and re routed it directly from the charge receptacle to the B-. After I did that and plugged the charger in the charger started normally, showed full amperage and seemed to be charging. I didn't have but about 3 hours to leave in plugged in before I had to leave for the night and didn't want to leave it running, so i'm really not sure how much charge it took.

What I am worried about is that I think by doing this I may have bypassed the OBCs function to regulate the amount of charge going to the batteries? If that is a function? I know the gray wire turns it on or off but beyond that does the OBC manage the charge current via these black wires?
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Unread 11-29-2012, 09:57 AM   #8
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Default Re: Club Car OBC issues with readapting to fit my build

Quote:
Originally Posted by Hust View Post
well I did some investigating yesterday. The two #10 black wire are not common, ie they arent' connected internally. I cut the one going to the charge receptacle and re routed it directly from the charge receptacle to the B-. After I did that and plugged the charger in the charger started normally, showed full amperage and seemed to be charging. I didn't have but about 3 hours to leave in plugged in before I had to leave for the night and didn't want to leave it running, so i'm really not sure how much charge it took.

What I am worried about is that I think by doing this I may have bypassed the OBCs function to regulate the amount of charge going to the batteries? If that is a function? I know the gray wire turns it on or off but beyond that does the OBC manage the charge current via these black wires?
. . . yes, the OBC regulates the amount of replenishment the battery pack requires and it also serves as a "lockout" to prevent driving the cart when plugged into charger . . . you could test the lockout function by connecting the charger to cart, put it in fwd or rev and "gingerly" step on GO pedal and see if cart attempts to move . . .
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Unread 11-29-2012, 10:10 AM   #9
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Default Re: Club Car OBC issues with readapting to fit my build

the lockout function is controlled via the green and yellow wires serving as a ground for the solenoid(s). I don't have them hooked up as I don't really need that function. I'm just concerned about if the OBC somehow restricts the flow through these #10 black wires and if bypassing that function (if it exists) will cause charging issues
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Unread 12-03-2012, 04:34 PM   #10
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Default Re: Club Car OBC issues with readapting to fit my build

So I ran the charger with the black #10 wire going straight to the B- side rather that going to the OBC. The cart charged for 14 hours until I finally unplugged it. It charged up great but don't understand why the Charger never shut off?
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