Need help rebuilding carts for my church

[Theflyinglineman]

I am in The process of rebuilding my church golf carts. what I need help with is the wiring. I have scoured the Internet and I found 45,000 different wiring diagrams. None of them match these carts. The carts are 2000 club car ds 6 seaters. They are series carts with a vglide and mechanical F/R switch with a Curtis 1204-410. Controller. I need to remove the OBC. It also has a switch on it that I cannot identify what it does. All of the wiring needs to be replaced. If there is someone that can give me a detailed drawing on how to remove the OBC, and also how to rewire the cart that would be great I know it sounds really vague but I am scratching my head on this one.

[Theflyinglineman]

More pics

[DaveMJ]

I think the switch by the controller is just a kill switch to deter unauthorized use. You could remove it and connect the smaller red wire to the controller terminal that the larger red wire is currently connected to.

Wiring looks pretty standard for that vintage of machine. Several questions:

Assume these are 48 volt machines, without two/run switches?
Why do you need to remove the OBC?
Why do you need to rewire?
Are they running?

Here's a wiring diagram for 2000 DS with some of the attributes you described. If this does not closely match your machines please explain variances.

[Theflyinglineman]

Originally Posted by djohns18

I think the switch by the controller is just a kill switch to deter unauthorized use. You could remove it and connect the smaller red wire to the controller terminal that the larger red wire is currently connected to.

Wiring looks pretty standard for that vintage of machine. Several questions:

Assume these are 48 volt machines, without two/run switches?
Why do you need to remove the OBC?
Why do you need to rewire?
Are they running?

Here's a wiring diagram for 2000 DS with some of the attributes you described. If this does not closely match your machines please explain variances.

Yes 48 volt, the obc is not working and they bought new chargers that don’t require the obc the wiring basso many splices and is in very poor shape and yes they are running

[DaveMJ]

If you indicate what charger they purchased someone will be able to help with OBC Bypassing. Need to know:

Brand.
Model.
Onboard or shelf charger.
Will three way receptacle be used or will it be hardwired?

[scottyb]

Go here for all things OBC bypass > https://www.buggiesgonewild.com/showthread.php?t=114227

[Theflyinglineman]

Originally Posted by djohns18

If you indicate what charger they purchased someone will be able to help with OBC Bypassing. Need to know:

Brand.
Model.
Onboard or shelf charger.
Will three way receptacle be used or will it be hardwired?

https://www.amazon.com/Volt-Golf-Cha.../dp/B074B78Y85

It will be stored on a shelf

[Theflyinglineman]

Originally Posted by scottyb

Go here for all things OBC bypass > https://www.buggiesgonewild.com/showthread.php?t=114227

I tried to pick through all the info on that forum. From what I gathered this is what I think I need to do
1. remove gray wire from obc and charge receptacle
2. Move black cable from controller - obc to controller - main post on battery pack
3. Move yellow wire from obc - solenoid to solenoid - b- on controller
4. Remove red wire from obc - solenoid
5. Remove brown wire from obc to voltage gauge
6. Remove orange jumper from key switch to voltage gauge

I will be installing a new voltage gauge wired directly to pack. Does that sound about all