Ii need a little guidance please. have a 2002 e825 that has the old DC to DC converter. The cart still runs well. However, I want to upgrade before I have an issue. I came across a guy unloading all his Gem parts and I now have a converter with all the parts and wiring. Being that it’s already a wired unit out of another cart, should this be plug and play in my cart? Or is there something else I need to do to make this converter work properly?
It is not a difficult job to do once you understand what is happening.
This was a conversion that was meant to be done to cars in the field by a technician, but could be done by someone with a reasonable skill set.
Unless you are having issues with your cart wiring now, I’d say that the entire swap is way more work.
I’d start by exploring how it is all hooked up on your upgraded harness from the donor car before you take it apart.
Then unplug at the 1x16 and 1x6 molex connector and remove just that harness and related components. The DC Converter and the two relays will come with it when transferred over to your car. Also will be the 2 pin plug with the two 12ga? 72v (grn and wht) wires. Note how it attaches to the donor car harness. You should also have a wandering green wire which will attach to your key source wire from your charger interlock. (looking at your pic, the current location is not correct).
Then go to your car and remove the old converter board and look for the connections you will be needing.
I should have the factory/dealer install instructions. The message board here does not allow pdf attachments so it will need to be sent via email.
If you include your email address I can send.
Thank you for your help. I have a complete cart that I can study the wiring layout on. I would appreciate the instructions. My email is moorenycc@hotmail.com.
Thank you again
Hello. I have been studying the dealer install instructions for the updated DC to DC converter. I believe I understand where everything goes. However, there is one potential issue I need help with. My original Rivian charger is still under the dash but is no longer hooked up. I have another on-board charger under the front seat for AGM batteries.
The instructions say to connect the long green wire from the updated harness to the green wire going to the Rivian charger. Would I still need to connect these 2 wires? Also, the instructions show another green wire from the timer connecting to the Rivian charger (for the interlock). Would I be able to disregard this wire? My AGM charger works fine but does not utilize the same connections as the old Rivian charger.
Any help / insight would be greatly appreciated.
Where you are getting confused is that the original instructions assume you are still using the old Zivan charger. If it is dead, then there is no reason to leave it in there.
That green wire coming from the timer relay(and your controller relay) is your KeyOn sense wire. It needs +12v to wake the car.
The green wire coming from the wiring update should be from your Key switch. IMPORTANT→ Verify that it has +12v(ref ChassGnd) on it when KeyON (and goes low when KeyOFF). (previously, this green KeyOn was B- (-72v ) and was changed in this wiring update.)
The reason it (formerly) stopped at the Zivan charger was to use an internal relay to breaks this wire when the charger is active(haulting activity from keyOn event). It prevents a drive away when cord is plugged in.
If your new charger has the interlock feature, feel free to use it. Otherwise, hooking both of these green wires together will bypass the interlock feature and allow the key to turn the car ON/OFF.
Thank you for your help. If I am understanding you correctly, I can connect the green wire from the timer to the long wandering green wire (assuming it has 12v) and once these 2 are connected, I will be able to power up the car with key on. Does this sound correct?
Yes- Do that!
Report back with what happens.
I was hoping to get this done this weekend but I ran out of time. I am hopefully swapping everything out this coming Friday. I will report back what happens!
Hello. I installed the updated DC to DC converter today. My original Zivan charger is still in car but non functional so I connected the long green wandering wire to the green wire on the timer. The cart powers up and moves in forward and reverse. However the headlights, taillights, brake lights do not work. The only thing working is the left front turn signal, horn, wipers, and reverse buzzer. I have verified that all fuses look good. Any idea of what to check? Did I miss wire something by chance?
Picture below is of the Zivan charger still hooked up. Should I remove this as well?
- Did you verify the the long Green wire had keyed 12v (ref ChassGnd) on it before hooking it up to the timer?
- Show me the wandering green wire and follow it back to it’s origin.
- Back at the timer, check the orange wire to make sure it has +12 (constant) on it when KeyOFF, and that it stays there when KeyON.
- If yes, Check the blue wire for 12v when KeyON.
Verify and report back with results.
I only have 3v at the long green wire with key on (nothing with key off). The orange/yellow wire at timer only has 12v with key on (nothing with key off). The blue has no power at all with key on.
This is what happens when you try and take shortcuts. Important steps were missed.
Back up at Post#5 I mentioned how important it was to verify that wire before plugging into it.
A Gibbs slap for you!
I can see in your recent pic you missed the two little wires going to the top of the charger. One is R/g and the other is Grn. They do not hang out there any longer and need to be disconnected off that charger.
First- Remove that little green wire. It has a small loop that goes up to the NEG on the controller. Either cut it off, remove it (if it has it’s own loop connector) or tape it up to the other wire it pairs up with.
Let us see if you did any damage. I have no idea how your car was actually running (after the install) because that red wire is part of your key loop.
Test the car to see if it still drives. KeyON, and observe dash display. Does it light up? Confirm (Y/N)?
The car drove fine and my display worked fine with the red and green wires plugged in to the top of the zivan charger. If I disconnect those wires, then I have no power to the car for some reason. Anything else I can test or troubleshoot? My apologies for missing step 5!
Now, Show me a pic of where you plugged in the long green wire from the timer.
Maybe another pic taken from down low so I can see the new harness wires.
Here’s a picture showing the long green wire connected to the green timer wire. My 2 zivan wires are unplugged at the moment. The zivan charger has never been in use since I have owned the car. I have another on board charger connected. Some other pictures are below.
OK, I think I see what you did here.
This is going to take a call to sort out.
See PMessage for more into.
Following up this post,
The problem was more/less due to the extensive use of green wire for B- and also for +12v key loop. It is tough to sort out if you don’t know what you are looking for. Whoever thought that was a good idea needs a good 10 minute earlobe flick session.
Once that was sorted out, the car wakes up like it should and should drive fine. Testing will be later today.
@Moorenycc is now sorting out a strange headlight harness issue which was non related to the DC Converter upgrade.
@AssyRequired, thank you again for your help! At the moment, the headlights are working again after replacing the spade connecters in the headlight wiring harness. I think corrosion was present. So far so good!