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Old 11-10-2015, 07:23 AM   #11
Sergio
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Default Re: Wiring for Voltage Reducer/New Key Switch

Check the fuse on the Voltage Converter.

A few notes and observations from analyzing the wiring diagram:

Harley 3-wire key switch:
Red - Main Power Input (Hot side)
Red/Black - Ignition/Lights Output (Position #1)
Red/Gray - Accessories Output (Position #2)

Existing Key Switch:
Blue - Hot side (Input) from FNR switch.
Green - Cold Side (Output) to Pedal Switch.

You have several ways to connect it depending on your driving needs, I personally prefer the "accessories" be the "Position #1" so that I can run the Radio/Lights without the possibility of the cart moving by pressing the pedal.

I looked at the wiring diagram and noticed that the "Key Switch" in that cart is just an interlock on the middle of the chain, so changing directions would cause the reducer to be powered OFF.

The available current is also severely limited by the Reed switch that feeds power to the system.

I am not an Ezgo cart owner, but if it was my cart, this would be my first modification:
Disconnect the Green and Blue wires at the Key Switch and splice them together.
Run 2 new wires, 1 - 16ga and 1 - 18ga to the Charger Receptacle.
Disconnect the existing small gauge Red wire from the White wire (positive).
Connect the small gauge Red wire to the 18ga wire from Key Switch.
Connect the 16ga wire from Key Switch to the Positive White wire on the charger receptacle.
That will give You a robust Key Switch power (the 16ga will be Hot side and 18ga would be Cold side of the Key Switch), reduce the stress on the Reed switch and still provide all the factory safety interlocks.
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Old 11-10-2015, 01:41 PM   #12
Jwade79
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Default Re: Wiring for Voltage Reducer/New Key Switch

Sergio - I connected small green and blue wires that went to my original key switch.

I have 3 wires coming from my charger receptacle. 1 thicker black wire, 1 thicker white wire and a small red wire. Here is how they connect:

The black wire connects to the main - and the white connects to the main +. The small red wire connects to the small blue wire that connected to my old key switch.

With this being said, It seems like my current set up is different than what you may picture or I am just very confused? I'm trying to figure out why I would need to run two new 16g and 18g wires to charger receptacle when it seems like the existing charger receptacle wires are already about the same size. Also, the small gauge red wire doesn't connect to the white wire as u mention.

Can you please clarify?

Thank you!
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Old 11-10-2015, 02:16 PM   #13
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Default Re: Wiring for Voltage Reducer/New Key Switch

Sorry if that confused You, what I proposed was a better way to wire the Key Switch so you could add an additional load without causing issues with the reed switch in the charger receptacle socket.

It is not necessary to make your converter work, but your converter will power OFF when You change directions using the OEM wiring.

I sketched where the wires should go in the attached picture.

You can also eliminate the reed switch entirely (leave both small red and white wires that are connected to the reed switch OFF) and run the 18ga wire from the key switch directly to that 0.250" quick connect.

The idea is the power will come from the white wire on the receptacle directly to the Key switch (16ga wire).

When You turn the key switch ON, the power will go to the small red wire (via the 18ga wire) and power the OEM wiring as it did before.

If You insert a charger plug, the reed switch will still interrupt the OEM wiring regardless of the Key switch position.

If this is not clear, You are better off leaving the wiring as it was so You don't accidentally cause a short.

It sounds like You had the correct voltages before, so a bad fuse on the converter was the only thing you could check.

Attached Images
File Type: jpg EZGO_charger_receptacle.jpg (125.1 KB, 0 views)
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Old 11-10-2015, 07:39 PM   #14
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Default Re: Wiring for Voltage Reducer/New Key Switch

Sergio - I have been trying to trouble shoot and confirm whether or not my reducer was even working before I start trying to change wires around.

I have 36v between main - and main +, but please note:

I have no key in my new ignition and the three wires from ignition are not connected to anything. Also, the blue and green wire that went to my original key switch are not connected to anything. And, The yellow wire from reducer is not connected to anything. I have no idea why the battery power is still on??

