CLub Car Melted Harness, what happened?

[SixSpeed]

Hey Guys,

Was trying to help out my neighbor with their golf cart (1994 DS Electric, V-Glide non-Resistor). He was driving it and heard a "pop" then the cart stopped. The solenoid wasn't working, I replaced it, and replaced an-inop anti-arc switch. I am 100% sure I had the diode on the right way on the solenoid per the factory service manual. I got it all back together, pushed pedal and heard a pop from the V-Glide (no solenoid click), then all hell broke loose, entire low current wiring harness started smoking. Everything back to the controller, F&R microswitches, V-Glide, to keyswitch etc is cooked.

I have a few questions....

1.) What the heck could have happened?

2.) Can a replacement harness be purchased?

3.) I am worried if I replaced the harness with a new one, the same thing would happen. Could a controller ever cause this?

[jakesnake27]

Hello Jack, it sounds like polarity was reversed somewhere. I don't believe a controller could fry the activation circuit like that. Yes, a replacement harness can be purchased. I recommend contacting David at Revolution Golf Cars.

https://www.revolutiongolfcars.com/contact

[NoleFan4Ever]

And David will walk you thru any needed checks to ensure safe installation.

[TahoeDawgZ71]

Originally Posted by SixSpeed

I have a few questions....

1.) What the heck could have happened?
Something is undoubtedly hooked up incorrectly and/or there is a frame/chassis ground that shouldn't be there. Electric cars don't have a frame ground.


2.) Can a replacement harness be purchased?
Unfortunately, no. Series drive-harnesses are no longer available. However, it's a very simple circuit that can easily be built rather quickly and easily. I recommend fusing it at the solenoid where the circuit begins this time.

3.) I am worried if I replaced the harness with a new one, the same thing would happen. Could a controller ever cause this?
If you fuse it, it won't happen. A bad controller can not cause this issue on the small control circuit. This is the result of an improper connection or a direct short to a frame ground that shouldn't be there.

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