2007 Ez-Go TXT, PDS 36 volt - Complete Upgrade to 48 volt - BUILD

[bubba4dad]

Ok - I have purchased and received all the new components for my upgrade. Thank you Scottyb.

I have the following:

1.) XCT500PDS Controller
2.) 400a solenoid
3.) 2 gauge cable set
4.) ML3 speed control
5.) Digital Dash Meter
6.) Admiral B2 motor
7.) 48v x 12v Reducer
8.) Yewy 1200z onboard charger
9.) 6 new 8 volt Trojan Batteries

I plan on taking many pictures prior to, during, and after all upgrades are completed.

Now that I got that out of the way. I need to get started.

My first question is. Should I change out each part/cable one at a time or just remove all the old stuff and start fresh with mounting everything and wiring up?

[Sero]

I'd say it depends on your knowledge of how everything goes and the condition of the cart.
If the cart is older and/or has a lot of rust it would be a good time to pull everything out and take care of the rust. That's if you feel comfortable with being able to put it all back together.

If not I'd attack it in sections. Like do the batteries and cables together. Then the controller and solenoid. Then charger and voltage reducer. Or whatever grouping makes the most sense to you. That way you don't have too many components disassembled at one time.

[Sideways]

I recently upgraded to 48v on my Medalist, take more before pictures and angles of wiring than you think you will need.
I started by swapping part for part but ended up taking everything out as the new hardware was not exact to what was removed.
Do what you are comfortable doing first then take your time doing the rest.
Good luck and keep us posted.

[bubba4dad]

I have never done this before but I am a master electrician so wires don't scare me. lol To me its just parts and wires. I have a good wiring diagram and I have the knowledge to read and understand it.

I don't see any rust and its all fairly clean.

I was leaning towards tearing it all out and just going for it. I just wanted some input from people that have done it.

Worse case, I have a account on a forum that has the most knowledgeable people in the world on golf carts. LoL

[scottyb]

Go for it - that's the way I would do it. Tear everything you will replace out. and pressure wash the cart. While it's drying put the old parts on CL or BGW classifieds. Then Rustoleum black the exposed frame parts and install the electronics.

[bubba4dad]

Ok Scottyb I took your advice and ripped it all out. lol

I have my second question:

Is there a trick to pulling the motor?

I have removed all three bolts to the rear axle and it doesn't seem to want to come off. I don't want to force anything as I would hate to break the axle housing.

Here are my first pics as well.

[bubba4dad]

More Pics

[bubba4dad]

And a few more.

[Bkfiremedic]

I did the same with the help of Scottyb, the guy is awesome. I just didn’t replace the motor, or add the onboard charger or speed control. I have the alltrax sr48500 Very happy with my setup!!! And I’m no electrician lol


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[bubba4dad]

I’ve hit my next hurdle.

On my original solenoid there was a resistor across the two large posts. The new solenoid came with a diode jumper. For the 48 volts, do I need the resistor, diode, neither, or both?