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Old 06-13-2021, 04:42 PM   #1
Jcgr81
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Default Club Car DS (48V) Runs without KEY

Hello all. I have a 1996 Club Car DS (48V). I recently bypassed the OBC with instructions from this site and the OBC sticky thread. I noticed while doing this that my solenoid engages as soon as I put the negative cable back on and will operate with or without a key. Also, when depressing the accelerator pedal, I no longer hear the solenoid engage, as I'm assuming it's staying closed at all times.

I've done some searching around the forum but am coming up short on my search abilities. Any help on where to go to correct this?

For clarification, on the OBC bypass, I cut the black wire from the charger plug and ran it to battery negative and also took the yellow wire from the solenoid and ran it also to battery ground. Am I missing something or somehow grounding my solenoid out and causing it to stick closed?

Thanks in advance!
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Old 06-13-2021, 06:25 PM   #2
Fairtax4me
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Default Re: Club Car DS (48V) Runs without KEY

Yes, you are “grounding” the solenoid, that’s what the yellow wire does, and that is the correct way to bypass the OBC on a series cart.
You have at least one other problem, possibly 2. The solenoid should not get power unless the key switch is On, AND the Pedal is pressed, AND the FNR switch is in F or R.
Since the solenoid is clicking On as soon as you connect the pack negative, that means either Both the Key switch and the microswitch in the throttle box are bad (supplying power when they should not)
Or someone has monkeyed with the wiring in the past and the solenoid is getting 48v from another source.

Wire diagram from the stickies section:

Check the solenoid for any “extra” wires other than the ones that are supposed to be there.
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Old 06-13-2021, 06:38 PM   #3
sthreatt
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Default Re: Club Car DS (48V) Runs without KEY

I suspect the latter, power from another source. Hard to imagine both the keyswitch and pedal switch failing closed at the same time.
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Old 06-22-2021, 05:56 PM   #4
Jcgr81
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Default Re: Club Car DS (48V) Runs without KEY

Thank you for the reply and my apologies for taking so long to come back to this. Bear with me here, I was a mechanic in a former life but generally on 12v systems. The Key switch seems to be operating as it should. When off it has 48V on one side but nothing on the other. When on, it sends 48v to the other side.

I've checked the solenoid against the manual, and the wires seem to be the only ones that should be on there.
IMG_0224.jpg

I've also figured out that I've essentially burned the positive cable to the solenoid up since it's carried amperage non-stop since the root of the failure occurred. I've tried removing the positive cable from the battery but it seems the posting is turning through, I'm guessing due to heat.
IMG_0226.jpg

Not sure where to go from here. I'm also worried I'm going to need a new battery(s) due to the post issue. It seems to potentially point back to my accelerator being part of the issue, but I have the problem regardless of directional position (F/N/R). Any input or help in the right direction would be much appreciated!
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Old 06-23-2021, 06:14 AM   #5
BBBHC
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Default Re: Club Car DS (48V) Runs without KEY

I'll let the others chime in on diagnosing your original question, as I am not familiar with your specific cart electrical system.

However, I can at least offer a bit of advice. It is best practice, when multiple wires/cables are stacked on a post/bus bar/etc., to stack biggest on bottom and smallest on top. I would think that might be the issue that caused the one battery post problem you are having.

Hope this helps, good luck.
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Old 06-23-2021, 10:10 AM   #6
Jcgr81
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Thumbs up Re: Club Car DS (48V) Runs without KEY

Quote:
Originally Posted by BBBHC View Post
I'll let the others chime in on diagnosing your original question, as I am not familiar with your specific cart electrical system.

However, I can at least offer a bit of advice. It is best practice, when multiple wires/cables are stacked on a post/bus bar/etc., to stack biggest on bottom and smallest on top. I would think that might be the issue that caused the one battery post problem you are having.

Hope this helps, good luck.
Thanks for the advice, and that makes sense. I should have caught that for sure.
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Old 06-27-2021, 11:43 AM   #7
Jcgr81
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Default Re: Club Car DS (48V) Runs without KEY

Bumping this back up hoping someone has some troubleshooting advice. Thanks!
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Old 06-27-2021, 04:32 PM   #8
rabbitreborn
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Default Re: Club Car DS (48V) Runs without KEY

From the pic you posted it appears there is a small red wire on the same post as the white with black tracer. Where is the red wire going to? If you disconnect it does the solenoid click off?
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Old 06-28-2021, 06:58 PM   #9
Jcgr81
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Default Re: Club Car DS (48V) Runs without KEY

Quote:
Originally Posted by rabbitreborn View Post
From the pic you posted it appears there is a small red wire on the same post as the white with black tracer. Where is the red wire going to? If you disconnect it does the solenoid click off?
The Black/White wire runs to one of the directional switches and the red wire runs to the controller. Looking at the wiring diagram, that appears to be correct.

I did remove the YELLOW wire from the solenoid and it would no longer engage when connecting battery ground. I hooked it back up and it’s working correctly now. I’m a bit perplexed…
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