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Electric pallet jack battery cable issue, need to temporarily fix asap #5429575 05/15/20 02:13 AM
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wing0 Offline OP
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Helping out my father who has a Hyster electric pallet jack, I think it's w60z model.
He wanted me to help with adding distilled water to the 4 batteries, which are 6v GC2 model typically used in golf carts as far as my research goes.

After swinging the first battery on its own arm mechanism to get to the one below it like this
[Linked Image from i.ibb.co]

One of the cables connected to the terminal via lug of the top battery broke most likely due to corrosion(I also saw ppl mention golf cart cables have the same issue)
The cable is marked as 6 AWG or 6-gauge, which is also typical for golf carts.
[Linked Image from i.ibb.co]

Would it be ok to get a 4-gauge car battery cable like these? I cannot find 6-gauge cable at least not searchable within the hardware stores around me and I want to avoid crimping the lug if possible due to lack of crimping tool.
https://www.canadiantire.ca/en/pdp/motomaster-top-post-battery-cable-4-gauge-0110931p.html#srp
https://www.canadiantire.ca/en/pdp/...-battery-cable-4-gauge-0110961p.html#srp

My father needs it in about 9 hours from now to unload pallets and I was thinking of heading to hardware stores to grab supplies in the early morning and fix it up before heading to work myself.
Would it be okay to temporarily replace this cable so that the batteries can be in a series again, charge it up and use it for 1 day?
Do I need to replace the other cable to the same battery with 4-gauge as well or just replace the bad one is fine and won't cause issue?

Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429581 05/15/20 03:05 AM
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wrcsixeight Offline
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You can certainly get it working with that, but that one end, is stamped steel with a hole drilled through it. They rust, and are pretty resistive even when new, and sae 4 gauge is 6 to 12% thinner than 6 AWG.

If copper earns a score of 100 on electrical conductivity, steel is down around 10.

http://eddy-current.com/conductivity-of-metals-sorted-by-resistivity/



The other series connections could be as fragile. Ideally, when you have time some time and $ to do it right, ...

http://www.genuinedealz.com/custom-cables

[Linked Image from genuinedealz.com]

You do not want stranding visible. Your broken ring terminal was quick and dirtily done. Proper cable termination requires proper tool$ product, and technique.

Proper can be taken to extremes.



https://marinehowto.com/making-your-own-battery-cables/

What you can get away with, is subjective.

Good luck

Last edited by wrcsixeight; 05/15/20 03:06 AM.


Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429603 05/15/20 05:48 AM
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vwmaniaman Offline
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Get a copper lug connector with a screw on the top. Clean up the end of that cable good so it can make a good connection.


Don't waste your time on a slipshod repair.
Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wrcsixeight] #5429636 05/15/20 07:02 AM
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wing0 Offline OP
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Originally Posted by wrcsixeight
You can certainly get it working with that, but that one end, is stamped steel with a hole drilled through it. They rust, and are pretty resistive even when new, and sae 4 gauge is 6 to 12% thinner than 6 AWG.

If copper earns a score of 100 on electrical conductivity, steel is down around 10.

http://eddy-current.com/conductivity-of-metals-sorted-by-resistivity/



The other series connections could be as fragile. Ideally, when you have time some time and $ to do it right, ...

http://www.genuinedealz.com/custom-cables

[Linked Image from genuinedealz.com]

You do not want stranding visible. Your broken ring terminal was quick and dirtily done. Proper cable termination requires proper tool$ product, and technique.

Proper can be taken to extremes.



https://marinehowto.com/making-your-own-battery-cables/

What you can get away with, is subjective.

Good luck


Thanks for the info.
The cable is from factory and the other ones look to be in better shape. I will still try and find a 6-gauge cable, but it's more of a time constraint thing.

Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: vwmaniaman] #5429639 05/15/20 07:08 AM
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wing0 Offline OP
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Originally Posted by vwmaniaman
Get a copper lug connector with a screw on the top. Clean up the end of that cable good so it can make a good connection.


