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Old 11-16-2010, 07:45 PM   #1
adam64850
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Default Controller Install

I have a 1998 EZGO DCS and am installing a Alltrax 400amp the wiring diagram that came with the controller is different from the original setup, the difference is the small terminals on the solenoid. Could one of you experts check out the pictures and see if I'm going to blow up the house. I think this is the correct way but am doubting myself. Thanks.
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Old 11-16-2010, 09:00 PM   #2
golfcarfixer
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Default Re: Controller Install

PM Rabbitreborn and he can help you out,he is an ezgo guru.
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Old 11-16-2010, 09:04 PM   #3
scottyb
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Default Re: Controller Install

Yes that is correct.
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Old 11-16-2010, 09:06 PM   #4
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Default Re: Controller Install

adam64850, I cannot verify the wiring (although it looks correct to me), but I want you to change the stacking order of the large terminals on the solenoid. Move the large copper lugs to be closest-in on each terminal, and the control wires, diode and resistor lugs to be farthest-out on those terminals. The way you have it stacked you are forcing full system current (AMPS) through the thin lugs, and they are not sized for this duty.
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Old 11-16-2010, 09:43 PM   #5
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Default Re: Controller Install

That is an interesting thought Gornoman. I have always stacked them like Adam has, I'm not saying that is right but it has never been a problem. Another thought on the the thin lugs is that they are securely sandwiched between the source and home. So technically the amps do not see their thickness.... only that they exist as a clean usable path... Isn't the nut contacting the 4g lug and the stud? Sending the current directly into the stud which has the end contact on it? I'm wondering if it matters how you stack it .....

By the way, VERY NICE LOOKING CABLES, and clearly marked for easy installation, too.
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Old 11-16-2010, 10:59 PM   #6
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Default Re: Controller Install

Those are the best cables, you do a great job Scotty, thanks for your help. I installed the voltmeter and a radio this weekend and now as you can see I'm working on the controller and rewiring. I loaded some pictures so you can see the progress so far.
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Old 11-16-2010, 11:14 PM   #7
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Default Re: Controller Install

Adam, That looks great. I am currently building a 1995 Medalist. I wish I would have done my entire frame like you. I will use mine for hunting so it doesn't need to be pretty, but yours looks fine.
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Old 11-16-2010, 11:25 PM   #8
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Default Re: Controller Install

Quote:
Originally Posted by scottyb View Post
I'm wondering if it matters how you stack it .....
I cannot prove this technique in the slightest, it just makes perfect sense to me. Call it a gornoism of the anal variety, LOL. Someone could argue the current from the lug radiates equally in all directions, but at the end of the day the current still goes INTO the solenoid. Electrons will always seek the path of least resistance.

Ooops, there I go again....
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Old 11-16-2010, 11:31 PM   #9
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Default Re: Controller Install

I stack mine like Gorno. I don't know if it right, but I use the same theory that he uses. It just seems like it makes sense to me. As long as it works and doesn't fry anything I am happy.

David J.
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