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Unread 12-25-2013, 06:57 PM   #51
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Default Re: charger is draining batteries

Today I took the dash apart , wanted to see the wiring to the key switch.

So far, this is what I have done :

Unplugged the blue accessory wire from the pack +, and let the cart sit for a couple days.

Now for 2 days, the cart has been at 50.6, with the blue wire disconnected, and not driving the cart.

I think I did locate the reducer, I can't see it but I can feel it, and see the wires from the headlites plug into it.

NOW the dash wires : Check out these pictures and tell me a few things.

First, see the 4 wires with stakon terminals that are just hanging? What are these for? Remember, I am original owner, the only thing added to my factory cart, was the club car dealer changed the key switch.

I took some readings on these wires and this is what I got :

These are the wires you see in the dash photo, the blue and green on the key switch, and the 4 wires hanging loose.

Scenario #1 : key switch is off, cart in neutral, tow switch is in run position, I have my red probe on the pack + and the black probe on the individual wires :


key switch blue =50.6 key switch green = no reading just flashes millivolts

4 wires---solid blue =50.6 blue/white = 50.6, orange = 50.6, green/white = flashing millivolts

same scenario as above, I just switched the test leads and now am reading from pack - to wires :

key switch--blue = flashing millivolts, green = 50.6 all 4 other wires read flashing millivolts.

Scenario #2 I turned the tow switch OFF, all other conditions are the same as scenario #1. I am again reading from pack + to wires Readings :

key switch blue = 50.6, green = 47.3, other 4 wires are all 50.6, except the green/white is flashing millivolts.

LASTLY, I read continuity thru key switch, with tow in run, and key switch in either position!

I'm wondering if the key switch is bad and is draining the batts?

Does these 4 hanging wires seem normal? What are they? Why are they not tywrapped with the others? Why is there voltage on them?

Remember the dealer installed the key switch so it would have a unique key. I am wondering if the switch is bad, will that drain the batts?

Also wondering if I should follow the key switch trail or stay on the reducer trail?
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Unread 12-25-2013, 08:16 PM   #52
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Default Re: charger is draining batteries

I meant to say "facing towards the front".
Anyway, the red arrow points to the wires going to the reducer.
If you cut the zip tie pointed by the green arrow, spread those wires and take a picture, we will be able to see if the connections are right.
You may not have a trigger wire, meaning the reducer is always on. Not all reducers are created equal and some are very inefficient, that is why I always prefer the ones with a trigger wire, or as someone else suggested, just put the switch on the +48v side of the reducer.
Those extra spade/quick connectors are for the optional harness for brakes, etc...
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Unread 12-25-2013, 08:38 PM   #53
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Default Re: charger is draining batteries

Sergio

Thanks so much for answering me, especially on Christmas day.

I cut the tyrap, and took a picture. Let me know if you can see what you are looking for, or do I need to take another one?

Thanks again
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Unread 12-25-2013, 09:18 PM   #54
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Default Re: charger is draining batteries

Sorry, I pointed to the wrong harness. The harness I pointed to goes to the front light assembly.
I placed a red marker pointed to the correct dc converter harness this time.
Maybe you can take a better picture of those wires.
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Unread 12-25-2013, 09:36 PM   #55
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Default Re: charger is draining batteries

Here are some more pics. I tried to get the area you indicated.

Thanks again

Does this reducer run thru the key switch?
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Unread 12-25-2013, 10:08 PM   #56
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Default Re: charger is draining batteries

That last pictures was a good one:
A: -48v (pack negative)
B: +48v (from key switch - used as a trigger wire)
C: +48v (constant from fused blue wire on pack positive)

D: +12v converter output
E: -12v converter output
F: +48v (from key switch - used as a trigger wire)

If the blue/white wires as physically connected to your converter on the other side of the harness, than the converter will only be on when the switch is on.
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Unread 12-25-2013, 10:46 PM   #57
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Default Re: charger is draining batteries

I was outside messing with my cart and this message thread came to mind. So I checked the current through the blue battery wire for the lights. With lights on it was 5 amps, lights off 0 amps. All along I thought the 10 gauge red wire connected to the 48v positive post was the + connection for the lights. It's not. There wasn't any change in current when the lights were on. By the way I was checking with a clamp on DC amp meter. You can buy a good Klein clamp on meter at Home depot. It might save you a lot of trouble.
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Unread 12-25-2013, 11:14 PM   #58
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Default Re: charger is draining batteries

The red wire on the pack positive goes to the charger socket.
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Unread 12-26-2013, 10:08 AM   #59
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Default Re: charger is draining batteries

So the wire "B" and wire "F"are going to the same place? If that is the case, could they have only used one wire instead of two?
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Unread 12-26-2013, 11:01 AM   #60
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Default Re: charger is draining batteries

The wire marked "F" (source) is connected to the key switch, the wire marked "B" takes the switched 48v signal into the rest of the harness.
I guess they could have spliced the wire between the 2 12pin connectors, but it works either way.
The important part is to make sure it is actually connected to your voltage reducer.
By the way, what make model clamp meter are you using?
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