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Old 02-05-2017, 03:03 PM   #1
toothninja
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Default Customizing my 2003 EzGo TXT PDS-build

Hey! I'm a newbie to the golf cart world. I purchased a 2003 EzGo txt PDS golf cart, obviously used! The batteries are all less than two years old. It has 4 gauge battery wires. I'm planning on customizing it... lift, bigger tires, rear seat, new body, lights etc.. It runs pretty good. Just purchased a freedom chip. It sped it up, but apparently it had a "mild hill chip" already, so I didn't see much difference. I have a multitude of questions and an endless number of problems which I'm sure I'll run into, but I'm excited to get started into this build!

First off, where to start?? Obviously I am not going to do everything at once! Thinking of replacing the controller and solenoid. If I plan on hauling several people around on a regular basis, then which size would I want to go with and why? I mean I can see go big or go home, but is it necessary to do so? If I replace with a 500 amp controller, then I have to replace my cables, right?

Like I said, this is my first step in a long process...any guidance would be appreciated! Thanks in advance!!
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Old 02-05-2017, 04:28 PM   #2
cgtech
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Default Re: Customizing my 2003 EzGo TXT PDS-build

400 or 500 would both be a big power upgrade (and a speed upgrade as well). Both can be used with 4ga cables, but should be 2ga if lifted with big off road tires. Neither can be used with stock solenoid. First thing I would do is care for & address the health of the batteries. Check the water levels, fully charge, wait 12 hours & take individual battery readings to verify they are getting a full charge. Take a good ride & check individual voltages again to see if they are all even. You should be using the meter setting that reads to the hundreds of a volt (like 6.xx volts). If you don't have any type of meter on the dash for battery monitoring, I suggest getting & learning how to use ScottyB's meter (www.cartsunlimited.net). His website also has tons of info for you to learn from.
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Old 02-06-2017, 08:00 AM   #3
toothninja
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Default Re: Customizing my 2003 EzGo TXT PDS-build

Thanks! I am planning on reaching out to ScottyB for some assistance. Although this is my first thread, I have been reading for a few weeks! . Do I need to disconnect all of the batteries if I am going to test individually? Seems to me that if they are wired together then they would be picking up each other's voltage as well. Also another dumb question, do you fill a battery with regular tap water or do you need bottled water of some specific sort?
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Old 02-06-2017, 08:10 AM   #4
2016CTD
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Default Re: Customizing my 2003 EzGo TXT PDS-build

Distilled water in the batteries.
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Old 02-06-2017, 09:56 AM   #5
mutant
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Default Re: Customizing my 2003 EzGo TXT PDS-build

go from the - to + on the same batt. will isolate the charge reading of other batts.
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Old 02-07-2017, 08:38 AM   #6
toothninja
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Default Re: Customizing my 2003 EzGo TXT PDS-build

Here's another question/problem I am having: Whenever I flip the F/R switch, doesn't matter whether it's from N>F, F>R, R>F, etc., the solenoid won't click and the cart doesn't move. I can hear a click coming from under the pedal, but not the solenoid...any ideas?? It is a periodic problem, not a constant. Most of the time if I flip the switch a few times, it'll start working...thankfully I haven't been left stranded anywhere.

Also, I checked the battery voltages, pack was 38.7, and all of the individual readings were between 6.43-6.48. After driving for half a mile or so, the pack voltage was 37.95 with the indivual readings between 6.31-6.34.
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Old 02-07-2017, 08:44 AM   #7
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Default Re: Customizing my 2003 EzGo TXT PDS-build

looks like time to go with that upgraded controller and hd solenoid....you may have a solenoid starting to go bad,so if you are upgrading-might as well do it....if my guess is right,it will fix your f/r problem...
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Old 02-07-2017, 08:52 AM   #8
toothninja
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Default Re: Customizing my 2003 EzGo TXT PDS-build

Thanks! That is what I was guessing, but I am, by no means, an electrical engineer! LOL!
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Old 02-07-2017, 08:54 AM   #9
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Default Re: Customizing my 2003 EzGo TXT PDS-build

let us know what you do and how it turns out!
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Old 02-07-2017, 09:03 AM   #10
JohnnieB
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Default Re: Customizing my 2003 EzGo TXT PDS-build

Quote:
Originally Posted by toothninja View Post
Here's another question/problem I am having: Whenever I flip the F/R switch, doesn't matter whether it's from N>F, F>R, R>F, etc., the solenoid won't click and the cart doesn't move. I can hear a click coming from under the pedal, but not the solenoid...any ideas?? It is a periodic problem, not a constant. Most of the time if I flip the switch a few times, it'll start working...thankfully I haven't been left stranded anywhere.

Also, I checked the battery voltages, pack was 38.7, and all of the individual readings were between 6.43-6.48. After driving for half a mile or so, the pack voltage was 37.95 with the indivual readings between 6.31-6.34.
Your might have a bad F/R switch. When the cart is misbehaving, check for battery pack voltage on J1 Pin-3 in F, or J1 Pin-2 in R. (J1 is mounted upside-down, so Pin-2 is second from right side on bottom row and Pin-3 is third from right.)

As for battery voltages: The batteries acquire a surface charge while charging and read artificially high, so let them rest for about 12 hours after charging to get an At-Rest voltage reading. The pack should read 38.2V when fully charged and each battery should be 6.37V and all batteries ought to be within 0.1V of the others.

The opposite occurs when battery is used, but battery voltage recover to the At-Rest voltage in about an hour instead of 12 hours. Attached is the recovery rate I observed with Trojan T-105 batteries
Attached Images
File Type: jpg Voltage Increase after load.jpg (100.4 KB, 0 views)
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