2003 48v Club car DS IQ new XCT controller shuts off when KSI turned on

[Bnkedwards]

Originally Posted by R&TBabich

This is a strange problem.
I would try calling Alltrax in the morning and see if they have any ideas.
I've talked to Will ....

Thanks again man. That’s definitely my next move, was hoping to get her runnin today badly. Spent the whole weekend workin on this thing. Just not in the cards. I know it’s gonna be something so small and obvious.

[R&TBabich]

Originally Posted by Bnkedwards

I’ll check it in a bit to confirm, but I did check it already. Wanna say it’s set to something like 28 and 58v

Edit: It was at 24 KSI, 28 under, 57 over. I moveD the KSI and under up a bit to 38/43, still same issue

Mine are set to: KSI - 16, Under - 17 & Over - 62.
Will at Alltrax set them when he had control of my computer.
I don't think they are anything special, he said their controller is tolerant of odd voltages.

[Fairtax4me]

May have a bad connection on the B- from controller to pack -
Can you post any pics of your setup? Cable layout, and connections?

[Bnkedwards]

Originally Posted by Fairtax4me

May have a bad connection on the B- from controller to pack -
Can you post any pics of your setup? Cable layout, and connections?

That’s something I haven't tried...removing the 400a fuse from B- to the controller to see if that’s bad (It looks good). I’ll take pics in the morning and post them. However, it’s gonna look a bit weird since I ran all new 4AWG red cables to the controller and motor and labeled them with a sharpie.

[Fairtax4me]

I have all red cables on my carts too.

The best place IMO for the big fuse is on the Solenoid if there is room to mount it there. That keeps it away from battery acid and corrosion. That’s a $45 fuse so it’s worth it to keep it away from potential damage.
Ultimately the placement of the fuse doesn’t matter, it works the same no matter where it is in the circuit.

[R&TBabich]

I didn't like the idea of one end of the fuse having a cable hanging on it when going over bumps.
Found a mount for that type of fuse so it sits on the frame rail behind bat3.

[Bnkedwards]

Originally Posted by Fairtax4me

May have a bad connection on the B- from controller to pack -
Can you post any pics of your setup? Cable layout, and connections?

I removed the 400a fuse, same issues. As promised, here are pics of my setup (yes, she’s hot pink).
Thanks again for trying to help me troubleshoot!

Sorry about the orientation of the pics. It looks like the forum rotated them all when I uploaded.

[Bnkedwards]

Tried calling alltrax a few times today, couldn’t get an answer. Guess they’re still shut down from the fires

[Sergio]

Make sure the diode on the solenoid coil is oriented properly, hard to verify it in your picture.

[Bnkedwards]

Thanks Sergio. It’s got the grey stripe facing the B+ terminal. I did install it backwards originally. Could that have fried it without the solenoid ever closing contacts? It still hasn’t clicked once since I put her in there.