4 Guage Cables

AndyT

I was in the process of upgrading my ('85 36V EZ-GO) battery cables to size 4 awg when it occurred to me that I needed to upgrade ALL cables that carry current to the motor, not just the 5 that connect between the batteries. This would include the cables to the F/R switch, the solenoid, through the coils, and directly to the motor. In all, I upgraded 16 cables ranging from about 6 inches to 2 feet long.

My thinking was that the heavy current flows through the whole circuit to get to the motor, not just between the batteries. And the longer cables (which would have higher resistance and thus voltage drop) are actually the ones to the resistor pack and to the motor.

In the end the only cables I did not change from size 6 to size 4 are the ones that go from the charger receptacle to the batteries because they are not carrying as much current when the cart is charging.

This cable upgrade took a little more time than I originally planned on because I made all the new cables myself. I crimped and soldered each end, and marked each with heat-shrink wire markers. Looks nice, and I was able to use different color cables for battery, motor, and speed control.

Now I'm waiting for my new resistor assembly and motor parts to arrive so I can put it all back together and test it out.

Any thoughts on my rationale to upgrade the coil cables and motor cables in addition to the battery cables? Was I thinking right, or did I just spend time and money for nothing?

buckmanmike

sounds like your doing good. Heavy gauge wiring is always good on high amp circuits. But why replace old style resistor when you can go to newer controller. Good luck. There are kits to do the conversion. I have the parts to convert, just no time. Looking at Thanksgiving wked to accomplish.