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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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06-12-2013, 03:26 PM | #1 |
Not Yet Wild
Join Date: Apr 2013
Posts: 27
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2002 ezgo pds battery cable upgrade
I have a new to me 2002 ezgo pds 36 volt stock golf cart. I use the cart on flat terrain on paved and dirt roads. The cart is lifted with 22 inch tires. I want to change out the stock battery cables with 2 or 4 guage cables. I will eventually upgrade controller if needed when the stock one quits to a 400 or 500 amp controller and possibly upgrade the motor later on. Are the stock cables sufficient for the stock controller and motor or would heavier cables help performance? Besides the obvious cables that connect the batteries what other cables should I change out? How many high voltage cables are there in a 36 volt pds cart? Should I change the cables that go to the controller and the motor as well? Just wanted to get the most out of my stock cart. Should I go with the 2 guage or 4 gauge? Any help would be much appreciated. Thanks
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06-12-2013, 05:15 PM | #2 |
Gone Wild
Join Date: May 2013
Location: Mississippi
Posts: 301
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Re: 2002 ezgo pds battery cable upgrade
If you plan on controller/motor upgrades in the future, you need to go ahead and buy 2 ga. cables, so you only buy cables once. ScottyB has great cables. He also has Alltrax controllers & sells D&D motors. They can be found here:
http://www.cartsunlimited.net/Batter..._Upgrades.html Oh yeah.....welcome to BGW!! |
06-12-2013, 06:16 PM | #3 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 2002 ezgo pds battery cable upgrade
There are 10 high current cables on a PDS cart with six batteries, 11 with seven batteries and 12 with eight batteries.
Replace all of them with 4Ga or heavier. The F1&F2 cables from controller to motor only carry about 1/10 the amps as the A1&A2 cables, so they are adequate and don't have to be replaced, unless the insulation is worn where they are routed around the battery frame. 22" tires up the speed by about 20% and reduce torque by same percentage. Going to a 400A amp aftermarket controller will return the lost torque and unlike with the stock PDS controller, the motor is not limited to 4,400 RPM. so you should see speeds in the 20's. |
02-16-2014, 11:41 PM | #4 | |
Gone Wild
Join Date: Jan 2014
Location: FL
Posts: 294
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Re: 2002 ezgo pds battery cable upgrade
Quote:
I also noticed that the stock cable from the controller to the motor (F1, F2) are 4 g cables. Do those need to be increased to 2 g if I wants to increase the other cables to 4 g? |
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02-17-2014, 07:03 AM | #5 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 2002 ezgo pds battery cable upgrade
Quote:
There are 5 High Current cables that connect the battery pack to the motor via the solenoid and controller; And there 5 High Current cables that interconnect six 6V batteries into a 36V battery pack and one addition High Current cable is needed for each additional battery added to the pack. Therefore: A 36V system has 10 High Current cables, a 42V system has 11 and a 48V system has 12. All 10 ( or 11, or 12) High current cable should be at least 4Ga for controllers under 500A and at least 2Ga for 500A controllers and above. Technically, the A1 and A2 cables carry Total Amps less what is carried by the F1 & F2 cables, but they are the longest cables, so they should be the same size as all the other High Current cable. |
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02-17-2014, 12:36 PM | #6 | |
Gone Wild
Join Date: Jan 2014
Location: FL
Posts: 294
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Re: 2002 ezgo pds battery cable upgrade
Quote:
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02-17-2014, 01:05 PM | #7 | |
Master of All Things
Join Date: May 2013
Location: West Columbia, Texas
Posts: 17,892
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Re: 2002 ezgo pds battery cable upgrade
Lets go back to YOUR original question.....You stated:
Quote:
but just in case.....get you new cable sets from ScottyB at Cartsunlimited.net and here is the link again.....you really need kit #11 or kit #10 if you are going to go with 4 ga. http://www.cartsunlimited.net/Batter..._Upgrades.html |
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02-17-2014, 01:10 PM | #8 | |
Gone Wild
Join Date: Jan 2014
Location: FL
Posts: 294
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Re: 2002 ezgo pds battery cable upgrade
Quote:
I saw your other post and appreciate the link. When you say matched cables, do you mean matched from the same manufacturer, size and cable age? Or do you just mean size? Because the stock cables from the controller to motor are already 4g. If I upgrade the other cables, then everything will be 4g. |
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02-17-2014, 01:58 PM | #9 | |
Master of All Things
Join Date: May 2013
Location: West Columbia, Texas
Posts: 17,892
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Re: 2002 ezgo pds battery cable upgrade
Quote:
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02-17-2014, 02:46 PM | #10 |
Gone Wild
Join Date: Jan 2014
Location: FL
Posts: 294
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Re: 2002 ezgo pds battery cable upgrade
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