1996 Ezgo TXT to 48v?

Jim_Smith33

I am in the process of my first cart upgrade and have some questions. I currently have a 1996 Ezgo TXT 36v regen cart with a 6" Jake's lift kit and 22" tires. I am upgrading the controller to a Alltrax DCX400 and the motor to a D&D 5500rpm. What else would I have to do in order to be able to run at 48v? I realize I need a 48v 400A solenoid, resistor, diode, 48v charger, and 8v batteries instead of 6v. But it's that it? Also is worth upgrading to 48v? Any help would be appreciated.

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BGW

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Olman

Jim---You need to post this in the electric EZGO section instead of Garage and Workshop. You will get a lot better response.

Welcome to BGW!!

UroGator

Welcome Jim,

I'm in the process of doing the same 36v to 48 v conversion. I'm pretty sure I have to get longer inter-battery cables to replace the shorter 9" ones for 36V configuration. This is for a 6- 8V battery configuration. I'll let you know once I measure my battery post distances once I get my batteries in next week. I'm not sure of the cable lengths for the other 2 batteries if you go to 8-6V (I guess it depends on where you place those other 2 batteries).

lockman1

Moved!

JohnnieB

Sounds like you have a 1996 TXT DCS.

UroGator mentioned the fact that 8V batteries require longer interconnecting cables (due to the terminals both being on same side), but didn't mention upgrading to a minimum of 4Ga or that all ten high current cables had to be upgraded.

What is the D&D part number for motor are you installing? They will all spin at 5500 RPM (and higher )

The 22" tires will reduce torque by about 18%, but the 400A controller will up it by about 20% so that evens out.

Depending on which D&D motor, you nay have an additional 10% torque loss (170-500-000) or a 10% torque Gain (170-501-0001) or a 40% torque gain (170-502-0001)

Of course, any of those three ought to get you into the 29MPH (5500RPM) to 34MPH (6500RPM) range at 36V, and maybe a bit faster with 48V.

However, if the 22" tires are the low pressure type, you may not reach those speeds.

Also, if you get the Super-Duty (400A/1000A) 48V solenoid, it works at 36V, 42V and 48V.

UroGator

JohnnieB, will any of the D&D motors you posted above for a 48 v conversion? What's the difference between them all? Just price?

I found a nice new old stock D&D motor locally (ES 65-51) for good price but I can't tell if it will fit my EZGO or if it is built for speed. Any ideas on this. I tried searching already and didn't come up with much

JohnnieB

All the motors I listed should work fine on 48V. Motors run on Watts, which is Volts X Amps. The Higher the Volts, the fewer the Amps needed to deliver the same amount of Watts.

If a motor is rated at 36V, that is only the voltage that was used to establish that particular rating, rather than what the maximum voltage that it ought to be ran at. There are limits to how high you can go on the voltage, but from 36V to 48V is only a 33.3% increase. On the other hand, going to a lower voltage doesn't work too well because lower volts means higher amps and higher amps means more heat.

The difference between High-Speed, High-Torque and Standard motors is the ratio of the turns of wire in the field and armature windings. With the same number of turns in the armature winds, a High-Speed motor would have fewer turns in the field windings while a High-Torque motor would have more turns in the field windings, and the field winds in a Standard motor would have something between the two extremes. There is more to it than just that, but that is the general idea.

I don't know what a ES 65-51 is either and find nothing on it. Best bet would be to give D&D a call and ask.

Jim_Smith33

The model number of the motor it's 170-505-0001. My tires are knobby not sure if they are low pressure. I can't wait to get it all built and running.

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JohnnieB

The tires will have a Max Inflation Pressure printed (raised lettering) on the sidewall. Hopefully, it is 15PSI or more.

The 170-505-0001 is a speed motor that has roughly stock torque, so with a 400A controller and 22" tall tires at 36V, you will just about break even in the torque department. With a 500A controller, you'd get about a 10% gain in torque.

On the other hand, with a 400A controller, 22" tires and a 48V battery pack, you'd get about a 30% overall gain in torque as well as a speed increase.

How much speed increase depends on the inflation pressure of the tires. The sidewall flex on the low pressure ones eats up a lot of torque and the faster they turn, the hungrier they get.