Ezgo PDS upgrade
 

I will show basic electronic upgrades and install here on a typical CL find.
Subject is a 2007 Ezgo TXT PDS from Craigslist.
Dead charger and batteries.
Actually 2 dead chargers so both went in the trash.

I will use an Alltrax XCT400 control with Shift on the fly personality switch
SW180 200 amp solenoid with magnetic break outs
4g cable set (custom)
6/8v batteries for 48v operation
And I will start with the stock motor.

My first choice for Charger is the DPI Accusense but I have recently removed the receptacle and 48v charger from my 2010 TXT48 (lester on-board charger project featured in another thread) so that triangular shaped receptacle will go into this cart.

Battery pack held 1.5 volts upon arrival. I plugged in my force start Lester 36v charger. Every shop should have a 'jumpered' charger that will start on a dead pack for service calls.
The jump charge brought the pack to 40v quickly so I jacked a rear wheel off the deck and tested Forward and reverse. Both directions worked so we know the cart is operational. After 45 minutes of 25 amp charge the pack read 33 v - She's toast. Called the battery guy, he will be here in the AM. :thumbup:

So I began stripping the battery bay. Removing a rat's nests of aftermarket light wiring. Previously connected to 2 6v batteries :thumbdown:
Removed the battery hold down and cables.
Removed the controller cover
Unplugged all the controller plugins and disconnected high amp and low amp wires and cables.
NOTE: Be sure to tag, photograph, and diagram where wires went so you can easily ID where small wires and big cables were originally. This is very important unless you can do this stuff in your sleep it will bite you in the but if you think you can remember where the red wire went. Believe me we see it here everyday 8)
Removed solenoid with bracket and controller.....found enough dirt to plant potatos under the controller heat sink.

Hosed down the battery bay and cart. Nothing crazy. Just got the bulk off of it

Re: Ezgo PDS upgrade
 

Resurrecting the dead!

Re: Ezgo PDS upgrade
 

Cool Scotty 8)

Sounds like fun! I love resurrecting old dead carts!

Sent from my SM-G930R4 using Tapatalk

Re: Ezgo PDS upgrade
 

Made a deal with my Battery Man for a gently used set of 190 amp hour 8v batteries. These large capacity 8v are in excellent shape and will provide plenty of run time.

Removed the old batts, spayed a can of Deka battery cleaner on the whole battery compartment. Hosed it all off and pleased to see the metal rack in excellent condition, most of the original paint still on the rack. :thumbup:


Note these batts have single point fill system caps which we will be changing out for speed caps next week. The single fill point system was designed to save fleet managers time. The down side is without seeing into a cell much under-fill and over-fill occurs - sometimes in the same set... and there is always the danger of hydrogen gas collection in the tubes which presents a potential for explosion should a spark occur.

Re: Ezgo PDS upgrade
 

Now the work begins. New cables and electronics.
I will be using the new generation XCT control with FNKS shift on the fly.

I better check the rear end oil - this thing is gonna boogie :lol:

Re: Ezgo PDS upgrade
 

Limit the motor to 6500 RPM in the XCT and you'll get 28MPH on level ground and it probably won't slow down very much on hills with less than 20° grade. :mrgreen:

Put 20" tires on it and it'll do 31MPH on level ground, but will probably slow some on 20° hills.

Re: Ezgo PDS upgrade
 

Good info Johnnie :thumbup: Initial tests will be done on the stock tires and yes, I do have a pair of 20" knobby tires lying around that need using

Some small progress and

a quick pic of the new pack

Re: Ezgo PDS upgrade
 

Changing out the charge receptacle is simple with the right tools on the Ezgo. No rusty bolts to deal with... Aluminum rivets drill out easy with a small 12v drill and install in seconds with the HF pneumatic rivet gun.

Note the correct rivet for this job is slotted to expand when installed. All the rivets you see here are aluminum.

Re: Ezgo PDS upgrade
 

Last pic just shows a different rivet for the (previously non existent) seat hinge brackets. These brackets came from my junk collection - All TXT seat brackets are the same. If installed correctly they should last a lifetime so , who knows where the originals went

Posting this while I wait for the freshly soldered cable ends to cool enough for finishing.