Club Car 2017 always on even with key switch wires disconnected

[Carts4you]

we have a 2017 CC precedent that is on and running even when we disconnect the key switch wires. we thought it was a faulty switch but were able to run the car with the blue and green wires disconnected. Has someone seen this before? When looking at wiring diagram I see that keyswitch only goes to number 7 on controller connector. What could cause this to occur?

[meimk]

I believe a solenoid that's welded closed could cause your issue.

[Sergio]

That key switch wire goes to a lot more places but the issue is most likely using a couple of batteries for accessories.

Look at the battery pack to see if there are any wires connected to a battery post (other than the cables).

Disconnect the negative accessory wire if plugged to battery #2 or #3 (pack positive is #1).

[Carts4you]

thanks for the hints. only accessory connected was the light kit. the car does have positive in main positive and negative at second battery positive for a 16 volt connection. would this also cause the car to suddenly stop running? intermittently?

[Carts4you]

Sergio that is the problem. Can you guide me through this wiring problem? but this should not cause the car to stop running and after a while start running again correct? can I connect to other two batteries without this happening?

[Sergio]

The proper solution is to install a 48v->12v reducer.

If You want to continue to use only two batteries, the negative must be the pack negative battery post and the positive will be the battery post where You measure 16v from pack negative.

Make sure You disconnect the accessory positive wire from the pack positive battery post before moving the negative wire.

[Carts4you]

Originally Posted by Sergio

The proper solution is to install a 48v->12v reducer.

If You want to continue to use only two batteries, the negative must be the pack negative battery post and the positive will be the battery post where You measure 16v from pack negative.

Make sure You disconnect the accessory positive wire from the pack positive battery post before moving the negative wire.

got it. so why would hooking up to batteries 1 and 2 cause the switch not to function? cant tell from looking at wiring diagram. and thanks for the help

[Sergio]

It is a little tricky to see the issue, the reason is that in the dash harness there is a fly-back diode for the brake relay that is connected to the "switched" side of the key switch.

The same fly-back diode is also connected to the negative from the bucket harness.

Your negative wire connection was 32v as measured from pack negative so when the key switch was OFF, current would travel from the negative wire through the forward biased relay fly-back diode to the switched side of the key switch where it would power the Controller and Solenoid.

[Carts4you]

Originally Posted by Sergio

It is a little tricky to see the issue, the reason is that in the dash harness there is a fly-back diode for the brake relay that is connected to the "switched" side of the key switch.

The same fly-back diode is also connected to the negative from the bucket harness.

Your negative wire connection was 32v as measured from pack negative so when the key switch was OFF, current would travel from the negative wire through the forward biased relay fly-back diode to the switched side of the key switch where it would power the Controller and Solenoid.

thank you. trying to learn to understand wiring diagrams completely. really tricky. but will go back with the info. now this would not cause the car to stop intermittently. could be more of a mcor starting to fail? it has not done it for a few rides now. i am helping my brother in law but he does not have a scanner with him.

again thanks for your help Sergio