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Electric Club Car Electric DS, and Precedent golf cars |
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12-11-2015, 08:15 PM | #1 |
Not Yet Wild
Join Date: Sep 2012
Posts: 56
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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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12-11-2015, 08:18 PM | #2 |
Old Sky Soldier
Join Date: Dec 2011
Location: Kentucky
Posts: 3,881
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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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12-11-2015, 08:23 PM | #3 |
Not Yet Wild
Join Date: Sep 2012
Posts: 56
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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 |
12-12-2015, 12:01 AM | #4 |
Gone Wild
Join Date: Apr 2014
Location: Oregon City, Or
Posts: 1,977
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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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12-12-2015, 06:21 AM | #5 |
Old Sky Soldier
Join Date: Dec 2011
Location: Kentucky
Posts: 3,881
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Re: Upgrade to 4ga all around or just on batt pack and to controller & Solenoid
I agree
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12-12-2015, 08:15 AM | #6 |
Not Yet Wild
Join Date: Sep 2012
Posts: 56
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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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12-13-2015, 04:08 PM | #7 |
Gone Wild
Join Date: Feb 2011
Location: Chattanooga TN
Posts: 2,105
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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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01-03-2016, 09:41 PM | #8 |
Not Yet Wild
Join Date: Sep 2012
Posts: 56
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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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06-13-2016, 06:52 PM | #9 |
Not Yet Wild
Join Date: Sep 2012
Posts: 56
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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. |
06-13-2016, 07:16 PM | #10 |
Gone Wild
Join Date: Jan 2014
Location: Lafayette, Louisiana
Posts: 1,677
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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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Tags |
4 ga, 4 gauge, lift kit, wires |
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