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Old 06-19-2012, 09:50 AM   #1
tyhuck
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Default 4g Conversion needs some parts

I have been replacing all of my battery cables with 4g welding wire. The battery and motor leads are easy, but the wire that goes on the "sweeper" part of the accelerator and the two wires on the charger plug have me stumped. Does anyone make replacement cables, or sell the crimpable ends, to convert those parts to 4g?

Or, is it even worth it to convert those wires? To me it seems like they would be a restriction if not scaled up with the rest of the cables.
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Old 06-19-2012, 06:22 PM   #2
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Default Re: 4g Conversion needs some parts

There is no need to convert these wires to 4g. They don't have the current flow the batteries and motor demand.
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Old 06-19-2012, 07:59 PM   #3
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Default Re: 4g Conversion needs some parts

So the wire on the sweeper arm doesnt affect any flow on the motor? Isnt that where to current comes from that is passed through the resistor?

I know the others dont because current only flows through them during charging, but I really dont know how the cart works beyond the basics of the sweeper contacts and the resistor.
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Old 06-19-2012, 09:05 PM   #4
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Default Re: 4g Conversion needs some parts

Have you checked the schematics at the top of the section guide? You can follow the power line from the batteries to the motor. Maybe that can better answer your question.
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Old 06-19-2012, 09:55 PM   #5
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Default Re: 4g Conversion needs some parts

It kinda helped, but the diagram isnt exactly like my cart is wired, so it makes it hard to follow the current. I guess Im gonna have to reassemble the cart and then trace it down.
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Old 06-20-2012, 06:52 AM   #6
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Default Re: 4g Conversion needs some parts

Here are a couple of the best diagrams for a resistor cart that I've found.
They are both electrically the same, but each shows different parts of the circuits more clearly.

The wires from the charger receptacle only carry about 20 Amps, so 12Ga (or bigger) is sufficient.

The cable from the solenoid to the wiper arm carries total motor current, so it should be same gauge as rest of high current cables.

EZGO sells replacements, but they are probably 6Ga.
http://www.shopezgo.com/products/Wiper-Contact.html

Give Scottyb a yell. http://www.cartsunlimited.net/
He will most likely know if anybody has that cable assembly in a heaver gauge or the components needed to build one.
Attached Images
File Type: jpg Resistor cart - Schematic.JPG (87.4 KB, 0 views)
File Type: jpg Resistor cart - Wiring Diagram.JPG (89.3 KB, 0 views)

Last edited by JohnnieB; 06-20-2012 at 06:58 AM.. Reason: Forgot attachments
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Old 06-20-2012, 09:15 AM   #7
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Default Re: 4g Conversion needs some parts

OK, so all of the diagrams Ive seen so far show the motor power feed coming from the sweeper board contact 4. My cart feeds the motor from the resistor stud 4. Is this something I should replace, or is it all the same since the current isnt actually going through any of the resistor coils?
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Old 06-20-2012, 09:48 AM   #8
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Default Re: 4g Conversion needs some parts

It is the same point electrically.
I'm not sure, but you may have to choose between shorter cables or a current path with fewer connections in it.
If it were my choice, I'd go with fewer connections. (As shown in drawings)
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Old 06-20-2012, 11:59 AM   #9
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Default Re: 4g Conversion needs some parts

Cool, Thanks.
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Old 07-03-2012, 09:40 PM   #10
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Default Re: 4g Conversion needs some parts

Quote:
Originally Posted by JohnnieB View Post
It is the same point electrically.
I'm not sure, but you may have to choose between shorter cables or a current path with fewer connections in it.
If it were my choice, I'd go with fewer connections. (As shown in drawings)
Would it help, or for that matter hurt, anything to run a wire from both points to the motor?
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