PDS Cart Wiring question(s)

[hitmanharleyk]

Originally Posted by gornoman

OK, pay attention. Standard issue from E-Z-Go is 6g cable throughout, EXCEPT on DCS/PDS carts where they use 6g on the batteries and to the controller, and 4g from the controller to the motor. Replace them ALL anyway because they don't use high strand count cable and the lugs are junk.

I got a customer (Truck Shop) who buys all the parts from me to make up there own cables, I think I'll take mine off and get them to make me some up that way I know I'll have cables made out of the best possible components !!!

Do I need 4 ga. terminals with a 1/4" stud or for a 3/8" stud ?

Also will it cause me any problems if I use double insulated cable due to tight area's ?

[roady89]

Neither. Use 5/16.

[hitmanharleyk]

Originally Posted by roady89

Neither. Use 5/16.

Cool, we have those that are good for up to 600V and 4 ga. cable good for 60V in their shop.

[gornoman]

Originally Posted by hitmanharleyk

Cool, we have those that are good for up to 600V and 4 ga. cable good for 60V in their shop.

Typo???

[hitmanharleyk]

Originally Posted by gornoman

Typo???

Might be !

That is the minimum volt rating on the cheaper one they stock not the amps and with my cart being 36v, I figured that would be plenty.
They have 2 different strand counts. 1 has 420 and is really flexible, it can be tied in a knot like a rope (up to the 2/0 size) and the other is more of a standard cable with 425 strands in the 4 ga. size


They have some that is UL rated at 2000v and 600v for continuous service, but they only stock 2/0 and that might be a little big for my application

[hitmanharleyk]

I now have 4 ga cable on top of the batteries, from the batteries to the solenoid/controller and from them to the motor, This should take care of whether or not I have heavy enough cables on my cart and eliminate that from causing my controller and/or motor going out prematurely.

I made the cables myself with copper lugs soldered onto double insulated cable, I also put some heat shrink on to clean up the look.


They look good enough I might make up a few sets to try on Ebay or to show some of the local cart dealers ! Here's the cable and lugs I used.

[scottyb]

I see you soldered the lugs to the cable. That is the best connection in my opinion. I have one set that I installed a year ago and sprayed them with a a 'marine' lube...they collected a little dust but not one bit of corrosion due to no air getting to them ......Since then I have changed to spraying with Marine Varnish (no dust collection) ...we will see.

[gornoman]

A correctly soldered connection is the best, IMHO.

[hitmanharleyk]

Originally Posted by gornoman

A correctly soldered connection is the best, IMHO.

I put a little heat on the lug and just melted the solder into it until it was about 3/4's full, then I plunged the cable in and topped it off. I cleaned up and overflow with the wire brush on my bench grinder.

I also coated all of the ends on the battery studs with some battery terminal protector and then I put a lite coat of Vaseline on each.


But I am curious about the 1st product on this attachment, I might have to get some to try.

[scottyb]

A friend uses somthing that looks like that but, in a spray?