Fuse between solenoid + and KS blows

[jeff.peters]

What would cause the blade fuse between large solenoid + post to key switch to blow? I replaced a 15A fuse that burned out with a 20A (it's all I had on hand) and that one blew too.

In process of upgrading '97CC DS w/ new 500A SW-180-93 solenoid, Alltrax SR 48500, D&D 4:2A motor, on-board Lester Summit II, using previously installed HDF/R w/ 1 microswitch, and v-glide. OBC removed, charging receptacle removed. Pretty bare bones - no lights, reverse buzzer, run/tow, voltage reducer or accessories. Checked continuity throughout and it works the way I think it's meant to (foot switch works, anti-arc works...) using the Alltrax SR to CC DS wiring diagram.

[handtools]

If it's a standard automotive blade fuse I believe they are only rated for 32v. The voltage going thru the key switch is full pack voltage, is your cart 36v or 48v?

[jeff.peters]

it's 48v...I didn't know the automotive blade fuses were only rated 32v...I'm sure that the one I used was one I bought from an automotive store years ago.....when I find one that's rated for 48+v, how many amps would the fuse need to be in that location in the KS circuit?

[Sergio]

It sounds like the diode on the Solenoid is backwards or shorted.

Make sure the diode side with the stripe is connected to the positive activation wire.

[jeff.peters]

Sorry - I started another thread when I realized my problem may be bigger than this question. So I'm abandoning this thread and sticking with the other one.