Applicable: 20082013 ClubCar Precedent with legacy OBC (OnBoard Computer). OBC bypass is mandatory for lithium upgrade. The factory OBC is designed for leadacid batteries; it will cause charging failure, drive lockout and fault alerts when using lithiumironphosphate battery packs. Warning: This modification voids original manufacturer warranty. If you lack electrical experience, hire a qualified golfcart technician. EXXPOWER B1

Required Tools & Materials

· Insulated gloves, safety goggles, multimeter

· Wrench set (1/2inch, 7/16inch), wire crimper

· 1012 AWG stranded copper bypass wire

· Adhesivelined heatshrink tubing (seal all splices)

· Cable ties, electrical tape

Prework Safety Steps (Must Complete First)

1. Park cart on flat ground, turn ignition key fully OFF and remove the key.

2. Flip vehicle service switch from RUN to TOW position to disable main drive circuit and prevent accidental startup.

3. Disconnect the main battery pack negative terminal first. Isolate cable end with tape to avoid accidental shortcircuit. Remove jewelry (rings, watches).

4. Remove seat assembly and access battery compartment. Clear debris, check for frayed, corroded wiring.

StepbyStep OBC Bypass Procedure

Legacy OBC routes charging receptacle negative current through its internal shunt. We will reroute charging negative directly to battery main negative, and resolve chargerplugin interlock lockout signal.

1. Locate the charging receptacle at rear of cart. Trace the heavy black negative wire from back of receptacle; this original wire runs into the OBC module.

2. Cut this heavy black wire coming from receptacle side. Cap / heatshrink the loose wire end that leads toward OBC (do not leave bare exposed copper).

3. Run new heavygauge bypass wire (minimum 1012 AWG):

o One end securely connects to the negative stud on back of charging receptacle.

o The other end connects firmly to main battery pack negative terminal. Torque terminals properly, avoid loose connections which cause overheating.

4. Resolve OBC interlock / drive lockout signal (6pin Deutsch connector on OBC unit):

o Unplug the 6pin Deutsch connector from OBC.

o Splice together Red wire (Pin #2) and LightBlue wire (Pin #6) from this harness. This tricks the controller to cancel “chargerpluggedin” drivelockout logic.

o Seal this splice completely with heatshrink tubing.

5. The original OBC hardware can stay mounted in cart; it will no longer participate in charging or drive control functions.

6. Doublecheck: No bare wires exposed. Secure all new wiring with cable ties, keep cables away from sharp metal edges and moving parts.

7. Reconnect main battery negative terminal.

8. Leave cart still on TOW mode for now. Complete full lithium battery physical installation before switching back to RUN.

PostBypass Verification Checklist

1. Confirm all splices and terminals are tight and insulated. No loose strands inside battery compartment.

2. Switch service switch back to RUN. Insert key, test forward / reverse driving function. Cart must drive normally.

3. Connect your 16S LiFePO4 dedicated charger (58.4V output) to cart charging receptacle. Verify charger initiates charging cycle correctly.

Never reuse original factory leadacid charger. It uses leadacid charging profile and will permanently damage lithium battery pack.

1. Use multimeter to measure total pack DC voltage. Confirm stable 51.2V58.4V working range.

2. Test regenerative braking: drive downhill slowly, confirm cart does not cut power abruptly (BMS must support regenerative reverse current).

Critical Important Notes

1. 

OBC Function Loss

2. 

After bypass: Original OBC stateofcharge monitoring, charging history logging and OEM charger interlock functions are fully disabled. The original dashboard fuel gauge will show inaccurate readings with lithium. Install external Coulomb meter / BMS Bluetooth APP to read real battery remaining capacity.

1. 

Charger Requirement

2. 

Only use 48V(16S) LiFePO4specific smart charger with 58.4V fullcharge voltage. Leadacid OEM charger is forbidden.

1. 

BMS Mandatory Requirement

2. 

Your lithium battery BMS must support regenerative braking reverse current. Without regencapable BMS, downhill braking will trigger unexpected overcurrent BMS shutdown, creating safety risk.

1. 

DCDC 12V Converter Check

2. 

Verify the onboard 48Vto12V DCDC converter accepts full lithium working voltage range (42V58.4V). Replace it if incompatible; do not tap single lithium cell for 12V accessories.

1. 

Wiring Quality

2. 

All splices must use crimp terminals plus adhesivelined heat shrink. Loose connections create fire hazard under golfcart vibration environment.

1. 

Model Distinction Reminder

2. 

For ERICsystem vehicles built after late2013 (Tempo / Onward): There is no separate legacy OBC module. Do NOT apply above bypass procedure to ERICplatform carts, wrong wiring will destroy controller.

1. 

Risk Warning

2. 

· After bypass, cart can still drive while charger is plugged into receptacle. The original safety interlock is removed. Always unplug charger before operating vehicle.

· This conversion voids ClubCar factory warranty. Commercialuse carts shall comply with local electrical safety regulations.

Common Troubleshooting

1. Cart cannot drive after bypass: Check red & lightblue interlockwire splice; confirm TOW/RUN switch is set to RUN.

2. Charger will not start: Check bypasswire connections; confirm you are using lithiumspecific charger.

3. Power cuts off while descending hill: BMS lacks regenerativecurrent handling capacity; upgrade to regensupported lithium battery pack.

If you need, I can also provide a short onepage fieldcheck checklist for onsite technicians.