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Old 02-01-2011, 03:30 PM   #1
Ryan T
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Question 48v conversion

Hey new to the site, Im building a 03 Ez go PDS from the ground up and have a few questions. I understand the factory voltage was 36v, Ive fiqured out how to add 2 more 6v under the seat to make it 48v but some of the wiring is getting confusing at this point. I had the motor redone up at Plum Quick along with purchased a 500a controller from Altrax. Im in the middle of building a set of all new cables from 2 ga welding cable and also got a HD 48v sol. The first place I find my self confused in the new wiring is the low voltage to the new solinoid. Can the small yellow and blue wires that went to the orig. 36v piece be put right back in place on this new 48v sol. or does this need to be changed some how? Also theres a red wire that looks to have orig. come off right there where the charger plug is under the drivers side of the seat, you can tell someone has cut that wire and moved it onto a positive lug on one of the batteries, my question is what is this wire and can it be put right back as it was. What voltage does that wire need, it was lugged under the first battery and now theres another one in front of it so Im quessing this is going to change the voltage to that wire if I go back to the same battery is was on. Everything else seems pretty straight forward on the wiring and going together nicely, theres not much direction with the Altrax DCX500PDS but from studing the orig. Curtis that was in place most of it seems to be common since so far. I as well got a new diode, resistor, and 400a fuse to wire into the system. I hope to get this all fiqured out and have fun with this cart soon. It's stock higth and will remain that way but do have a bit taller tire but not too much, 215/40/12. I just got in a new black body, a short style stainless windshield, new folding style rear seat, and a few other goodies, cant wait to get it going. Thanks in advance for help in answering any of my electrical questions making this 36 to 48v swap a sucess!
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Old 02-01-2011, 04:51 PM   #2
mauistardog
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Default Re: 48v conversion

welcome....

Yes, the small wires that come off the original solenoid goes back on the new hd48v solenoid. The wire from the charger plug that came off the first battery goes back to the first battery...so if you added one in front, put it to the new number 1 battery...otherwise you will not charge the whole series of batteries. same goes for the last battery. (I am assuming you bought a 48v charger) the only wires you need to upgrade are the big wires, which you are using 2ga. at least this is what I did and nothing blew up yet If I said anything wrong I will be corrected shortly

aloha
joe
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Old 02-01-2011, 05:29 PM   #3
Ryan T
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Default Re: 48v conversion

Thanks for the reply. On the pass. side of the cart I found that I could unbolt the plate that the controller was mounted to and flip it and bolt it back on, this gives a raised and now flat surface to mount the first battery on. In doing this I found I had to cut the rear or back feet off of the heat sink so it could me moved back a couple inches to make room for the new battery, the drivers side was a piece of cake it had great room for the other battery in the conversion.

With the controller now being a few inches further back the old contactor wires dont quite reach so they will need to be lengthen'ed a bit; I just wanted to be sure that they could be put back just as they were [yellow and blue wires], Ive not traced out the wires in that loom to see where they really go yet.

On that red wire I mentioned, its not one of the 2 main charge wires, its the 3rd small red wire that comes out of the factory 36v charge plug though. I can tell it was cut and lenghen'ed and lugged under the + on the first battery, Im just not sure what this wire is for?

Ive read through the stickys up top and not found a really good PDS wiring diagram yet, this also would help me fiqure out how all this system really works. I just got back to the throttle pedal box and it looks like brand new inside, is there any maint. that should ever be done inside there as well? Thanks again.
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Old 02-01-2011, 05:42 PM   #4
EZGO-77
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Default Re: 48v conversion

I thought on 48 Volt you just run 8 volt instead of 6 Volt batteries??
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Old 02-01-2011, 05:46 PM   #5
Ryan T
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Default Re: 48v conversion

Quote:
Originally Posted by EZGO-77 View Post
I thought on 48 Volt you just run 8 volt instead of 6 Volt batteries??
I quess you could but I just bought the cart and it had one brand new A11 6v in it and 5 more older batterys. I knew I wanted a 48v system so I choose to buy 7 new 6v rather than 6 new 8v and have a new 6v setting around that I'd have no use for. Plus I think it should give more run time? This was what I was thinking......
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Old 02-01-2011, 07:37 PM   #6
EZGO-77
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Default Re: 48v conversion

Quote:
Originally Posted by Ryan T View Post
I quess you could but I just bought the cart and it had one brand new A11 6v in it and 5 more older batterys. I knew I wanted a 48v system so I choose to buy 7 new 6v rather than 6 new 8v and have a new 6v setting around that I'd have no use for. Plus I think it should give more run time? This was what I was thinking......
Yea Just the Weight And Room to Put Two more Stinks!
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Old 02-01-2011, 08:32 PM   #7
Spawn
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Default Re: 48v conversion

You also get more power and longer range with 8 6v batts.
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Old 02-01-2011, 09:29 PM   #8
mauistardog
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Default Re: 48v conversion

I run 8- 6v. you can run 4-12v if you want, but range will be shorter. 48v is 48v.
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Old 02-01-2011, 10:29 PM   #9
Ryan T
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Default Re: 48v conversion

So... anyone have a great link to a pds wiring drawing. Im still curious if the factory blue and yellow wires that were on the 36v solenoid can just be made longer and go right back on the new 48v sol. coil lugs, Im just not sure to where those wires go on the other end. Ive got all parts here now to do the swap if I can just fiqure it out and not make any mistakes, well, besides a 48v charger; I still have to buy one or swap someone for my 36v charger that came with the cart.
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Old 02-01-2011, 10:35 PM   #10
scottyb
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Default Re: 48v conversion

Your new solenoid works the same way as the old one. Blue goes to the negative side and yellow is the positive side of the solenoid activation posts.
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