Club Car IQ System Solenoid blows fuse when jumped, solenoid not working

V

Vette79lt1

New Member
Good Morning!
I have an early 2000s Club Car DS 48V with 1515-5210 controller and EJ8-4001A motor. I purchased this cart from a decent kid who replaced the harness, all switches, mcor, batteries, controller, solenoid, and bypassed obc. When key on and switch in reverse, buzzer comes on, no movement when pedal depressed. I read though all the no run condition links and did all tests on key, fnr switch, mcor, etc on the various pin positions and I see the values are accurate. Solenoid does not open and with both small contacts jumped (one to 48v pack voltage, one to pack ground) the ground wire makes a huge spark and blows the fuse in the main circuit. Replaced controller again, same thing. I can't find anything miswired or any breaks in the new harness. I would greatly appreciate any wisdom! Thank you guys!!!
 
Thank you Diode!

Both wires on to solenoid were disconnected for testing. With primary wires removed, solenoid clicks. Also tried another solenoid, same issue.

Uh oh, I am missing the top resistor...
 
Here are a few pictures
 

Attachments

  • 20241122_092333.webp
    20241122_092333.webp
    175.7 KB · Views: 8
  • 20241122_092331.webp
    20241122_092331.webp
    148.2 KB · Views: 8
  • 20241122_092326.webp
    20241122_092326.webp
    143 KB · Views: 8
Which fuse is blowing the 15 amp? That controller is for the Excel system not iQ, unless that wire harness is also an Excel harness that may be why you are blowing the fuse. When you were checking the values at the 16 pin connector and they were good were you referencing the iQ or Excel troubleshooting guide?

Also that is an aftermarket wire harness so the wire colors are completely different from what they should be, but that black wire on the solenoid may be negative. With the key on check which of the 2 wires has positive voltage on it. If the blue is indeed positive then you have it backwards and it is shorting out through the diode
 
Thank you all for the help!!! Here's where I'm at:

Replaced Main Battery Cables

Blue wire has 0v when off
With key and tow switch on has 2.5v
With key and tow on and pedal midway has5v
With key and pedal all the way down has 2.5v

Wiring diagram I found was in another post here. I honestly don't know what system I actually have. The person I got it from put all new wiring and components in but never got it running

Fuse blows when I jump both small leads on solenoid to pos/neg on battery, happens with two different new solenoid that bench test fine

Thank you guys very very much for the help. I greatly appreciate it
 
Here are all the components and connections
 

Attachments

  • 20241122_160847.webp
    20241122_160847.webp
    67.3 KB · Views: 5
  • 20241122_161153.webp
    20241122_161153.webp
    134.2 KB · Views: 4
  • 20241122_161153.webp
    20241122_161153.webp
    134.2 KB · Views: 8
  • 20241122_160855.webp
    20241122_160855.webp
    212.4 KB · Views: 4
  • 20241122_160807.webp
    20241122_160807.webp
    142.9 KB · Views: 6
  • 20241122_160800.webp
    20241122_160800.webp
    98.3 KB · Views: 6
Sorry for the multiple messages, I forgot to mention, the brown wire to solenoid has 0v with tow switch off, has pack voltage when tow, key, and F switch are on without pressing pedal
 
Vette79lt1 said:
Fuse blows when I jump both small leads on solenoid to pos/neg on battery, happens with two different new solenoid that bench test fine
Click to expand...
What are you talking about jump the small leads? Your connecting the wires to the battery? Whatever you are doing is obviously blowing the fuse and may have killed the controller
 
Golf Cart Wizard said:
What are you talking about jump the small leads? Your connecting the wires to the battery? Whatever you are doing is obviously blowing the fuse and may have killed the controller
Click to expand...
I put pack voltage where I have brown wire connected and ground where blue wire is connected with only the 3 top post wires connected. Ty again
 
Vette79lt1 said:
I put pack voltage where I have brown wire connected and ground where blue wire is connected with only the 3 top post wires connected. Ty again
Click to expand...
When I did that without wires on top connected solenoid opens. With wires connected, blows 15a fuse in main harness (only fuse)
 
Are you sure that jumping the solenoid is what is blowing the fuse or could it be from turning the key or the pedal? What if you unplug the OBC connector?
 
Golf Cart Wizard said:
Are you sure that jumping the solenoid is what is blowing the fuse or could it be from turning the key or the pedal? What if you unplug the OBC connector?
Click to expand...
Thanks for the reply!

Just disconnected the on board computer and turned everything else on. Still won't move with pedal down but solenoid clicks with jumper to ground on left side (where blue was plugged in)
 
Vette79lt1 said:
Thanks for the reply!

Just disconnected the on board computer and turned everything else on. Still won't move with pedal down but solenoid clicks with jumper to ground on left side (where blue was plugged in)
Click to expand...
The cart will not run with the OBC disconnected. If the fuse is no longer blowing with it disconnected then you need to redo the bypass with a resistor as described here:
Golf Cart Wizard

Thread 'How to bypass iQ OBC the right way'

To bypass the Club Car iQ OBC properly you need to get a 10,000 ohm pull down resistor. Then you need to go to the 6 pin plug. You can cut the wires, but I have Deutsch pins so I just depinned all the wires from the plug. To do that you use a hook tool to pull out the green wedge lock and then pull back the tabs holding the pins
IMG_5434.webp

Now you need the blue and white wire, either cut from the OBC or new wire. Get a male .250 spade connector and crimp the blue wire together with one end of the resistor. This spade connector will plug into the separate gray wire on the OBC that goes to...
  • Like

I have seen Excel carts where people did the “just splice the wires together” method of bypassing the OBC that constantly blew the 15 amp fuse, not sure why it does that on some carts and not others but sounds like that may be the problem.
 
Golf Cart Wizard said:
The cart will not run with the OBC disconnected. If the fuse is no longer blowing with it disconnected then you need to redo the bypass with a resistor as described here:
Golf Cart Wizard

Thread 'How to bypass iQ OBC the right way'

To bypass the Club Car iQ OBC properly you need to get a 10,000 ohm pull down resistor. Then you need to go to the 6 pin plug. You can cut the wires, but I have Deutsch pins so I just depinned all the wires from the plug. To do that you use a hook tool to pull out the green wedge lock and then pull back the tabs holding the pins
IMG_5434.webp

Now you need the blue and white wire, either cut from the OBC or new wire. Get a male .250 spade connector and crimp the blue wire together with one end of the resistor. This spade connector will plug into the separate gray wire on the OBC that goes to...
  • Like

I have seen Excel carts where people did the “just splice the wires together” method of bypassing the OBC that constantly blew the 15 amp fuse, not sure why it does that on some carts and not others but sounds like that may be the problem.
Click to expand...
Thank you very, very much wizard! I will see what I can make happen and respond. I really do appreciate it!!!
 
Good Evening Guys!
I went ahead and wired a 10k ohm resistor in between the blue and white wires. Now when I ground the solenoid, it clicks without blowing the fuse! However cart still doesn't move... I tried the pedal with solenoid jumped, nothing. I'd appreciate any other ideas or tests you can come up with. I just can't believe 3 different controllers are bad....

Thanks a million!
 
You must log in or register to reply here.
Back
Top Bottom