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Unread 12-11-2015, 08:15 PM   #1
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Default Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

I apologize in advance if this topic has already been posted. I may or may not have a unique setup but here is what I have.

2001 Club Car DS (series) with MCOR
6" lift w/ 23" AT tires
rear seat
48 Volt system
36 volt club car motor
400 amp controller
what I think is a stock solenoid...

Now that I have larger tires on the cart I can sometimes smell what I believe are the wires getting hot when I have a full load (4 people) and trying to maintain full speed/WOT. I have 4ga going between the batteries now and just bought a set that includes the positive and negative to go to the solenoid and controller.

My question is do I also need to make the wires going from the controller and to/from the F/R switch 4GA as well or are the 4 ga wires through the battery pack and to the solenoid and controller sufficient?

Any help is appreciated and again, I apologize if this is a duplicate post.
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Unread 12-11-2015, 08:18 PM   #2
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Default Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

Use the same size cables on all high amp draw cables. You may also need a HD F R. Switch.
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Unread 12-11-2015, 08:23 PM   #3
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Default Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

Ok, Thanks!! That was quick mrgolf. I will get these wires in now and get the F R switch and wires ordered. For these cables that are so long is it worth ordering pre-made or having them made. If so, who would you recommend?

Also, I live in FL so the terrain is flat
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Unread 12-12-2015, 12:01 AM   #4
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Default Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

I would give Scotty at Carts Unlimited (site sponsor page) a call. He has the F+R switch you need and knows the cable lengths you need and can provide them. Also, before you call, check the amp rating of that solenoid. With a 400 amp controller you may need to upgrade it to avoid future trouble.

.
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Unread 12-12-2015, 06:21 AM   #5
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Default Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

I agree
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Unread 12-12-2015, 08:15 AM   #6
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Default Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

I appreciate the help!! How do I check the amperage of my solenoid? What is the stock amperage of a 48 v CC solenoid?
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Unread 12-13-2015, 04:08 PM   #7
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Default Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

Just guessing but I think that smell is your motor getting hot.
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Unread 01-03-2016, 09:41 PM   #8
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Default Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

So I upgraded the solenoid (thanks to carts unlimited) and got all new wires at a local battery shop. The lengths, in case anyone else plans to get cables made, are 1x48" 3x54" 1x16" and then cables to connect to the batteries and through the series. Note, I went a little longer with the cables as I do have a 6" lift and didn't want anything to be tight. Thanks again to those who helped out. Love this site
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Unread 06-13-2016, 07:52 PM   #9
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Default Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

Well, I melted a post off one of my batteries I have 4GA wires throughout on my cart but some were still getting hot. Could this be because the wires going between the batteries could be cheap? I had a battery shop make the long wires with welding wire for everywhere but between the batteries.

Cart Specs:
6" Lift w/ 23" AT tires
36 v CC motor
48 system
HD Solenoid
HD F/R switch
4GA throughout
2001 CC DS

I have installed a HD F/R switch as well. The welding cables will stay cool with the exception of two that make the forward connection at the F/R switch, these get warm, but not to the point of melting.

I guess what I'm really trying to figure out is if there is something else wrong or just cheap cables between the batteries. The battery cables were purchased from someone on eBay. Slowly learning my lesson that you get what you pay for...

I have triple checked all the connections, all of which were very tight. Thank you in advance for any help.
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Unread 06-13-2016, 08:16 PM   #10
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Default Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid

Your wires should never get warm or hot. Your drawing high amps for some reason, poor connection, motor drawing too much, too much load maybe. Have you checked the motor heat after a run?
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