Buggies Unlimited Golf Cart Troubleshooting Text Support

2003 Club Car Gas blowing headlight fuses when engine runs

2003 Club Car Gas blowing headlight fuses when engine runs

Postby knorman » Mon Mar 23, 2009 11:23 pm

I just purchased a used 2003 Club Car gas model which came with headlights and tail lights. When I bought it, there was no fuse in the headlight fuse socket. I put a fuse in and it worked fine while the engine was off. Once I start the engine, the fuse blows immediately. Otherwise, the cart seems to operate just fine.

Does this sound like a common problem anyone else here has encountered? possibly a bad voltage regulator?

Any input greatly appreciated.
knorman
 
Posts: 3
Joined: Mon Mar 23, 2009 11:20 pm

Re: 2003 Club Car Gas blowing headlight fuses when engine runs

Postby TheCartDude » Tue Mar 24, 2009 1:22 am

I have a sneaking suspicion someone has a split feed from that headlamp fuse going through a starter micro to ground. Trace the wire for the headlamps and see if it winds up in the solenoid box hooked up to something else.
2002 Gas Club Car
6" BU spindle lift
22" Mudlites
24HP Engine

Rest in Peace, Keyguy. You Will Always Be Remembered.
User avatar
TheCartDude
 
Posts: 5483
Joined: Tue Jan 25, 2005 9:50 pm
Location: Baton Rouge, Louisiana

Re: 2003 Club Car Gas blowing headlight fuses when engine runs

Postby knorman » Tue Mar 24, 2009 7:35 am

The fuse is connected directly to the positive terminal and the negative return wires are tied togather and grounded to the frame at a common point.
knorman
 
Posts: 3
Joined: Mon Mar 23, 2009 11:20 pm

Re: 2003 Club Car Gas blowing headlight fuses when engine runs

Postby TheCartDude » Tue Mar 24, 2009 4:16 pm

For the fuse to blow when the engine starts, it is most likely a switched ground short problem. Trace the hot from the fuse and see if it goes anywhere other than to the headlamp switch, or from there to the lights.
2002 Gas Club Car
6" BU spindle lift
22" Mudlites
24HP Engine

Rest in Peace, Keyguy. You Will Always Be Remembered.
User avatar
TheCartDude
 
Posts: 5483
Joined: Tue Jan 25, 2005 9:50 pm
Location: Baton Rouge, Louisiana

Re: 2003 Club Car Gas blowing headlight fuses when engine runs

Postby TheCartDude » Wed Mar 25, 2009 4:35 pm

Higher voltage = Lower amperage.

If anything, a high voltage situation would lower actual amps across the fuse, as I recall most of the ATC type fuses are rated at 14.4V. Only thing that might happen as you pointed out, is a high resistance short that needs the extra volts to occur. But the starter-generator has a max capacity of only 20A at 14.4V at full speed...at idle, it might be able to only push 2A at charging voltage. Any draw over that would be coming off the battery, and at battery voltage.

Since the lights are most likely 55w, they draw a total of 9.16A running at 12V. At 15V, they draw 7.33A.

I recommend 15A fuses minimum, as the wiring you have going to the lights should support at least 200W at battery voltage. If you choose to rewire, I would recommend (at minimum) a wire size 14AWG with a 15A fuse. I personally use only 12AWG on my cart, and run 20A fuses.
2002 Gas Club Car
6" BU spindle lift
22" Mudlites
24HP Engine

Rest in Peace, Keyguy. You Will Always Be Remembered.
User avatar
TheCartDude
 
Posts: 5483
Joined: Tue Jan 25, 2005 9:50 pm
Location: Baton Rouge, Louisiana

Re: 2003 Club Car Gas blowing headlight fuses when engine runs

Postby knorman » Wed Apr 01, 2009 7:58 pm

I got it ficed. It ended up being a very short in the wiring. thanks to all who offered advice.
knorman
 
Posts: 3
Joined: Mon Mar 23, 2009 11:20 pm


Return to Club Car Gas

Who is online

Users browsing this forum: Google [Bot] and 4 guests