From 36v to 42v conversion

[Phil0411]

Yes, I meant 42 volt. I have a PDS with a stock motor rated at 36-48 volt. I read much on the net that just adding a seventh battery yielded more power and longevity running at 42 volt. The only two potential failure point are the solenoid and controller. So far so good. The cart runs extremely well with no heating of components I can find. As far as charging, I have a Summit ll with a 42 volt battery profile. It charges perfectly. My questions are these. Anyone else doing this and if so, for how long? Is everything holding up? The one major concern I have is the solenoid. Does anyone know how to reduce the activation voltage from the 42 volt system back down to 36 volt using a diode or similar? Thanks in advance.

[scottyb]

The controller supplies both sides of the solenoid activation circuit with the same current it is powered up with. There is no way to tell the controller to use a lower voltage on the solenoid. And there is no way of knowing how long it will work.
I once bought a 48v PDS that was simply stuffed with 8v batteries and still had the original solenoid and controller installed. I asked the seller how he had been running like this and he said he just got it running... So I quickly disconnected it and sold the controller and solenoid for a quick buck on ebay and put that $ towards a proper 36-48v controller and solenoid. That cart ran 42v around the ranch for years and years. 42v is a sweet spot with these carts.

[Phil0411]

ScottyB so will the 36volt solenoid be okay? I hear both opinions. Also, if not, should I be running a 48 volt solenoid instead? My cart runs great at 42 volts so far.

[coosa]

I did the conversion several years ago. I bought a heavy duty solenoid from ScottyB that would work on 36 to 48 volts and that's the only thing I bought, other than an extra battery and a new charger. It made it a much stronger cart. Mine has 22" tires and is used mostly in the woods.

The factory motor eventually started getting hot on hard trips. I carried a laser thermometer and and read 240 degrees on the motor casing a couple of times. It's very possible that running it on 42 had nothing to do with that, and I was just working the motor too hard.

At any rate, I decided to get an Admiral motor and that solved all the issues. Good luck with it.

[kgsc]

Could you put a 6 volt zener diode in the solenoid activation circuit to drop it to 36?

[Volt_Ampere]

Originally Posted by kgsc

Could you put a 6 volt zener diode in the solenoid activation circuit to drop it to 36?

You could do that. You would have to know the current requirements and make sure that the Zener could handle the power dissipation. I would bet that most solenoids could handle the extra 6 V on the coil anyway. There are a bunch of Western 42V carts here in Rio Verde.

[scottyb]

The Western carts used 48v controllers and solenoids. Most solenoids will handle under voltage better (longer) than over voltage.

[Volt_Ampere]

Originally Posted by scottyb

The Western carts used 48v controllers and solenoids. Most solenoids will handle under voltage better (longer) than over voltage.

Good to know. I have a buddy with one of these that wants to upgrade to Lithium. Sounds like he can go to 48V without worrying that his solenoid and controller are underrated.

[scottyb]

Originally Posted by Volt_Ampere

Good to know. I have a buddy with one of these that wants to upgrade to Lithium. Sounds like he can go to 48V without worrying that his solenoid and controller are underrated.

If you mean he wants to run a 36v controller and solenoid on 48v no, those 36v components should not last long on 48v. I say should not because we have occasionally heard from the owner who says he has been running 48v in his 36v cart for years but the majority say it lasted a little while then let the magic smoke out - it's a craps shoot

[Volt_Ampere]

I meant my buddy with a Western cart. You said they have 48V controller and solenoid.