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Unread 04-20-2009, 11:39 AM   #1
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Default New Owner - 01 DS 48V - Headlight Wiring

Hello to everyone! I have been a member of this forum for a few days now and have learned alot from just reading the posts. But did have a question about my headlight wiring on my Cart. I just got this cart from my workplace, it is a 2001 DS 48V model (Non regen from looking at the posts here) and had a few things wired into the system that was required in the workplace (it had a scanner system mounted on the cart and a blinking yellow light on the canopy) I removed all that wiring. A few questions:

1) It also had a horn with a button on the floor that I assumed was installed at my workplace and I removed that. (Is it possible it came from the Factory with a horn installed?)

2) There was a toggle switch mounted in the dash below where the Battery Light is that I removed also, from what I could tell I thought it was part of the scanner system wiring so I removed it also.

3) Ok the headlights were Factory Installed and werent working when I got the cart so I looked at the wiring of them and the best I can tell there is no power running to them. I have looked for a wiring diagram showing the headlight hook up but havent found one. The headlights are connected to each other with two wires, I want to say red and black that runs from one side of the cart to the other, and each headlight has a short blue wire hanging off of it with a Male connector but isnt hooked up to anything! I also have a black wire in the front behind the dash that comes from the back (I can tell because its in the little plastic flexible conduit with the other wires comeing from the back of the cart) that has a female connector on it that isnt connected to anything right now. Is it possible that this black wire should be connected to one of the blue headlight wires? And after I took the Toggle switch out I got to thinking "Where the heck is the headlight on and off switch?" Maybe that toggle switch was supposed to be it, but no wiring associated with the headlights was connected to it that I could tell!

Any thoughts?

As you can tell I'm a new owner to the ranks!! Thanks for any input...
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Unread 04-20-2009, 11:49 AM   #2
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Default Re: New Owner - 01 DS 48V - Headlight Wiring

howdy razor3367.someone will help you soon.in the meantime.:http://www.buggiesgonewild.com/introductions/
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Unread 04-20-2009, 12:13 PM   #3
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Default Re: New Owner - 01 DS 48V - Headlight Wiring

Thanks dock! I posted on the intro page...
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Unread 04-20-2009, 12:23 PM   #4
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Default Re: New Owner - 01 DS 48V - Headlight Wiring

This is a basic easy diagram. When you get a switch make sure it is rated for high amps. The blue wire are the little yellow lights on the side of your headlights known as maker lights. connect these wire to your main red wire coming off of your headlights if you want them to light up. The black wire coming from the back to the front is probably coming from your voltage reducer, this black wire is your ground. wire the black wires from you headlight to the voltage reducer. The swtich was for your headlight im sure, so run a red wire from you headlight to your switch. then run another red wire from your switch to your voltage reducer. You voltage reducer should be hooked up to, two of you batteries. What this does is take the voltage of the 8 volt batteries and restricted it to 12 volts. If you dont have a voltage reducer on the cart it maybe wise to buy one. My wiring diagram is not drawn to scale and the voltage reduce may not be located according to my picture.
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Unread 04-20-2009, 01:16 PM   #5
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Default Re: New Owner - 01 DS 48V - Headlight Wiring

Thanks for the reply 10507851. I noticed when I took the headlights out, the little amber sidelights didnt have an electrical connection or a bulb in them, They have little plastic plugs that you can rotate a 1/4 turn and pop out but its not an electrical type of plug. The blue wire is connected to the main headlight bulb. I see no way for the Amber lights to work. Since these came installed from the factory, where is the Headlight Switch supposed to be on the cart? That little up and down metal toggle switch didnt look like something from the factory to me, thats why I removed it. Sorry Im just confused.

Thanks!!
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Unread 04-20-2009, 07:08 PM   #6
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Default Re: New Owner - 01 DS 48V - Headlight Wiring

The little amber lights should ground them selves to the housing. Post a picture and i will let you know what to do. You can put any switch you want, any where. just make sure the switch you use is heavy duty.
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Unread 04-22-2009, 01:08 PM   #7
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Default Re: New Owner - 01 DS 48V - Headlight Wiring

Thanks again 10507581, Ill take a picture of the headlight wiring and post here, will try and get a shot of the wiring conduit underneath the dash also. I can't believe that factory installed lights didnt come with a headlight switch in the dash someplace. But it may have been replaced with that metal toggle switch at my workplace to run some other equipment.
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Unread 04-23-2009, 02:23 PM   #8
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Default Re: New Owner - 01 DS 48V - Headlight Wiring

its rather odd for factory lights to have a toggle switch instead of a push pull switch but that toggle was more than likely for the lights so you may want to hook that back up and now the hard part trace wires from headlights to see where they go, the power wire from headlights......after you get the toggle back in get a test light to see if you have power to it and work backwards..........also check the battery pack for wires and trace them to see where they go it could be as simple as just reconnecting a few wires.......are your lights cut into the body or mounted to it?...............................
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Unread 04-23-2009, 04:17 PM   #9
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Default Re: New Owner - 01 DS 48V - Headlight Wiring

Hey Shadowman, thanks for the reply! The lights are cut into the body, in other words the body has cutouts where the lights fit into and they look just like pictures i have seen of other carts with factory lights on them so thats why I assumed they were installed at the factory. I work at a place with alot of electricians so sometimes they get ahold of things and no telling what they do to them! I took out all the wire that looked like it had been installed at work (I could tell from the type of wire that was used and the end connectors) and am left with what I have now, which is really confusing. There were several things installed on this cart at my workplace, a blinking yellow light on top, a horn with a floor mounted button (both items were for safety regs) and also a scanner system that was powered by the batteries on the cart. They also had installed a little yellow electrical device to the frame back by the controller that had a red wire coming in, and one leaving going to the front of the cart to the toggle switch if i remember correctly. The more i read now, the more I think this was a voltage reducer or regulator cause I sure cant find one on the cart anywhere to power the headlights! But I sure think it was installed at my factory cause self tapping machine screws were used to fasten it to the frame.

Anyway, its a mess now. I have that black wire with the female connector loose under the dash that I will see if it has voltage on it and go from there. The headlights just have the two wires that connect them together and then the blue wires hanging off of each unconnected! Is the Blue Wire the hotwire and if I hook up power to one headlight it will power the other also because they are connected? Thanks for the help.....
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