12v wiring in 36v cart

Commander2100 · 07-10-2016, 02:54 PM

Rebuilding a 2002 Cushman Commander 2100se. It's up and running. We've figured out the headlights and taillights but can't get the brake lights figured out. The switch on the pedal seems to be working but the taillights do not get brighter when the pedal is pushed in. Also, there are extra wiring connectors under the hood that don't seem to have a mate. Pics are of these connections.uploadfromtaptalk1468180439762.jpg uploadfromtaptalk1468180446983.jpg

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Clemsoncartguy · 07-10-2016, 03:08 PM

I think those are the turn signal hookups. I had ones that looked similar in my dash and that's what they said they were for. If there in another area maybe not the same thing?

kernal · 07-10-2016, 05:56 PM

As stated the connections behind the dash are for an OEM turn signal kit.

Are there wires zip tied to the brake pedal arm ? (should be two). If so can you see them on the other side of the firewall (foot rest) Should be spade connectors there.

Also, do you know history of cart. Maybe someone put the wrong bulbs in the tail lights. Need to be dual filament (1157 I think)

Commander2100 · 07-10-2016, 08:37 PM

Turn signal wires make sense. The wires that were zip tied to the pedal were cut right by the switch on the back of the pedal. We moved the switch because the springs on the pedal were worn out. The switch was rewired so that, when the pedal is pushed in the switch is disengaged, the brake lights come on and when the pedal is let go, the switch engages and shuts off the brake lights. We made sure it would work this way with a meter but there's no power making it's way back to the lights. The bulbs are dual filament.

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Clemsoncartguy · 07-11-2016, 07:05 AM

The right dual filament though? There probably half a dozen bulbs that may fit but they may not work right?

Commander2100 · 07-11-2016, 08:49 AM

One of the lights is original and the other one I ordered new from ezgo so I'm assuming they're the right bulbs

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kernal · 07-11-2016, 09:44 AM

So If I'm reading this correctly, you have power leaving the switch but not getting back to the lights? If true then there is a break in the wire(s) between the switch and the light housing. Have you run separate temporary wires back there just to test? What am I missing?

I have a TXT with original factory wiring system including brake lights. I'm the original owner. Not the same model as yours but should be the same wiring system. Would it help if I described the tail light wiring connections--color coding etc?

Commander2100 · 07-11-2016, 05:18 PM

We've decided to just run new wire all the way back. There's got to be a break somewhere in the harness

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Clemsoncartguy · 07-12-2016, 12:30 PM

If a temp wire solved the problem this is ually the easiest fix and the right one to do. I have done this many times when chasing wireing gremlins.

07-10-2016, 02:54 PM	#1
Commander2100 Not Yet Wild Join Date: Mar 2016 Location: Minneapolis MN Posts: 14	12v wiring in 36v cart Rebuilding a 2002 Cushman Commander 2100se. It's up and running. We've figured out the headlights and taillights but can't get the brake lights figured out. The switch on the pedal seems to be working but the taillights do not get brighter when the pedal is pushed in. Also, there are extra wiring connectors under the hood that don't seem to have a mate. Pics are of these connections.uploadfromtaptalk1468180439762.jpg uploadfromtaptalk1468180446983.jpg Sent from my SPH-L710 using Tapatalk

07-10-2016, 03:08 PM	#2
Clemsoncartguy Gone Wild Join Date: Apr 2016 Location: Greenwood, SC Posts: 1,291	Re: 12v wiring in 36v cart I think those are the turn signal hookups. I had ones that looked similar in my dash and that's what they said they were for. If there in another area maybe not the same thing?

07-10-2016, 05:56 PM	#3
kernal Gone Wild Join Date: Jul 2010 Location: Peachtree City, Ga. Posts: 2,759	Re: 12v wiring in 36v cart As stated the connections behind the dash are for an OEM turn signal kit. Are there wires zip tied to the brake pedal arm ? (should be two). If so can you see them on the other side of the firewall (foot rest) Should be spade connectors there. Also, do you know history of cart. Maybe someone put the wrong bulbs in the tail lights. Need to be dual filament (1157 I think)

07-11-2016, 07:05 AM	#5
Clemsoncartguy Gone Wild Join Date: Apr 2016 Location: Greenwood, SC Posts: 1,291	Re: 12v wiring in 36v cart The right dual filament though? There probably half a dozen bulbs that may fit but they may not work right?

07-11-2016, 09:44 AM	#7
kernal Gone Wild Join Date: Jul 2010 Location: Peachtree City, Ga. Posts: 2,759	Re: 12v wiring in 36v cart So If I'm reading this correctly, you have power leaving the switch but not getting back to the lights? If true then there is a break in the wire(s) between the switch and the light housing. Have you run separate temporary wires back there just to test? What am I missing? I have a TXT with original factory wiring system including brake lights. I'm the original owner. Not the same model as yours but should be the same wiring system. Would it help if I described the tail light wiring connections--color coding etc?

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07-10-2016, 08:37 PM	#4
Commander2100 Not Yet Wild Join Date: Mar 2016 Location: Minneapolis MN Posts: 14	Turn signal wires make sense. The wires that were zip tied to the pedal were cut right by the switch on the back of the pedal. We moved the switch because the springs on the pedal were worn out. The switch was rewired so that, when the pedal is pushed in the switch is disengaged, the brake lights come on and when the pedal is let go, the switch engages and shuts off the brake lights. We made sure it would work this way with a meter but there's no power making it's way back to the lights. The bulbs are dual filament. Sent from my SPH-L710 using Tapatalk

07-11-2016, 08:49 AM	#6
Commander2100 Not Yet Wild Join Date: Mar 2016 Location: Minneapolis MN Posts: 14	One of the lights is original and the other one I ordered new from ezgo so I'm assuming they're the right bulbs Sent from my SPH-L710 using Tapatalk

07-11-2016, 05:18 PM	#8
Commander2100 Not Yet Wild Join Date: Mar 2016 Location: Minneapolis MN Posts: 14	We've decided to just run new wire all the way back. There's got to be a break somewhere in the harness Sent from my SPH-L710 using Tapatalk

07-12-2016, 12:30 PM	#9
Clemsoncartguy Gone Wild Join Date: Apr 2016 Location: Greenwood, SC Posts: 1,291	Re: 12v wiring in 36v cart If a temp wire solved the problem this is ually the easiest fix and the right one to do. I have done this many times when chasing wireing gremlins.

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