Bypass question 48v

Ryan T · 04-01-2018, 02:26 PM

Hey working on a 48v series Club car, factory charger and once worked fine. But we built him a set of 1/0 cables so the ground no longer fit through obc hole, so we went around it. I found the heavy blk wire from the back of the charge rec. and cut it and ran to pack ground. Left all else alone and intact including the fused small grey wire.
Plugged in factory charger and it took maybe 10 seconds but it came on and charged with out any issue. Started at 30 and meter was down to 5 in around 5 or 6 hours pack voltage at this time was 63.8. I fiqured it was finishing up just fine on trickle but didn't know if it could shut off automatically so unplugged it . Pack voltage was 51.8 the next morning so I feel like it got a good charge. Question is, would the charger have shut off IF I'd left it alone???? Thanks in advance

LukeL · 04-01-2018, 02:33 PM

If the wire isn’t going through the hole in the OBC nothing will work right. The OBC won’t be able to monitor the charge and it won’t know how to operated the charger.

I know a 4G cable will fit through the hole- not sure about a 2 or 1AWG. Don’t drill it out!

If the OBC is bypassed the charger will not shut off. You will have to get a different charger that works independently of the OBC.

Sent from my iPhone using Tapatalk

Ryan T · 04-01-2018, 02:40 PM

I got you, thanks. Glad I didn't go in and leave it for the night. But it still senced voltage and turned on charger and operated normal besides the fact that it wouldn't have turned off. Right? It fully charged the pack from way down at a 48.5 starting pack voltage. No trick to continue using this charger other than unplug when charging volts get up around 63 to 65 volts?

Swan · 04-01-2018, 03:50 PM

most people use a brass bolt kit to go though the obc and attach your cables to that on each side of the obc

scottyb hass a kit at >http://www.cartsunlimited.net/battery-cables.html

Ryan T · 04-01-2018, 04:14 PM

I like that idea, thx

NoleFan4Ever · 04-01-2018, 09:11 PM

You need to hook the black 10 gauge wire back up, it went to your OBC. As Luke mentioned, an OBC can take most 2 gauge, but no way a 1/0 will ever go through it. Like Swan said, get a thru-bolt kit and connect the cables to both sides of it so your OBC can account for the energy units being used with cart usage and properly recharge the pack.

04-01-2018, 02:26 PM	#1
Ryan T Getting Wild Join Date: Jan 2011 Posts: 124	Bypass question 48v Hey working on a 48v series Club car, factory charger and once worked fine. But we built him a set of 1/0 cables so the ground no longer fit through obc hole, so we went around it. I found the heavy blk wire from the back of the charge rec. and cut it and ran to pack ground. Left all else alone and intact including the fused small grey wire. Plugged in factory charger and it took maybe 10 seconds but it came on and charged with out any issue. Started at 30 and meter was down to 5 in around 5 or 6 hours pack voltage at this time was 63.8. I fiqured it was finishing up just fine on trickle but didn't know if it could shut off automatically so unplugged it . Pack voltage was 51.8 the next morning so I feel like it got a good charge. Question is, would the charger have shut off IF I'd left it alone???? Thanks in advance
Ryan T Getting Wild Join Date: Jan 2011 Posts: 124

04-01-2018, 02:33 PM	#2
LukeL Gone Wild Join Date: Jun 2017 Location: Savannah, GA Posts: 6,539	Bypass question 48v If the wire isn’t going through the hole in the OBC nothing will work right. The OBC won’t be able to monitor the charge and it won’t know how to operated the charger. I know a 4G cable will fit through the hole- not sure about a 2 or 1AWG. Don’t drill it out! If the OBC is bypassed the charger will not shut off. You will have to get a different charger that works independently of the OBC. Sent from my iPhone using Tapatalk

04-01-2018, 02:40 PM	#3
Ryan T Getting Wild Join Date: Jan 2011 Posts: 124	Re: Bypass question 48v I got you, thanks. Glad I didn't go in and leave it for the night. But it still senced voltage and turned on charger and operated normal besides the fact that it wouldn't have turned off. Right? It fully charged the pack from way down at a 48.5 starting pack voltage. No trick to continue using this charger other than unplug when charging volts get up around 63 to 65 volts?
Ryan T Getting Wild Join Date: Jan 2011 Posts: 124

04-01-2018, 03:50 PM	#4
Swan Cave Dweller Join Date: Apr 2013 Location: Always On The Move Posts: 22,238	Re: Bypass question 48v most people use a brass bolt kit to go though the obc and attach your cables to that on each side of the obc scottyb hass a kit at >http://www.cartsunlimited.net/battery-cables.html

04-01-2018, 04:14 PM	#5
Ryan T Getting Wild Join Date: Jan 2011 Posts: 124	Re: Bypass question 48v I like that idea, thx
Ryan T Getting Wild Join Date: Jan 2011 Posts: 124

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04-01-2018, 09:11 PM	#6
NoleFan4Ever MOD of all BS! Join Date: Sep 2011 Location: Florida Posts: 17,477	Re: Bypass question 48v You need to hook the black 10 gauge wire back up, it went to your OBC. As Luke mentioned, an OBC can take most 2 gauge, but no way a 1/0 will ever go through it. Like Swan said, get a thru-bolt kit and connect the cables to both sides of it so your OBC can account for the energy units being used with cart usage and properly recharge the pack.

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