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Unread 11-14-2013, 09:57 PM   #1
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Default need help with factory voltage reducer wiring

I have a 2002 DS, 48 volt. Here is what is happening :

The headlites are very, very dim, a faint orange color, looks like they are starving for voltage. The horn doesn't work either. I opened the small fuse box, and all 3 fuses are good.

I was trying to figure out how to check out the square factory voltage reducer, but don't understand it. I can feel a wire leaving the back end of the reducer , and that goes to the controller. Then there appears to be 2 wires leaving the front end, that go to a terminal block on the body.

I touched my voltage meter, to the pack negative, and to the back of the lite switch, and only read 4 volts. Is the reducer toast?

If so, can someone explain how to wire the reducer, it doesn't make sense to me from what I see, and I do not find a diagram in any club car service books?
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Unread 11-14-2013, 11:14 PM   #2
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Default Re: need help with factory voltage reducer wiring

Could be toast...

Do you have factory lights? The factory CC reducers are 16-12 and only have two black wires coming off each end.
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Unread 11-14-2013, 11:48 PM   #3
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Default Re: need help with factory voltage reducer wiring

yes, factory lites.
it looks like the 2 wires that are coming out of the front end of the reducer, are BOTH going to that small metal terminal block. That can't be right? Maybe that is my problem?
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Unread 11-15-2013, 12:13 AM   #4
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Default Re: need help with factory voltage reducer wiring

why is the wire on the back of the reducer, going to the controller?
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Unread 11-15-2013, 12:51 AM   #5
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Default Re: need help with factory voltage reducer wiring

why is the wire on the back of the reducer, going to the controller?
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Unread 11-15-2013, 07:09 AM   #6
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Default Re: need help with factory voltage reducer wiring

Quote:
Originally Posted by smokey tennis shoe View Post
yes, factory lites.
it looks like the 2 wires that are coming out of the front end of the reducer, are BOTH going to that small metal terminal block. That can't be right? Maybe that is my problem?
. . . what color wires are going to terminal block? are these wires coming from 3 wire connector?
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Unread 11-15-2013, 07:36 AM   #7
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Default Re: need help with factory voltage reducer wiring

I think that is correct for those reducers...
The single wire with the 5/16 lug goes to the B- on the controller (all negative connections should go there so the OBC can measure the current being drawn from the battery).
The end with the 2 spade connectors are the negative for your accessories. You can plug each one to an accessory or run one or both together to the fuse box.
The positive for the accessory will come from the 2nd battery, assuming 8v batteries and the 1st battery being the one where the pack negative to B- is connected.
Not a real good system, You should consider a 48v-12v reducer instead.
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Unread 11-15-2013, 10:09 AM   #8
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Default Re: need help with factory voltage reducer wiring

Are you saying that this factory reducer has a total of only 3 wires coming out of it? AND ALL wires are negative??
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Unread 11-15-2013, 10:13 AM   #9
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Default Re: need help with factory voltage reducer wiring

Steve

no terminal or connectors. From the end of the reducer that faces toward the steering wheel, there is a long "sleeve" that has has 2 wires in that sleeve. Both wires inside the sleeve are black, both have female spade terminals on them, and both plug onto the small metal terminal board mounted to the back side of the cart body. The large wire exiting the back, goes to the controller.

If all wires are negative, with no positive wires of any kind going to the reducer,that just sounds bizaar!
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Unread 11-15-2013, 10:36 AM   #10
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Default Re: need help with factory voltage reducer wiring

It may help you visualize it if you think of it this way:
You have a 12v accessory in series with a 4v drop device all connected to a 16v source.
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