Major Club Car Issue!?!?

rstov · 02-13-2011, 05:34 PM

Ok, I tried to hook up a voltage reducer last night on my 1998 Club Car DS. I hooked everything up the way the instructions said and flipped the tow/run switch to run. My wires from the tow switch to the passenger side solenoid burned up immediately. Not sure where I start now to repair. Is there a way to bypass the tow/run switch? Any feedback is greatly appreciated.

rstov · 02-13-2011, 06:37 PM

I think the issue goes further now that I look at it. It burned up most of the wires in the harness as well. I know I need a new harness now but any ideas on anything else it may have fried as well?

scottyb · 02-13-2011, 10:33 PM

Did you figure out what you did wrong? That may help us figure out what all got burnt? any more info will help. Like reducer info or where you connected it?

rstov · 02-14-2011, 12:20 PM

Sure I will look at the instructions this evening and post details. Thanks for the reply.

scottyb · 02-14-2011, 01:27 PM

Okay, Good. The info you can post on this the more likely it is that somebody can help.

OLD MEC · 02-14-2011, 03:38 PM

I always install the voltage reducer hooked directly to battery pack positive and negative posts. I install a proper size inline fuse just after battery plus connection to protect from just what happened to you. You are lucky as I had neighbor loose a new EZGO because of reducer shorting? I also add a HD switch or relay unit between reducer and power sourse so power is off when not needed. Some installation instructions show that you can hook to some where in wiring loom but I never do as you can see it can cause problems and beside if not hooked up correctly you could end up with shorting to the frame which is NO NO on electric carts.
Sorry you had this happen, but remember we have all make mistakes and learned from them and by passing solution on to next person we all gain from them.

Gale Hawkins · 02-14-2011, 03:47 PM

Sorry man. Since ours came with two missing battery posts I figured with that much energy things can go fast. Hope your controller is OK.

rstov · 02-15-2011, 05:42 PM

I see you wrote something about shorting to the frame. The istructions told me to ground the - battery to the frame in which I did. That is most likely my problem. I hooked the positive side of the voltage reducer to a 30A switch and then to battery. The Negative goes to negative and the other wire to my 12Volt items to hookup. What is the worst case scenario of what grounding to fram would do. I know it fried the wires from solenoid to tow switch and green ignition wire even though ignition was never on. I have a new wire harness on order to replace the whole thing. One spot got burnt pretty bad. There appears to be no burnt wires going directly into anything besides passenger side solenoid which may have fried that as well.

rstov · 03-03-2011, 11:55 AM

Well I found out that a new wire harness would be $250 from a CC parts dealer so I took the harness out and rewired it myself. Apparently nothing was burnt up and my cart is running fine now.

OLD MEC · 03-03-2011, 01:56 PM

Happy to hear that you got wiring done without much problem. You were very lucky especially with a shunt motor to not have major damage.

02-13-2011, 05:34 PM	#1
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31	Major Club Car Issue!?!? Ok, I tried to hook up a voltage reducer last night on my 1998 Club Car DS. I hooked everything up the way the instructions said and flipped the tow/run switch to run. My wires from the tow switch to the passenger side solenoid burned up immediately. Not sure where I start now to repair. Is there a way to bypass the tow/run switch? Any feedback is greatly appreciated.
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31

02-13-2011, 06:37 PM	#2
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31	Re: Major Club Car Issue!?!? I think the issue goes further now that I look at it. It burned up most of the wires in the harness as well. I know I need a new harness now but any ideas on anything else it may have fried as well?
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31

02-13-2011, 10:33 PM	#3
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Major Club Car Issue!?!? Did you figure out what you did wrong? That may help us figure out what all got burnt? any more info will help. Like reducer info or where you connected it?

02-14-2011, 12:20 PM	#4
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31	Re: Major Club Car Issue!?!? Sure I will look at the instructions this evening and post details. Thanks for the reply.
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31

02-14-2011, 01:27 PM	#5
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: Major Club Car Issue!?!? Okay, Good. The info you can post on this the more likely it is that somebody can help.

Today
BGW	Sponsored Links __________________ This advertising will not be shown in this way to registered members. Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

02-14-2011, 03:38 PM	#6
OLD MEC Gone Wild Join Date: Mar 2009 Location: South Texas Posts: 2,391	Re: Major Club Car Issue!?!? I always install the voltage reducer hooked directly to battery pack positive and negative posts. I install a proper size inline fuse just after battery plus connection to protect from just what happened to you. You are lucky as I had neighbor loose a new EZGO because of reducer shorting? I also add a HD switch or relay unit between reducer and power sourse so power is off when not needed. Some installation instructions show that you can hook to some where in wiring loom but I never do as you can see it can cause problems and beside if not hooked up correctly you could end up with shorting to the frame which is NO NO on electric carts. Sorry you had this happen, but remember we have all make mistakes and learned from them and by passing solution on to next person we all gain from them.

02-14-2011, 03:47 PM	#7
Gale Hawkins Gone Wild Join Date: Jan 2011 Location: Murray KY Posts: 219	Re: Major Club Car Issue!?!? Sorry man. Since ours came with two missing battery posts I figured with that much energy things can go fast. Hope your controller is OK.

02-15-2011, 05:42 PM	#8
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31	Re: Major Club Car Issue!?!? I see you wrote something about shorting to the frame. The istructions told me to ground the - battery to the frame in which I did. That is most likely my problem. I hooked the positive side of the voltage reducer to a 30A switch and then to battery. The Negative goes to negative and the other wire to my 12Volt items to hookup. What is the worst case scenario of what grounding to fram would do. I know it fried the wires from solenoid to tow switch and green ignition wire even though ignition was never on. I have a new wire harness on order to replace the whole thing. One spot got burnt pretty bad. There appears to be no burnt wires going directly into anything besides passenger side solenoid which may have fried that as well.
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31

03-03-2011, 11:55 AM	#9
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31	Re: Major Club Car Issue!?!? Well I found out that a new wire harness would be $250 from a CC parts dealer so I took the harness out and rewired it myself. Apparently nothing was burnt up and my cart is running fine now.
rstov Not Yet Wild Join Date: Oct 2010 Posts: 31

03-03-2011, 01:56 PM	#10
OLD MEC Gone Wild Join Date: Mar 2009 Location: South Texas Posts: 2,391	Re: Major Club Car Issue!?!? Happy to hear that you got wiring done without much problem. You were very lucky especially with a shunt motor to not have major damage.

Similar Threads
Thread	Forum
Major corrosion	Electric Club Car
major problem	Big Block Talk!
Major Help Needed!!!!	Electric EZGO
Major Changes	Extreme DC!
Need Major Help!!!!!!	Electric EZGO