So far I only found crimp or solder style lugs on hardware website like this
https://www.canadiantire.ca/en/pdp/motomaster-copper-lug-terminal-4-gauge-0111078p.html

Can you show me a pic of the style you're referring to?
I assume the screw will be used to crimp. The rest of the cable? The cable is actually quite tight fit and if I try to add a lug to it after cutting off the blue sleeve portion, it will not likely be able to reach the terminal anymore.

Only this cable seem to be this tight based on routing.

Last edited by wing0; 05/15/20 07:08 AM.
Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429649 05/15/20 07:18 AM
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mk378 Online Content
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There's no problem replacing a 6 ga cable with 4 ga since more conductor is better anyway (wire gauge is like shotgun bore or golf score, lower number is more). If the existing cable ends up too short to put a new terminal on, make up a new cable with two screw on terminals.

You keep saying golf cart which hints what sort of local dealer may have these items.

Last edited by mk378; 05/15/20 07:21 AM.
Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429650 05/15/20 07:18 AM
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andyd Online Content
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A 4awg cable is HEAVIER than 6Awg. The lower the AWG,the Heavier the cable. Also that crimp on lug shown is NOT steel, it's tinned copper. grin2


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Thick oil is better grin2
Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429657 05/15/20 07:28 AM
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eljefino Offline
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The only issue I see is metal fatigue the next time you swing those batteries out.

These connections are never great-- one gets stress points just beyond the lugs, and corrosion makes it worse, as you see.

Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: eljefino] #5429682 05/15/20 08:14 AM
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wing0 Offline OP
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Originally Posted by mk378
There's no problem replacing a 6 ga cable with 4 ga since more conductor is better anyway (wire gauge is like shotgun bore or golf score, lower number is more). If the existing cable ends up too short to put a new terminal on, make up a new cable with two screw on terminals.

You keep saying golf cart which hints what sort of local dealer may have these items.


Originally Posted by andyd
A 4awg cable is HEAVIER than 6Awg. The lower the AWG,the Heavier the cable. Also that crimp on lug shown is NOT steel, it's tinned copper. grin2




Thanks guys.
Do I need a pair? Or just one cable is ok for time being?

Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: eljefino] #5429683 05/15/20 08:15 AM
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wing0 Offline OP
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Originally Posted by eljefino
The only issue I see is metal fatigue the next time you swing those batteries out.

These connections are never great-- one gets stress points just beyond the lugs, and corrosion makes it worse, as you see.


It's mostly due to the routing and I had to swing this battery a full 90 degrees to get full access to the bottom battery to add water. Bad timing frown

Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429698 05/15/20 08:31 AM
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In the future, disconnect that lug before swinging the battery all the way out (or moving it at all, if you can reach it). If you replace the cable make one long enough to have a loop over the top of the battery and come back to the terminal, then the loop will take up the flex of moving the battery.

Having it short and clamped to the frame like it is isn't helping.

Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429725 05/15/20 09:01 AM
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Jethro_Bob Offline
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A 4 gauge cable is thicker than 6 gauge, if it fits and is flexible enough is could easily be a suitable permanent fix.

Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429741 05/15/20 09:25 AM
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Smaller gauge #, heavier wire, is always better...

Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429744 05/15/20 09:28 AM
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spackard Offline
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> Do I need to replace the other cable to the same battery with 4-gauge as well or just replace the bad one is fine and won't cause issue?

It's fine to replace just one 6GA cable with one 4GA cable.
In fact, once you buy it and are trying to install it you'll probably be thankful to only have to do one, as the thicker cable will
be more of a pain than the original one to bend and route in the same place as the original.

Re: Electric pallet jack battery cable issue, need to temporarily fix asap [Re: wing0] #5429766 05/15/20 10:00 AM
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IMSA_Racing_Fan Offline
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If you used your head should have fixed it without wasting your time and others with a thread.
Get two washers, split the cable 1 inch or more, put one washer on the stud, sandwich the stud, zip tie the cable on both sides of the stud so it doesn't spread, now the other washer and nut. Get back to work.


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