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Originally Posted by JohnnieB
The controller in the picture is a Curtis 1206SX so you have a 1994 TXT DCS.
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Thank you very much! Really appreciate the information. There was no marking on it so I couldn't really tell what controller it was.
Quote:
Originally Posted by JohnnieB
The picture also shows the front panel of the controller is bowed away from the top panel, possibly indicating overheating has occurred.
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I went back to take a closer look and you indeed have a very good eye. It is indeed bowed from away from the top panel. On closer inspection the top of the unit there is indeed evidence of overheating. The white plug on the top closest to the second cable on the right (in the photo) shows evidence of heat as well. You are correct that overheating has occurred.
The cart is 25 years old so I am not surprised. As well, prior to my ownership it wasn't well taken care of.
Quote:
Originally Posted by JohnnieB
The DCS controller was a failed design, so going to an aftermarket controller in the near future is definitely a good idea.
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Now I have the evidence to support my case for a new controller with my wife. :)
Quote:
Originally Posted by JohnnieB
All cart slow on inclines, some drive types more than others. Series drives slow the most and AC drive slow the least. Sepex drives, like the DCS, are someplace between the two extremes.
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I am not looking to fly up hills really. Just want to be able to get up them without burning the motor/controller up.
Quote:
Originally Posted by JohnnieB
Tires taller that stock height (18") cause carts to slow more going uphill, as do weak batteries, undersized high current cables and high current cables in poor health.
You haven't mentioned your tire height, are they 18" tall or are they taller?
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I failed to read your guidance on this forum in other threads prior to putting on a RHOX LIFT-100 6" lift and put 14"x23" Duro off-road tires. The new wheels will slow it down going uphill for sure. Hopefully, it won't cause additional issues.
Quote:
Originally Posted by JohnnieB
The cables seen in the picture are in poor health and if they are the original ones, some were 6Ga.
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Again, good eye! I didn't notice but, the wire on the far left does indeed have some issues. The cables to the controller are also original and have not been touched as far as I can tell.
The cables on the batteries are new but, the ones running from the two main posts to the controller are original. The ones on the batteries are red. I have included a photo of them. There is no writing on the wires so I don't know what gauge they are.
Quote:
Originally Posted by JohnnieB
All 10 high current cables need to be 4Ga or thicker. (Note: If 48V might in future, get cable set for a 6 x 8V battery pack, the cables connecting batteries together have to be longer for 8V batteries since they have both terminals on same side.)
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The only new wires that I see are they 5 on the battery pack. I am assuming the other 5 that need to be replaced are the 2 coming off the batteries to the controller. The one that is has the stress on it that is running from the solenoid and the 2 big ones that run to the motor. Correct? (I am a noobie so bear with me. :) ) Ok, educated myself and watched which explains which wires need to change.
https://www.youtube.com/watch?v=pb-6XQfqH3w
If all my wires suck and need to be changed what is the best kit to get to support 48v as suggested? Sourcing parts in Ontario, Canada is a pain. If there is a specific set you can point me to it will make it easier to find here. Part numbers generally match up but, not always for some reason.
Quote:
Originally Posted by JohnnieB
The solenoid shown in picture has an 85A rating, needs to be 200A or greater. (More on this later)
The stock DCS motor has good torque, can handle a 500A controller and loves a 48V battery pack, so other than new brushes and bearing and cleaning, it'll probably suffice unless you have taller than stock height tires.
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I have taller than stock tires. :( I am more mechanically than electronically inclined so I did the lift and wheels without thinking about the overall impact.
Quote:
Originally Posted by JohnnieB
Nobody except you can answer the question if 36V is going to provide the performance you want, so the trick is to maximize the performance at 36V with new cables, controller and solenoid while creating a pathway to 48V at minimal expense when you are ready to buy new batteries. Do it right and the only expense is a new battery charger and cost difference between 6v and 8V batteries.
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Ok. Your recommendation gives me an excellent path forward.
1. New cables.
2. New controller and solenoid.
3. See what happens. If happy with performance stop. If not happy go to step 4.
4. Put in 6x8v to get to 48v and new charger.
Now, this is if I don't have to change the motor. If I have to change the motor because of my tire upgrade which motor should I get. I am assuming one that can operate on 36v and 48v. But, which one?
Quote:
Originally Posted by JohnnieB
The controller, Navitas or Alltrax, work at 36V and 48V. Only a few setting need to be changed. (I prefer the Alltrax, but if Navitas is local to you, it might be a good choice.)
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If Alltrax which model specifically is the best to go with for this cart? If I can source one here in Canada I would consider it. All the research I have done points to the direction of Alltrax. Navitas is a good choice too but, I can't find hundreds of videos of the install of one.
Quote:
Originally Posted by JohnnieB
As mentioned earlier, get cable set for 48V pack, they will work with a 36V pack.
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Will order once I figure out which ones to get and find a source in Canada. :(
Quote:
Originally Posted by JohnnieB
Get a MZJ400-48V solenoid. It will work at 36V and 48V later.
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Check.
Quote:
Originally Posted by JohnnieB
BTW: There is a market for used 36V battery chargers.
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Problem is one of the largest golf cart dealers is only 10-15 drive from my house and they just posted on Kijiji a photo of about 30+ 35v EZGO chargers. They are a dime a dozen in my zone (Greater Toronto Area) as a result. The good news is that if I need used parts they have a yard full of old EZGO cart parts. Cowels, tie rods, etc...
Again, thank you for all the help. I really appreciate it a lot. I am a complete and utter newbie when it comes to all this stuff.
Cheers,
Impaled