Need more Torque...speed optional for now

kidchaffeur

I've read a number of threads on upgrading to 48v and I anticipate this where I will find myself over time. However, I am interested in doing this in stages not only to spread the investment but also the fun of tinkering a bit at a time. My speed is ok for now, we use the cart for getting around in our subdivision and typically have 3 kids loaded on the rear seat. However, moderate hills are slowing us down to a crawl.

I have a 2005 TXT Fleet with stock components all the way around. I have old batteries that I will likely replace in the spring.

So what order should I take on this upgrade in order to gain moderate improvements out of each step until I finally make the full pass to 48v? I am looking to spend $300-$400 on the first stage (excluding the price of replacing the batteries and cables...this has do be done regardless).

Batteries - Should I just go ahead and buy 6-8 volts? Seems liking I am jumping all the way in as this will require that I upgrade the controller, solenoid and charger. Will the stock motor run on 48v?

Controller upgrade - Will I see any improvement in torque or speed with a stock motor? Would the solenoid need to be updated at the same time I upgrade the controller?

Motor - Would a motor upgrade alone at 36v gain me much as a first step? I assume the performance would remain limited due to the stock controller?

I appreciate the insight as it appears a number of you have been down this path a time or two!

BGW

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buckmanmike

A higher amp controller will give you more torque but no more speed. I have 2 carts, one of them is stock 03 CC and it runs great around camp with moderate hills. You need to check your batteries and make sure they are performing correctly. Take readings with a volt meter and hydrometer(whatever they call that thing).

AugustaResident

I done the same thing you are doing a few years back. I bought an Alltrax AXE controller, HD Solenoid, 4 ga wires and 6-8volt batteries. Don't forget you will need a 48 volt charger to do it right! More torque? Hang on! More speed? You betcha! That 36 volt motor should be just fine.

36 to 48 volts will be like going from a 6 cylinder to a V8.

I am sure Gornoman will chime in on this one as he has done basically the same upgrade and he will tell you the performance increases.

gonfast38

I'm in the same situation except mine is a PDS cart. Been doing the research and what I have found out is that an ALTRAX 500 controller, plus cables and solinoid will get you about 30% more torque with the stock motor. You can gain more speed and torque going to 48v. I plan on getting new 6v trojans this year, and maybe adding two more, 8-6v, to go to 48 next year. This should also increase run time, more lead=more runtime. I understand the shunt motors won't take the 48v for long, but yours should be ok.

As someone said, G'man can weigh in and correct me if I am wrong.

buckmanmike

Kid, You will not regret going to 48v. Budget your money to batteries, controller, wiring and solenoid. You can do this all in stages. Most Alltrax controllers will work at 36 or 48v. Be sure to check because controllers are voltage sensitive. I would suggest from personal experience to go with 8v batteries if you replacing the whole pack. I have run with 10 6v batteries and the cart gets heavy in off road situations. Good luck and have FUN.

gornoman

My '97 Series/Fleet cart was upgraded in stages over a few years. Everyone who drives it comes back smiling. It is my first electric cart and I am no cart genius, but I listened and learned to forums just like this one to get the right combinations and not waste money.

Road to 48v cart:
4g welding cable with soldered copper lugs throughout (helped a tiny bit)
Alltrax AXE 4844 controller (nice jump in torque, no extra speed)
2 extra 6v batteries and a charging solutuion (NOW we're talking torque AND speed)
My stock 36v solenoid is still inline, my F/R switch has not been upgraded. Both of these parts WILL fail eventually and will be replaced as needed, but until then, we ride. And everyone tries to keep up....

kidchaffeur

Thanks for the insight and tips. G'man...are you still running the stock motor?


Based on the various threads and the feedback I am leaning toward the following.

4g cables - Does any one have a recommended source? Most kits I have found do not include the cables from the solenoid to the motor? I would prefer to replace them all. There also seems to be a good amount of debate on solder vs. non-solder (may just be a preference thing).

Alltrax controller - This appears to be the consensus on the first large investment but should definitely get one rated for 36v and 48v to support the upgrades long term. How many amps should this be rated for? I don't intend to build a monster cart, but I do want this to support a moderate motor upgrade if I find interest later?

48v - Additional batteries 2-6v to increase the total pack to 48v. I would like to avoid the additional batteries and start with 6-8v, but don't know that I am ready to bite off the whole project at once. I do like G'man's charging strategy...avoids the cost of a 48v charger.

48v Solenoid and HD F/R switch - Interesting to see how G'man has worked around this...worth a shot. Like he states...run'em till the fry!

Optional Motor Upgrade - It appears that most are content with the stock motor at 48v. I had no idea these motors would handle the voltage. I am all for not spending the $$ but want to be sure I don't burn up my stock motor in the event I sell the cart down the road (I would probably return to stock and hold on to the upgrades for another day).

Am I missing anything...oh yea, seat belts so the wife doesn't dump the kids on starts!

scottyb

Most carts will never need more than 400 amps at 36 or 48v with a stock motor...

gornoman

Yes, stock 2hp 36v motor on 48v with a 400a controller.

Made my own 4g upgrade using welding cable (425 strand count) and copper lugs, soldered of course. I don't care what anyone says, properly soldered lugs are the way to go.

Three advantages to adding 2 more batteries: Cheaper charging solution, AND you still have 12v taps available from the pack. If you go 6-8v you MUST buy a 48v charger AND a power convertor OR seperate 12v battery. Now you need a 12v charger too, AND you have added another battery. Adding 2 6v batteries also increase your range.

I don't know, it sells itself...

kidchaffeur

All good points...thanks again!