Battery and buzzer stay on after light kit install

namyot11

I am installing a Madjax light kit on a 2014 Precedent. I installed the new under dash harness, the new bucket harness, and 48-12 voltage reducer. I checked the reducer for proper output before hooking it up to the light kit. When I hook the wiring up to the batteries the orange battery light and reverse buzzer come on and won't shut off. I tried a different light kit, thinking that maybe I had a bad wiring harness but it does the same thing. Also tried a different voltage reducer, same result. Any ideas?

BGW

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Htownblue

How is your voltage reducer wired? Your reducer input positive and ground should be hooked up to the pack positive and pack negative or black female ground bullet near pack negative. Your HARNESS INPUT POSITIVE AND NEGATIVE should be hooked up to the REDUCER OUTPUT positive and negative.

yawood

Your reducer 48V should get its power from the main terminals on the pack (if you do NOT have an ERIC charger (i.e. you have a PowerDrive charger and an OBC) the negative will be connected to the black cable with the yellow bullet connector near the main pack -ve). If you have an ERIC charger then ignore that.

Your lights should connect to the +12V and -12V from the reducer. Make sure that the negative from the lights does not just go back to the cart negative.

Think of the reducer as being a 12V battery. All 12V connections (+ve and -ve) should go just to it and there is a complete separation of the 12V system and the 48V system.

namyot11

All the wiring is hooked up properly, double and triple checked. I'm beginning to wonder if the battery pack, being original, is weak and is causing this problem. I can't imagine the draw from the voltage reducer is enough to cause this issue.

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islandcartsmacpro

Take out the voltage reducer, go across to 8's to create 16 volts. It can handle it. Try it again.. Don't use the main neg at your ground instead use the main positive and two batts from that to get the neg post you'll need for the - end of the light kit

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namyot11

That is assuming the voltage reducer is the problem, which I'm not sure it is. Also, I have heard that an LED light kit can handle the 16 volts but I have the basic halogen kit.

Short of having any other solutions, next chance I get, I will try to run the wiring independent of the cart's wiring harness.

yawood

You sound like you know what you are doing so I don't want to try to teach you to suck eggs, as the expression goes, but we need to take it a step at a time.

Check the batteries in the normal manner by measuring the voltages of each battery and the pack before and after charging (12 hrs after) and by monitoring the voltages of individual batteries under load (measure them while you're driving). There are plenty of threads here to tell you if the voltages you measure are OK. That should be your first check just to satisfy yourself that it is not the batteries. Remember to check the individual batteries because it only takes one bad egg.

In fact, you said you have the resources to try another light kit and another reducer so perhaps you can try another battery pack. Swap batteries from a mate's cart. If it still behaves the same then that should eliminate your batteries as the problem.

Next I would disconnect the lights (and any other 12V accessories) from the reducer so that you have a reducer connected to the cart but nothing connected to the reducer. If the cart runs normally then you should be able to eliminate the reducer itself, and its harness, as the problem.

Connect the light kit and see if the problem is still there. Try disconnecting individual parts of the light kit e.g. disconnect the headlights and test, then the tail-lights and test etc.

This is a long-winded way of saying I don't know what your problem is but test it logically one step at a time to see if you can narrow it down.

Good luck.

islandcartsmacpro

You did say you ruled out the reducer. I couldnt help but give a suggestion since in my head the controller is throwing a code, if not a code a safety threshold that could be seen with the handheld. I would sit and stare at it from tip to tip. Think.... Is that 9 pin plug the issue. Check the pins to see if any got pushed out in the process.

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namyot11

Thanks for the good suggestions. After that first day of frustration, I took today off from the cart, and planned to look at everything with fresh eyes in a day or two. I did charge the batteries last night, however, and after sitting all day the pack showed 50.5 volts with each battery showing between 8.41 and 8.45 volts. I know that means nothing without a load on them, but once again, I will do further testing in the following days.

Modder2018

When I installed my reducer, I wired the reducer to a fuse block with negative buss already built in. I then ran all of my accessories from the fuse block to any necessary switches to control my accessories. Did you wire the reducer to be switched on and off with your ignition? If so, did you possibly wire it to a constant lead instead?

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