OBC 3 wire bypass trouble with photos

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  • OBC 3 wire bypass trouble with photos

    Converting to lithium with new onboard charger.
    Seems to be a 2005 Club Car Carryall 48v (see serial number)
    3 wire OBC (no blue & white!)
    Cart is basic with no tow switch or 12v step down transformer

    After reading as much as I could find on these old 3 wire OBC bypasses, the cart turns on but will not move forward or backward. Here is what I did:

    1. I cut the yellow from OBC, then took remaining yellow wire from harness and attached it to B- on controller.
    2. I cut the grey wire from OBC
    3. I removed old charging plug completely.
    4. I cut the Black from OBC going to front of cart where old charger was.
    4. Red & Brown from OBC ignored.
    5. I ignored another Black from OBC going to B- on controller.

    Why won’t cart go forward or backward?
    Should I remove the 2nd black wire from OBC going to controller? (Circled in blue on photos)

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  • #2
    Additional pics for overall view of cart.

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    • #3
      Okay for series carts you gotta follow the yellow wire from the little solenoid post all the way to the OBC. Then, cut it as close as you can to the OBC (don’t freak out, it’s fine), and crimp a 5/16” ring terminal on it. After that, just hook it up to the pack negative or controller B-... Easy, right? Now do the exact same thing with the black 10-gauge negative wire that’s chilling at the back of the charger receptacle. Yeah, that’s it. Done.

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