I then just went on and temporally connected everything back to how I had it, which is the following:

Yellow wire from reducer to + on ignition switch. Blue wire (runs to small red wire from charger receptacle) that went to my original key switch is also connected to the above mentioned yellow wire and + from ignition.

Small Green wire that also went to my original key switch is now connected to the ground from new ignition switch.

Any idea why I can't turn off the 36v, even with several wires mentioned above being disconnected?
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Old 11-10-2015, 07:40 PM   #15
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Default Re: Wiring for Voltage Reducer/New Key Switch

BTW, reducer works. I think the fuse wasn't in all the way.
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Old 11-10-2015, 07:43 PM   #16
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Default Re: Wiring for Voltage Reducer/New Key Switch

Quote:
Originally Posted by Jwade79 View Post
BTW, reducer works. I think the fuse wasn't in all the way.
Lol - the missed step 1
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Old 11-10-2015, 08:02 PM   #17
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Default Re: Wiring for Voltage Reducer/New Key Switch

Quote:
I have no idea why the battery power is still on??
The Key switch does not turn the battery power On/Off, it is only a safety interlock that must be ON for the cart to run.

Quote:
Yellow wire from reducer to + on ignition switch. Blue wire (runs to small red wire from charger receptacle) that went to my original key switch is also connected to the above mentioned yellow wire and + from ignition.
The Blue wire does not go to the charger receptacle according to the wire diagrams I saw, it goes to the FNR interlock micro switch.


What Are You calling + from Ignition?

Quote:
Small Green wire that also went to my original key switch is now connected to the ground from new ignition switch.
There is no ground on the previous switch or the new Harley switch.


This is the correct way to wire the Harley switch (OFF, #1, #2) to the original wiring:
Switch Red - Blue Wire (Hot side)
Switch Red/Black - Converter Yellow (Key Position #1)
Switch Red/Gray - Green Wire (Key Position #2)
That way Position #1 will only get You the converter, the cart will not run.

Position #2 will get both Converter and cart to work.

You can connect Your voltage meter to whichever position will give You what You want:
ON all the time = Red wire
ON with Converter or Cart = Red/Black wire
ON only when cart is ON = Red/Gray wire
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Old 11-10-2015, 08:04 PM   #18
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Default Re: Wiring for Voltage Reducer/New Key Switch

Quote:
Originally Posted by scottyb View Post
Lol - the missed step 1
This is very common.... Step one is usually the most overlooked step...
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Old 11-10-2015, 09:24 PM   #19
Jwade79
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Default Re: Wiring for Voltage Reducer/New Key Switch

I am referring to the + on ignition as the Main Power Input.

"The Blue wire does not go to the charger receptacle according to the wire diagrams I saw, it goes to the FNR interlock micro switch." My blue wire does indeed connect to charger receptacle via the small red wire. This was as a result of installing new controller, reverse contactor, etc...

"Switch Red/Gray - Green Wire (Key Position #2)" Where is this green wire coming from?. I spliced the small green and blue wires per your recommendation on your original post.

My plan is connect the key switch per your original suggestion:

"Disconnect the Green and Blue wires at the Key Switch and splice them together.
Run 2 new wires, 1 - 16ga and 1 - 18ga to the Charger Receptacle.
Disconnect the existing small gauge Red wire from the White wire (positive).
Connect the small gauge Red wire to the 18ga wire from Key Switch.
Connect the 16ga wire from Key Switch to the Positive White wire on the charger receptacle."
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Old 11-11-2015, 06:26 AM   #20
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Default Re: Wiring for Voltage Reducer/New Key Switch

To make sure we are in the same page, if You follow my original instructions, which was assuming a stock wiring, the switch connections should be:
Switch Red wire - 16ga wire from charger receptacle (Hot side)
Switch Red/Black wire - Converter Yellow (Key Position #1)
Switch Red/Gray wire - 18ga wire to reed switch in charger receptacle (Key Position #2)
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