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Unread 03-16-2012, 09:37 PM   #51
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Default Re: Upgrading a 1999 Club Car DS to 48v

Looks great, curious on top speed, I’m running re-wound / modified 36V motor in my 97 DS (48V) with 500AMP controller and the required upgrades (solenoid/2g cables) and 6:1 gears. Topping out at 36mph, I’m good with this, for I run DS to work and back on “legal” public roads; both are plated as LSV in VA. It did lower my battery life span between charges, I go to work, charge during day and return home (15 miles one way) with no issues.

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Unread 03-17-2012, 07:13 AM   #52
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Default Re: Upgrading a 1999 Club Car DS to 48v

Quote:
Originally Posted by oconnorb View Post
Looks great, curious on top speed, I’m running re-wound / modified 36V motor in my 97 DS (48V) with 500AMP controller and the required upgrades (solenoid/2g cables) and 6:1 gears. Topping out at 36mph, I’m good with this, for I run DS to work and back on “legal” public roads; both are plated as LSV in VA. It did lower my battery life span between charges, I go to work, charge during day and return home (15 miles one way) with no issues. OC
Wow, 36 MPH must be pretty nice. I'm curious...you have a charger on board, and charge when home at night too?

Sorry for the hijack Bill....
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Unread 03-17-2012, 08:18 AM   #53
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Default Re: Upgrading a 1999 Club Car DS to 48v

I have three chargers, work, home and studio… DS is light, removed anything that wasn't critical to operating, but still met VA LSV requirements.

Also, apologize I shouldn’t have interrupted your thread… I am curious on top end when finished with your upgraded 48V motor, your cart build looks great~
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Unread 03-18-2012, 01:52 AM   #54
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Default Re: Upgrading a 1999 Club Car DS to 48v

Started test fitting the throttle conversion today. I clamped down the bell crank assembly, and also the potentiometer. I stretched everything as tight as possible; if I put the pot any further back, the microswitch wouldn't be closed when the throttle is closed.

So with everything clamped down looking good, if I push the gas peddle all the way down the pot lever doesn't get all the way to the "limit line" on the pot.

Scotty, I would have emailed these questions to you, but thought other folks might like to listen in. I am not a electronics expert, but I hooked up my little Micronta multimeter to the two output wires on the pot. The multimeter is a "auto ranging" device, so I'm not sure if I can set the range above 5000 as you describe in your docs. With the throttle closed (gas pedal at rest), the reading bounced around 20 ohms. With the throttle wide open (remember the pot lever isn't all the way open), the reading said 3.82 K-ohms.

So, it looks like the pot lever does need to go farther? How do I adjust the relationship between the pot, the bell crank, and my stock throttle linkage? Thanks as always!
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File Type: jpg throttleOpen.jpg (76.5 KB, 0 views)
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Unread 03-18-2012, 03:37 AM   #55
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Default Re: Upgrading a 1999 Club Car DS to 48v

Your peddle linkage should move about 2" from 0 - wide open. Check the measurement there. That should give more than enough travel at the pot arm.

Maybe if the bell-crank wasn't laid over quite so much to start with.....?
Move everything forward until the bellcrank arm is more vertical. At the angle you show some of the peddle linkage travel is used to lift (not pull) the linkage. Straighten everything up and retest.

You have my email and phone if you have any other questions.
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Unread 03-18-2012, 08:26 PM   #56
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Default Re: Upgrading a 1999 Club Car DS to 48v

As instructed, I moved the bell crank a bit forward, and just fooled around the with the placement until it looked optimum. After driving in the screws, while the pot lever doesn't come all the way to the stops when the throttle is wide open, I am reading a range of 5-5400 Ohms. That seems to be a good range?

I also installed the solenoid on the frame, fairly high up. Stuck in a few of the batteries to make sure everything was going to fit.

Yikes. I think it's almost time to start attaching wires! Nervous.
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File Type: jpg throttleOpenInstalled.jpg (79.2 KB, 0 views)
File Type: jpg solenoid.jpg (84.8 KB, 0 views)
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Unread 03-19-2012, 07:52 AM   #57
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Default Re: Upgrading a 1999 Club Car DS to 48v

Lookin good man! Pretty soon you'll be ready to>>>
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Unread 03-19-2012, 10:00 AM   #58
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Default Re: Upgrading a 1999 Club Car DS to 48v

If you find that the #2 cable (solenoid to controller B+) is too short to reach, consider moving the solenoid up to the hole with the big red arrow in the yellow circle on the pic below.
Looking good.
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Unread 03-19-2012, 10:28 AM   #59
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Default Re: Upgrading a 1999 Club Car DS to 48v

Scotty, your diagram has cable #2 going from B+ to solenoid. B- goes to negative on the battery pack. Was that a typo in your message?

By the way, are the left/right posts on the solenoid interchangeable? And the top/bottom? In other words is there such a thing as left or right, or is that up to the user to decide.
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Unread 03-19-2012, 10:34 AM   #60
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Default Re: Upgrading a 1999 Club Car DS to 48v

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Originally Posted by wwford View Post
Scotty, your diagram has cable #2 going from B+ to solenoid. B- goes to negative on the battery pack. Was that a typo in your message?

By the way, are the left/right posts on the solenoid interchangeable? And the top/bottom? In other words is there such a thing as left or right, or is that up to the user to decide.
Yes that was a typo, thank you for catching that. I fixed my post.

You are correct, the solenoid has no polarity and no directional preference. The two small terminals are the activation circuit. The two large terminals are simply a cut off switch, a make or break connection.
The solenoid will activate, make the connection for the big terminals, when there is positive and negative pack voltage present at the small terminals.
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