2000 Ezgo TXT PDS upgrade problem

mhynd

Ok, I'm new here. Got pointed this way by ScottyB. New to carts but wanted one for hunting and getting around off road. I am confined to a wheelchair so I need cart to get to and from hunting areas. I bought a 2000 Ezgo TXT PDS with the intend of completely upgrading it with motor, controller, 48v, well everything HD. The cart has bad batteries so I hooked up 3-12vs for testing but got nothing at all. Because I am upgrading everything it doesn't make sense for me to find this problem. Contacted ScottyB about an upgraded motor/controller but he tells me that the 2000 PDS cart is a failed system and I should contact JohnnieB about the PDS wiring harness for an aftermarket controller. Sorry this the only way I saw to contact him or others that might be able to help.

So here is my questions.
What needs to be done with the wiring harness in order to upgrade to a larger controller like a 500 amp Alltrax?

Would it be better to upgrade this cart to a series type because of the way that I am going to use it? Fall/Winter Little mud/snow/soft sand possible.

Seems like a complete rewiring is needed. I try and do all my own work for money savings and need to know how it is put together in case it needs to be worked on. So far, I have stripped the cart down pretty much to the frame and have cleaned and recoated everything. Modified the front end off an old Polaris to fit and will be using the 22" tires from it also. Reworked the rear leaf pack by leaving the main spring and adding 3 heavy trailer springs. More curve with the trailer springs so with the added front end, it gives about a 4-5" total lift.

I know, this seems terribly long to me also. I've included a picture of the controller with the cover off and the tow/run switch unplugged.

Any thoughts or help would be appreciated.

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sportcoupe

Looks like any other PDS controller I've seen. Still, I trust ScottyB to know something is amiss.

JohnnieB

The early 2000 PDS carts had a DCS type F/R switch and J1 was wired differently.

Is your cart's F/R switch a rocker switch on the dash next to the key, or is it a lever next to your right knee?

Need a picture of the top and bottom side of J1 showing what wires are going to which pins. Just pull the 10-pin plug and take a picture of both sides.

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As for converting it to a series cart, in general terms a Series wound motor has more low end torque than a Sepex motor like the PDS has, but if you are going to be replacing the motor, a sepex motor that is wound for low end torque will give you more speed at the same battery pack voltage than a series motor wound for low end torque. (The torque curve of a sepex motor is altered on the fly by a process known as Field Mapping - so they are more versatile)

The 22" tires will reduce torque by about 18%, but a higher amp controller, a high torque motor and upping the battery pack voltage to 42V or 48V will far more than offset that loss.

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Talk to the guys at D&D motors about building the right motor for your needs. Once you figure it out, you can order it through Scottyb.
http://www.ddmotorsystems.com/

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FWIW: The motor in my cart is wound for high speed and I get 28 MPH on stock height turf tires, but I do take it on dirt trails occasionally and I run out of traction or ground clearance before I run out of low end torque.

With taller tires and a more aggressive tread pattern it would go just about anywhere and with a motor wound for low end torque, it would run cooler at low speeds.

scottyb

Look closer the main molex plug is on the side of this control in a 2 row configuration, not the single row on top of the later year. It wont plug into any DCS control. I imagine he can get a PDS wire harness and have the correct plug and configuration. THis is something I thought would be better suited to the forum.

JohnnieB

Huh?

I thought he had a PDS rather than a DCS.

mhynd

Johnny this is a pds regen cart. I have included the pictures you requested. The flash still makes them a bit hard to see.

Looking at the top of the plug the wires go -green/black strip, white, white/yellow strip, yellow, dark blue.

Looking from the bottom side, wires go - red, red/white strip, green, orange, gray.

The FNR is located on the dash near the key.

What all would be needed to change this to a sepex motor setup?

Not sure which plug Scotty is speaking of.

mhynd

Sorry, I forgot the pictures.

The manufactor's code is E300, serial # is 1273280. The controll is a Curtis PMC, P/N 73326G02.

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JohnnieB

No pictures attached, but from the description of the wiring a standard PDS to DCX adapter will work. (Same wiring order that is on my 2008 PDS)

You already have a sepex motor setup.

Toss in a DCX500 (with a PDS to DCX adapter cable), a Super-Duty (400A/1000A) solenoid, 2Ga cables, a High Torque Sepex motor and a 42V or 48V battery pack and you are ready for hunting.

This is what mine looked like when I was running a DCX400 with a stock PDS motor at 36V. The DCX500 is the same install, the case is just a bit longer.

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I'm a slow typist, so you posted the pictures while I was typing.

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mhynd

Thanks, JohnnieB. ScottyB has this Pkg. #909 for PDS carts:
500amp Alltrax (DCX500PDS) 36 - 48v programmable
400a Super Duty 1000a peak Solenoid Kit w/ Mounting Bracket
Suitable for aftermarket motor on & off road use
Includes harness adapter, 400a solenoid, resistor & diode

Is this what you are talking about and would this be the correct harness adapter needed?

JohnnieB

Yes. That is the the controller, solenoid and wiring adapter I was talking about.