Did you ever take time to disassemble PSDM. I’m having a similar problem with F9 fuse keeps blowing when turning the key.
→ You have been working on this car for a while. Have you ever had it running?
→ What is the History of this car?
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Note : The charger is mounted in your car upside down. What you see is flipped version of this pic
If you are looking at the charger display, then it is probably plugged in
(Y/N?).
If your triangle is lit, then it is red and it is flashing a code. Count those flashes.
→ What is that code?
→ Does F9 blow when Charger is plugged in?
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Do this → Unplug all of the J connectors along the outside edge of the PSDM EXCEPT the J3 and J4. Unplug charger from wall, MainSwON, then KeyON. Does F9 still blow?
→ Have you had the PSDM apart for inspection?
→ You have been working on this car for a while. Have you ever had it running? Running a couple weeks ago. wasn’t charging sent charger/converter to manufacturer to refurbish.
→ What is the History of this car? Stock everything.
→ Does F9 blow when Charger is plugged in? Does not only when I turn the key the fuse blows.
Do this → Unplug all of the J connectors along the outside edge of the PSDM EXCEPT the J3 and J4. Unplug charger from wall, MainSwON, then KeyON. Does F9 still blow? Does not blow the fuse.when J3 and J4 only connected.
→ Have you had the PSDM apart for inspection? Have not
Let me rephrase this…
When you have the charger plugged in - Does F9 still blow when you turn the key? (leaving charger plugged in)
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You skipped over the charger error code. What error is flashing?
Or are there any other status lights?
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→ What is the History of this car?
I was looking more like
- Got it from the old lady at the end of the street. She only drove it to Bingo on Saturdays.
- I’ve had it for 10 years, It rean great until a buddy of mine drive it into the lake. It was only in there for a couple hours.
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Do this → Unplug all of the J connectors along the outside edge of the PSDM EXCEPT the J3 and J4. Unplug charger from wall, MainSwON, then KeyON. Does F9 still blow?
- Does not blow the fuse.when J3 and J4 only connected.
Ah, interesting… Is Dash display lit up?
Plug in J2 and KeyON.
Keep going through the sequence.
Report back with which one blows the fuse.
When you have the charger plugged in - Does F9 still blow when you turn the key? (leaving charger plugged in). Leaving J3 & J4 only plugged in with charged plugged in does not blow fuse.
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You skipped over the charger error code. What error is flashing? Currently flashing 3 times the current light AC. Flashing comes on after AC is on for a little while.
Or are there any other status lights? No lights on the on the display. Basically nothing turning on.
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→ What is the History of this car?
I’ve owned for about 7 years never had any issues, replaced the 8v gel batteries about 3 years ago.
Ah, interesting… Is Dash display lit up? Dash does not light up.
Plug in J2 and KeyON. Blows fuse on J2. Plugged all others and left J2 out. Tried with charged plugged and unplugged does not blow fuse F9.
Charger Currently flashing 3 times the current light AC.
Hang on- The Triangle Error light is Red. (You originally said the triangle was lit up). If Red(3) then your charger is timing out from an excessive charge cycle. Your charge profile may not be set properly for your installed batteries.
If the Yellow AC light is flashing this is totally different. It means there is something wrong with the input power. Put a meter on your plug as the charger is plugged in and look at supply voltage. It may also mean your charge cord is having issues.
Tr another cord, and even try another wall plug.
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Plug in J2 and KeyON. Blows fuse on J2.
Oh shoot!
My original quick scan missed that the key loop is fed by F9 and exits the PSDM on J2, and comes back on J3. I had that backwards.
Did you try J2 without J3? If yes, this would isolate something going on in the steering pod. Possibly a pinched wire?
Can you think back to when this all started and recall what might have set this condition.
The triangle on charger now RED flashing (2). The AC load light is solid yellow.
Tried J2 (with J3 & J4 plugged in as well) by itself and blew fuse F9. Currently have all other J’s (except J2) plugged in and not blowing fuse F9.
All started when I received the Charger/Converter back from the manufacturer.
Greatly appreciate patience and help.
have all J’s plugged in except J3 and F9 fuse does not blow.
Hang on a sec.
I have too many mental apps open.
Let me focus for a sec.
Let’s take a step back from exploding fuses as a diagnostic instrument, and review the charger install.
It has two cables coming out of one side of it.
The first one is easy. It is covered by split loom and a single plug on the end. This plug is J4 and plugs on to the PSDM.
The second cable runs out of the charger and splays out into 4 12g wires. These wires are Red, Black, Green, and White. In some cases, the White and Black are connected together in a molded connector.
Track down and report where you placed the wires.
The J4 connected to PSDM and the black to chassis
The other 12g Red 72v+ to the left bottom of the PSDM next to shut off switch.
The Black to negative side of motor controller.
The Green to another green via M/F connectors
The white to a orange/blue via M/F connectors
OK, Perfect.
Just to rule it out, If you unplug the green to green wire (aka- interlock)
Does the little yellow plug appear on the dash display?
Nothing appears on dash the whole dash. Nothing has lit up all this time.
But I still have J3 disconnected as well
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After pondering this for a moment, I think it might be worth pulling the PSDM and removing the cover for a look.
Will do. What will I be looking for?
Odd that it’s oozing molten copper and yet it’s only leaking out the one battery cable.
FYI, the electric voltage is NOT enough to cause arcing from just one conductor. You missed what was rubbing that spot and also melted or at least scarred.
FYI, the electric voltage is NOT enough to cause arcing from just one conductor.
There was that one time he was playing around with plasma…
But I agree w/Doug here.
What was rubbing on that cable? (or what was this cable rubbing on?)
Was this up under the dash? Back at the batteries?
Depending on your answer,
Back at the PDSM-
Remove those little black screws, and the screws at the 3 bulkhead studs, The green board will then lift out. (I would like a good clear pic of the front side).