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Unread 11-25-2012, 05:20 PM   #1
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Default battery cable help

I am not sure if I need to stick with 6 gauge wire for my 89 electric marathon . It is the older resister style . I just replaced the speed control board ( old swipe style ) and the resisters . A while ago we put new batteries in this thing and someone put 4 gauge wires on it . I have been restoring this cart so I have not been riding it at all since I replaced those parts . I replaced them cause the speed control was toast . I replaced the resisters because the 4 gear resister looked melted and was broken in two . Is it poss. that the 4 gauge wire on the batteries is too much ? I moved the cart a little today and smelt something burning... it seemed the resister box was hot and the 4 gear resister looks like it has gotten kinda warm ..... anyone?
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Unread 11-25-2012, 05:35 PM   #2
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Default Re: battery cable help

As long as the 4g cables are high strand count welding cable with properly installed copper lugs they are not your problem. If someone installed 4g distribution wire from a commercial electrical job, it could be an issue. Look for signs of heat at any connections.
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Unread 11-25-2012, 10:34 PM   #3
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Thank you ... I will change them out and check the connections ... You have any suggestions on pre crimped wires and where to buy ?
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Unread 11-25-2012, 10:57 PM   #4
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Wink Re: battery cable help

Do not, I repeat do not put auto cables on any cart. They are not meant for the amperage these carts produce. The cables shouldn't effect the swiper are anything as long as everything is correct. The new parts may smell some for awhile even if installed correctley. The old wiper boards are old school, very old school. Make sure non of the coils are touching each other.
Make sure the throttle rod is relaxed completely and the bottom stationary contactor shouldn't have anything connected to it.
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Unread 11-26-2012, 05:40 AM   #5
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Default Re: battery cable help

Many site sponsors can set you up with proper cables. Carts Unlimited hand builds custom cables to your specs, excellent quality.
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Unread 11-28-2012, 07:05 PM   #6
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Alright ...I just figured out that # 4 and 4/0 are different in number of strand count ..... Is #4 which has 392 strands ok to use to connect my batteries or do I have to use the 4/0 which has 2052 strands ?
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Unread 11-28-2012, 08:12 PM   #7
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Default Re: battery cable help

the 4/0 cables are listed as a 4 ought or 0000 they are way bigger.(say 2" diameter) that would be way over kill. what you want to look for is 4 ga or 2 ga welding cable that will be more than enough for your cart.

good luck.
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Unread 11-28-2012, 08:16 PM   #8
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Default Re: battery cable help

You want 4g Welding Cable with about 400 strands, not the 4/0g.
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Unread 11-28-2012, 09:24 PM   #9
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Great ... Then I don't have to return the #4 392 strand I ordered this morning .... Whew !... Thanks
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