2002 Club Car DS Electric Dead

[Roemer7]

2002 Club Car DS Electric IQ 48V

I’m in the process of installing a 12V voltage reducer and new LED lights. I put the cart in tow mode, disconnected the lead ground and lead positive cables from the battery pack and proceeded with my installation. When I was done I reconnected the ground and positive cables and switched back to run mode. Now the cart is dead as a doornail. The batteries are taking a charge, but when I turn the key, place the cart in run mode I get nothing. There is no reverse buzz, no power anything (including my new lights).

Any advice? My first thought is I blew a fuse somewhere, but where? I checked the yellow fuse at the charge terminal and it’s ok.

The cart was running fine before the install.

For the install I connected my 12V reducer to the lead positive and ground terminals. I also connected the reducer to the blue (what I think is the) switched ignition wire. The lights are connected to a new fuse block connected to the reducer and main ground from the battery pack. The reducer is a Relance 48v to 12v unit.

Thank you in advance.

[Roemer7]

Update:
I have full voltage at the key switch when jumping from battery pack negative cable to top terminal on key switch (red and green wires). Still no power to the cart.

[nickdalzell1]

IQs sometimes have a main fuse under the controller cover at the rear of the car. It's usually a 15 amp fuse, normally found on Precedents but I've seen it on DSs as well.

All that yellow one you checked does is protect the On-Board Computer (OBC) which is part of the battery charging system. That one is a 3/8 amp and I've never seen it blow.

[Mooncarter]

How many wires does this reducer have? What is the negative output from the reducer going to?

[Roemer7]

I tracked it down late last night. The keyed terminal at my ignition switch is bad. It's shorting out. I can hold it in place and the cart powers up. I may have broken it by removing the dash panel. I'll order a new one and see if that fixes it.
Anyway, thanks for digging into this with me. I'll update as this comes along.

The new lights look good. I ordered the Premium GTW LED light kit. It seems like lots of vendors carry the same kit. Interestingly, my kit came with a brake switch instead of the foot pad that's shown in photos. Having the adjustable headlamps is great.

[Sergio]

One thing to keep in mind when disconnecting spade terminals from the key switch or Tow/Run switch is to use a needle nose plier and pull the connector straight out, don't try to wiggle side to side as it can cause the terminals to break/come loose inside the switch.