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?

BGW

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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.

ROACH87

would those wires need to be upgraded if the cart was upgraded to 48V since there would be more voltage going the wires from the charger?

Paxdad

4 gauge is plenty for 48V especially if it is welding wire. The 6 gauge wires from the charge receptacle to the battery pack do not need to be upgrades as they are fine wire already if they are the stock cables.

scottyb

You can leave your old charger wires but, new wire would be nice....
Your logic is perfect on the F&R and motor wires. Glad to see someone using their head for more than a hat rack How about a pic of the battery bay?

ibelieve

Is there any reason to not leave both sets of cables on if you are upgrading? It would seem like doubling up on 6 ga. would be about the same as using 4 ga. Or just leave the 6 ga. on when you add the 4 ga. I would think the more copper you have the better unless there is an issue with the connections.

/Steve

scottyb

The old cables are likely just that. OLD and filled with interior corrosion and thus resistance..... The 4ga alone is good enough.