Headlight issues w/ 97 ds need help

[Purpleharley61]

Hi
I have a 97 48v ds converted to a 05 Iq system. I replaced non working head lights w new a/m head lights and blew the bulbs when turning them on. There is a black box on drvrs side frame w 1 wire going to solenoid and the other going to a block of spades located under r/t switch. I assumed this was a ground as there are numerous spades on it. I hooked my pos wire to battery and grd to block of spades and my bulbs blew. My horn is hocked up this was is why i thought i wired it correctly. Any ideas what i did wrong? Thanks

[DaveMJ]

Is this the black box you are referring to?

Reducer.jpg

[Purpleharley61]

Originally Posted by DaveMJ

Is this the black box you are referring to?

Attachment 219057

Yes but it measures around 2"x 2"

[DaveMJ]

I think you may have a 16v to 12v Reducer, the attached shows typical OEM Lighting Circuit - it's from a CarryAll but should be very similar.

One wire of the "Voltage Limiter" on Page 1 goes to B- (pack negative).

The second wire from the "Voltage Limiter" connects to the "Ground Terminal Block(s)". This is the negative for the lights. This is not pack negative, it's about 4v above pack negative.

Your lighting positive is pulled from battery #2 positive, via a fuse block.

[Purpleharley61]

How do i tell what battery is #2 in pack. I used the same positive on battery that the horn is hooked to and the neg to the block w the spades on it. Horn works fine.

[DaveMJ]

If you look at your pack you should see that the negative side of one battery has a heavy gage cable that disappears back towards the controller, this is battery #1. Battery #1 positive connects to battery #2 negative.

In your original post you said that one of the black wires goes to the solenoid. Can you take a photo showing where this is connected? Sounds a little strange.

[Purpleharley61]

I may have hook that other black wire to the solenoid which may b wrong. That should go to controller per wire diagram? Im at work now and can take pic when i get home this evening but do not have luck posting pics here.
I think i got that other black wire(solenoid) in wrong place. I have a 48 to 12v 10a reducer i can use for lights but i need to find out what i have done wrong here.

[Purpleharley61]

Originally Posted by DaveMJ

I think you may have a 16v to 12v Reducer, the attached shows typical OEM Lighting Circuit - it's from a CarryAll but should be very similar.

One wire of the "Voltage Limiter" on Page 1 goes to B- (pack negative).

The second wire from the "Voltage Limiter" connects to the "Ground Terminal Block(s)". This is the negative for the lights. This is not pack negative, it's about 4v above pack negative.

Your lighting positive is pulled from battery #2 positive, via a fuse block.

Ok the blk wire to b- that goes to controller then thru obc and to the battery neg. Can I hook that volt limiter blk wire to battery - where obc connects to my battery pack or does it have to go thru controller like wiring diagram?

[Purpleharley61]

DaveMJ thanks for your help on this. Im not good at electrical but im learning. Im going to put a volt meter on wires to hl's just to see what volts r running to it. I should have done this in the first place!

[Purpleharley61]

I think i got this HL issue figured out. Will find out tonight!