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Old 10-17-2015, 09:42 PM   #1
JDodson
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Default Ezgo conversion help

I have a 06 Ezgo Txt 36V and attempted to convert it to 48V today but after I added 2 6V batteries I couldn't get it to work. I was told that the motor and controller would work with 36 or 48V. I think I have the Regen motor (DE2-4007) and cant find anything saying that it will work. A Tech guy at a cart place told me my cart would work off either batt pack. Does anyone have any input that could help me out?
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Old 10-17-2015, 09:45 PM   #2
cgtech
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Default Re: Ezgo conversion help

You were told that you could just add 2 batteries and change nothing else, and everything would be fine? By whom? What controller do you have? What solenoid? Do you intend to charge a 48v pack with a 36v charger?
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Old 10-17-2015, 11:22 PM   #3
scottyb
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Default Re: Ezgo conversion help

The stock control will not work with 36 or 48v. Most aftermarket controls will. You need an upgraded solenoid too.
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Old 10-18-2015, 08:41 AM   #4
JohnnieB
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Default Re: Ezgo conversion help

Sounds like the "Tech guy at the cart place" was trying to drum-up some business.

Also sounds like you have a 2006 PDS cart. (Attached is a picture of the label on the motor originally in my 2008 PDS showing the DE2-4007 part number)

You can try to drop back to a 36V pack and see if it still works, but I seriously doubt if it will.

Your motor has most likely survived (It's happy with 48V), but the stock PDS controller (Curtis 1206MX) probably didn't and the stock (85A) solenoid needs to be upgraded even if it did survive.

Drop an Alltrax XCT48400PDS controller into it along with a heavy-duty (200A) or Super-duty (400A) solenoid and the cart will be good to go at 48V.

You'll also have to get a 48V battery charger. The DPI Accusense charger is the best bang for the buck.

Unless they have already been replaced, the high current cable are nearly 10 year old and weren't very good to start with, so they most likely need to be replaced too. 4Ga minimum (A 2006 probably had 6Ga connecting the batteries in series). Replace all 10 of them, plus the additional two needed for a 8x6V battery pack, making it a total of 12.
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File Type: jpg PDS Motor.jpg (134.7 KB, 0 views)
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Old 10-18-2015, 02:15 PM   #5
JDodson
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Default Re: Ezgo conversion help

I guess I need to elaborate, I didn't want my post so long where people wouldn't read it. lol. The guy told me that my cart would work with 36 or 48v. He said to get it to 48V then get a charger to charge the pack. He said the 36v solenoid will work for a short period so I would need to change it asap. Yesterday I added the batteries and installed a 48V solenoid that I had in my garage that came off a club car. The cart would not do anything, solenoid wouldn't even click then pedal was pressed. I then put the 36v solenoid back on and it still did nothing. I then dropped it back down to 36v and its working. I have a Alltrax 500 amp controller that I mailed off to get programmed so it will work on my cart (came off my club car with IQ system so im hoping it can be reprogrammed, waiting to get it back), I have a 48v charger already and have the 2 batteries to put in that are part of the same pack as the 6 already in my ezgo (bought new ones for Bad Boy and these were still good so put 6 in ezgo initially and put other 2 in yesterday). I basically have everything to do the conversion if the motor I have will work. Do yall know if it will? also will my stock controller work until my Alltrax comes in?
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Old 10-18-2015, 03:21 PM   #6
JohnnieB
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Default Re: Ezgo conversion help

Yes, the stock PDS motor will work at 48V, but the max amps is about 400A (You can turn down the max amps in a DCX controller)

You stock PDS controller will work at 36V until it dies of natural causes.

A PDS controller controls the solenoid, and it probably went into over-voltage shutdown when you connected it to 48V, so it wouldn't energize the 48V solenoid.

If the Alltrax 500A controller is the DXC model, it is user programmable, so all you have to do is connect it to a computer with Controller-Pro software loaded and any one of several throttle types can be selected, along with other parameters. (See attachments)

Controller-Pro software is a free download on the Alltrax website.

If you don't have one, you will need a PDS to DCX adapter to connect three separate cables in the PDS control wiring harness to the 10-pin connector on top of the DCX. (last two attachments)
Attached Images
File Type: gif Controller-Pro-Screen-Throttle.gif (25.1 KB, 0 views)
File Type: gif Controller-Pro-Screen-Control.gif (35.0 KB, 0 views)
File Type: gif Controller-Pro-Screen-Monitor.gif (34.4 KB, 0 views)
File Type: jpg 015_15-s.jpg (8.5 KB, 0 views)
File Type: jpg P6130063.jpg (14.4 KB, 0 views)

Last edited by JohnnieB; 10-18-2015 at 03:27 PM.. Reason: Corrected number of cable to connect from four to three
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Old 10-18-2015, 05:38 PM   #7
scottyb
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Default Re: Ezgo conversion help

Call who ever is programming it and ask for a 400A max adjustment.
Turbo off for max torque on this control. You will sacrifice a few mph but gain torque. Your call.
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Old 10-18-2015, 06:53 PM   #8
JDodson
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Default Re: Ezgo conversion help

thanks guys! Torque is what im looking for. It goes 20 now with everything stock & 36v but I have 25in tires so im sure im gaining a little speed from the tires. I need some torque for hills and take off. 20 mph is fast enough, with my kids riding it ill end up doing frame and body work. lol
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Old 10-18-2015, 08:39 PM   #9
Klunky Chris
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Default Re: Ezgo conversion help

JB & SB, I thought I read you guys saying in other posts that a stock PDS controller will handle 1 extra battery for 42v? Am I miss-remembering this?
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Old 10-18-2015, 11:29 PM   #10
scottyb
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Default Re: Ezgo conversion help

Quote:
Originally Posted by Klunky Chris View Post
JB & SB, I thought I read you guys saying in other posts that a stock PDS controller will handle 1 extra battery for 42v? Am I miss-remembering this?
No- the stock control will not handle voltage above 36v without being at risk of going up in smoke -
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