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Unread 05-27-2011, 11:52 AM   #1
Not Yet Wild
 
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Thumbs down Re-Wiring turned into BBQ

So I'm making the final connections last night, getting eager for my first ride on the newly acquired 1990 DS. Grabbed a beer and the wiring diagram for one last sweep of the connections. Made sure everything was good and tight, and checked voltages with the meter. Clicked on the key, threw her over to forward, and hit the pedal.

Suddenly, it looked like a bomb went off. I was engulfed with smoke from everything near the charger port and f/r switch. Then, the collection of wires burst into flames, shooting 2 feet out of the battery compartment. My beer didn't extenguish the flames, so I had to put the old hose to use.

Neighbor yells over the fence, "what the hell are you cooking over there". I must have looked like a kid that dropped his ice cream cone as I pulled what was left of wires in a ball above the solenoid. It was truly depressing.

I've rebuilt several cars, wired up dozens of buildings, but can't figure out what in the world happened here. I think I am officially done with trying on my own. Everything on the diagram matched up. Time to find a good cart repair place and bust out the checkbook.
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Unread 05-27-2011, 12:02 PM   #2
The Last Moja Morani
 
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Default Re: Re-Wiring turned into BBQ

man i hear ya the 1st elec cart i ever touched went up in flames.....i was 110% certain everything was right and was done according to wiring diagram but it still went up.........i looked like fire marshell bill for a while.....i rewired the cart again as per the diagram and the 2nd time all was well in the world.......so i have no clus as to what i fudged up the 1st time .........don,t give up go at it again let it know whos the boss......i know it looks intimidating right now with a bunch of burnt crap but dig into it...........2nd time is the charm and you learn its like falling off a bike....................good luck................
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Unread 05-27-2011, 12:08 PM   #3
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Default Re: Re-Wiring turned into BBQ

More Beer
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Unread 05-27-2011, 12:12 PM   #4
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Default Re: Re-Wiring turned into BBQ

Post the schematic your working with and I will try to help, baby steps as this is going to be new to me also 1990 ds.

I think your lucky I usually get shocked !!!
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Unread 05-27-2011, 12:17 PM   #5
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Default Re: Re-Wiring turned into BBQ

Connection to the motor are the only thing that don't match up, as mine has 4 post in a row. (Series motor?) Otherwise, I did it exactly the same. Even bought high-dollar heat-shrink to match colors. (In case I had more beers)

Of course that all is a melted pile of charcoal this morning. Batteries and other devices look to be okay, but I'll have to start checking everything all over again.
Attached Images
File Type: jpg VdlideWiring.jpg (69.9 KB, 21 views)
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Unread 05-27-2011, 12:33 PM   #6
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Default Re: Re-Wiring turned into BBQ

1st step is I need a schematic I can see this comes out too small I will see what I can find on the site that matches up.

2 we need to know whats still good and whats not, did large wires get hot or small wires or all wires

I have always said I would eat almost anything that was BBQed!! I may have found the exception.
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Unread 05-27-2011, 12:39 PM   #7
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Default Re: Re-Wiring turned into BBQ

Fuse didn't even blow. V-glide looks good, solenoid seems fine, f/r looks fine. I think the micro-switches might have fried, but I don't even know if they were working in the first place. All battery and motor wires look fine, just some sheathing charring. All the little wires are gone. I'm too irritated with the whole thing to dig much deeper.

If you have a 1990 too, I would love some pictures of inside the compartment and the devices.
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Unread 05-27-2011, 12:48 PM   #8
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Default Re: Re-Wiring turned into BBQ

I think at this point its a mater of going through it piece by piece.

first is testing the motor, on this site there is a drawing on how to hook the motor up to one battery and run a test on it.
then we will meter out the rest of the componets and try to get a good understanding on how each one works in the system.
No I do not have a 1990 I have an 06 IQ so if you don't mind we will learn togeather (hopfully).
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Unread 05-27-2011, 12:57 PM   #9
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Default Re: Re-Wiring turned into BBQ

here is another view of the same schematic

Attachment 49554
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Unread 05-27-2011, 01:01 PM   #10
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Default Re: Re-Wiring turned into BBQ

I have a 90 DS. Post pics of all of your components, including the motor ( 4 studs in a row?) And we can go from there... And check the micro switches for continuity to see if they work ON/OFF they melt at the drop of a hat.
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