Testing Eaton DC/DC converter on 2001 GEM

Still trying to find 12V to dash.
With the master switch on : Converter voltage (using chassis for ground)
Both red wires (#7 & 8) have 36 volts
Both orange & green wires (# 9 & 10) have 36 volts
Number 3 - blue wire has 36 volts
Orange and green on the ign. switch has 36 volts
Eaton converter - black box with cooling fins.
Am I testing it correctly ?
If I’m correct about 36V at the key, has it damaged any thing ?
(key had been turned on several times )
Dash flashes milage a few seconds when master switch is first turned on. (nothing after that)
When I plug the charger in, dash light flashes yellow twice then steady red while charging.
(it does charge correctly as far as I can tell)
Any conclusions ? Thank for the help.
P.S. you have probably already figured out I know nothing about electric cars!
I bought this non running.

Take your meter and probe across ONE battery.
What do you get?

How are you checking the feeds coming out of the converter? Are you probing the back of the connector or pinning trough the insulation of the wire?

Instead of using the chassis ground, try using the black wires coming out of 4, 5, & 6 for your reference. Same?

pinning through insulation.
will probe again using using 4,5&6 grounds.
(there are two black ground wires grounded to back side of mounting bolts on the converter but I don’t remember if they came from the converter.)
I have probed across several of the batteries seems like most show 24v - also if master is on or off is diferent.
Top of controller is where I chech the 72v (with master on)
will go back to shop this afternoon and try to make better notes ( can’t depend on what I remember)
How do you suggest I probe ONE battery ?
Thank You

Locate the top of one battery. It has a + on one end and - on the other end.
Put your Red meter probe on the (+) and the Black meter probe on the (-).
You don’t need to disconnect any cables off the batteries to do this.

LOL - Thanks brother, I ask for that.
I thought you might have a different way of checking in mind ?
My avatar is me beside my '50 Ford in 1956 at age 15. ( 6 volt positive ground ) i.e. -I’ve checked quite a few single batteries the ‘normal’ way since then.
BUT…this 72v closed system thing is all new to me.
And I do Thank You for your Help.

back from the shop. Total voltage 71 V.
#1=11.8 / 2=11.7/ 3=11.9 / 4=11.9 / 5=12.0 / 6=11.8 with master on or off.
Probing wires on the converter. #1 - 7 - 8 - 9 - 10 all at 35.? Volts while probing # 4 - 5 - 6 as the ground. (probed all separately )

still scratching my head ------ Thanks for any help.

Let me help out a bit more.
If you look at that last diagram I sent - ^^^^

The Master switch needs to be ON.
Probing across Pins 1 and 12 you should get 71v.
With the Key OFF
Probing across Pins 4 and 9 you should get 12v.
Probing across Pins 4 and 10 you should get 12v.
Probing across Pins 4 and 7 you should get 0v.
Probing across Pins 4 and 8 you should get 0v.

In your example above you see voltage (35) even on 7 & 8? Was that with key on?


Probing your batteries tells me that you have your meter on the correct setting. You may need to click it up to the next scale when measuring for 72v.

It also shows me your batteries are in desperate need of a charge. I
Are you having trouble with that system also?
What is their condition?
Have you checked if they need water?

While this is not the problem with your DC Converter it is something that needs to be addressed before you can drive your car.

Can you post a pic of the area over by the converter? I want to see some of the wiring.

In my above post - All the readings were with master ON.
I will probe #'s 7-8-9-10 with #4 as ground with 'Master Switch - OFF (correct)
*you said KEY - the ign KEY has never been ON in any of my test.
Have not probed 1 & 12 but will do so. (with master on)(and off)

Batteries were way down when I bought the car - it had been setting about a year I think.
Added distilled water - non had water below top of plates.
Charged each one separately to get up to 12v.
They will come up to 73 + volts while sitting after short charge.
They will show 74 + volts while charging and shortly after.
( I just had not charged before the test that I posted)

  • I don’t know how long they will hold a charge, have not let them alone for more than 72 hours or so.
    I don’t know if they will be any good once WE get it running.
    I hope they are good enough to get US past the problem WE are working on. - lol
    Yes my meter has several settings i.e. 20 vdc and 200 vdc is what I’ve been using.
    Do you want a picture around the contactor & big fuse area ?

Again, I do appreciate your Help very much.
I wish I could communicate on here while I’m at the shop 7 miles away from this computer. This is working OK for me but I feel like I using too much of your time.