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Old 05-15-2010, 03:52 PM   #1
kdeerman
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Default cable lengths for 2004 EZGO TXT Series

Just finished adding 4 gauge cables to my 2004 EZGO TXT Series cart. I made them myself from 4 gauge welding cable. The wires from battery to battery were done already, but I replaced all the rest with 4 gauge. My cart still has the stock Curtis controller for now.

I have previously read posts asking for an estimate to order new cable.

The lengths were as follows; ('inside' references terminal toward inside of cart, 'outside means terminal toward outside of cart)

Controller (B+) to Solenoid (outside) = 7.5 "
Controller (B+) to FNR (bottom) = 20"
Battery Pack (+) to Solenoid (inside) = 29"
Battery Pack (-) to Controller (B-) = 38"
Controller (M-) to Motor (A1) = 56"
FNR (outside) to Motor (S1) = 46"
FNR (top) to Motor (A2) = 45"
FNR (inside) to Motor (S2) = 43"

If you order new cable using the lengths above, don't forget to add enough for the cables from battery to battery.
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Old 05-22-2010, 10:33 AM   #2
cdb770
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Default Re: cable lengths for 2004 EZGO TXT Series

Quote:
Originally Posted by kdeerman View Post
Just finished adding 4 gauge cables to my 2004 EZGO TXT Series cart. I made them myself from 4 gauge welding cable. The wires from battery to battery were done already, but I replaced all the rest with 4 gauge. My cart still has the stock Curtis controller for now.

I have previously read posts asking for an estimate to order new cable.

The lengths were as follows; ('inside' references terminal toward inside of cart, 'outside means terminal toward outside of cart)

Controller (B+) to Solenoid (outside) = 7.5 "
Controller (B+) to FNR (bottom) = 20"
Battery Pack (+) to Solenoid (inside) = 29"
Battery Pack (-) to Controller (B-) = 38"
Controller (M-) to Motor (A1) = 56"
FNR (outside) to Motor (S1) = 46"
FNR (top) to Motor (A2) = 45"
FNR (inside) to Motor (S2) = 43"

If you order new cable using the lengths above, don't forget to add enough for the cables from battery to battery.
Did you use all 1/4 inch, 4/0 AWG lugs on you cables? Getting ready to replace all my other wires in the cart, I noticed after I put the lift on and climbed a few hills that some of the wires were getting pretty warm. Just want to know what grocery list of parts I will need to finish it off right, and not make a million trips back and forth to the store.
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Old 05-22-2010, 03:36 PM   #3
kdeerman
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Default Re: cable lengths for 2004 EZGO TXT Series

Quote:
Originally Posted by cdb770 View Post
Did you use all 1/4 inch, 4/0 AWG lugs on you cables? Getting ready to replace all my other wires in the cart, I noticed after I put the lift on and climbed a few hills that some of the wires were getting pretty warm. Just want to know what grocery list of parts I will need to finish it off right, and not make a million trips back and forth to the store.
cdb770,
They were all 4/0 AWG, but they had 5/16" openings - I believe that the 1/4" is too small for the battery, controller, FNR switch and motor terminals.

The 4 gauge cable cost me about $32, but I already had the 'battery to battery' cables. If I had it to do over again, I would have used 2/0 AWG, in case I wanted to upgrade further later. I believe the cost of the 2/0 AWG cable was around $60.
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Old 05-22-2010, 08:50 PM   #4
cdb770
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Default Re: cable lengths for 2004 EZGO TXT Series

Quote:
Originally Posted by kdeerman View Post
cdb770,
They were all 4/0 AWG, but they had 5/16" openings - I believe that the 1/4" is too small for the battery, controller, FNR switch and motor terminals.

The 4 gauge cable cost me about $32, but I already had the 'battery to battery' cables. If I had it to do over again, I would have used 2/0 AWG, in case I wanted to upgrade further later. I believe the cost of the 2/0 AWG cable was around $60.
Thanks, already bought the 4/0 cable this afternoon, and ordered an assortment lug sizes online since every where around me had only packs of two, and only one package in the whole store, lol. I need to replace the Club Car cables anyway so they will go to good use some where. Thanks again!
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