Golf cart cables

Golf cart cables DEFAULT

Golf cart cables do not refer to the small gauge control wiring in your vehicle.  But rather, to the4 Gauge Golf Cart Cables heavier gauge cables to conduct power from the batteries through your electrical components to the motor.  Although traditionally at the 36V/48V level, 6 gauge golf cart power cables have been sufficient for STOCK applications; many high performance modifications require thicker gauge wires to conduct higher power levels.  We’ll discuss these high performance modifications and how determine the proper wire size for your application.

Most modern golf cars operate on a 36 volt of 48 volt battery bank.  For stock applications, most of the golf carts at this voltage range will utilize a 225A-300A electronic speed controller.  The size of the golf cart cables are generally dictated by amperage level, not voltage.  For stock applications, 6 gauge cables are used, for a good cost point as well as handling the current level. For the purpose of this discussion, keep in mind that the smaller the “Gauge” number, the thicker the cable.

Many owners modify their golf carts for higher speed, greater torque, increased height and all manner of other performance reasons.  Many modifications may increase the current level of your cart and may require thicker golf cart cables  If you lift your cart and install large tires, upgrade your cables because it takes more current to turn those large tires. 

You may also need to upgrade other components, such as the motor, controller, solenoid and F-N-R switch depending on your application.  If you install a rear seat or bed on the back, you should upgrade your power cables because you’ve added more weight to the cart. Therefore more amperage is required to move it.  And of course, any time that ANY of your electrical components are upgraded, the cable size should be as well.  We’ll discuss that more below.

For carts which have a controller within the 400A-500A level, we always recommend upgrading your golf cart cables to 4 gauge.  Our custom American made 4 gauge golf cart cables feature 392 strands of 30 gauge 100% copper wire.  Many of the cheaper foreign made varieties have a much lower strand count and use less than 100% copper.  The lower strand counts equate to being a less flexible wire, as well as a lower conductivity.  The 4 gauge golf cart cables are generally sufficient for most high performance electric upgrades up to the 500 Amp level.

Many companies, have also traditionally offered 4 gauge power cable sets for even the higher amperage applications (600A +).  However, due to many years in this business, we now recommend 2 gauge.  Our reasoning behind this switch is the level to which many of these high end carts are modified.  The components which work on a non-lifted golf cart in a flat area, which performance electrical upgrades have been performed are not necessarily suitable for the same cart when a lift kit is added, as well as a rear seat kit in a hilly area. 

For this reason, we recommend 2 gauge for anything over the 600A level so if the cart ever had any of the modifications mentioned above added at a later date, the cart would not need to be rewired.   Our custom 2 gauge golf cart cables feature 644 strands of 30 gauge 100% copper wire.  The high strand count once again aids in flexibility for routing purposes, as well as greatly increases the conductivity for higher amperage levels.

This entry was posted in Maintenance Tips, Tutorials, Wiring Diagrams and tagged 2 gauge cables, 4 gauge cables, 6 gauge cables, battery cables, golf cart cables, heavy duty cables, power cables by Michael Williams. Bookmark the permalink. Sours: https://blog.golfcarcatalog.com/golf-cart-cables-battery-power-sizing/

Golf Cart Battery Cables
Prevent Corrosion and Increase Cart Reliability

Golf cart battery cables require some periodic cleaning and maintenance or you may find yourself with a golf cart that won't start or dies suddenly - like my son-in-law's golf cart.

golf cart battery cables

My daughter was driving on the golf cart paths near her home when her EZ Go golf cart suddenly died. Fortunately, it was close enough to their house to push it back into the garage.

As soon as I lifted the seat to look at the batteries, I pretty much knew what the problem was. The battery cables and terminals were full of corrosion. It is important to keep the cables and terminals clean to keep the power flowing. Corrosion can cause power to the golf cart to be disrupted at any point.

Golf Cart Battery Cables and Corrosion

It's normal for battery acid to seep out of the batteries.  You will notice a white, crusty material around the terminals and cables.   If you don't clean off the corrosion the result is a shorter battery life, meaning you will need to replace them more often. 



Always protect your hands and eyes with gloves and eye goggles when working with golf cart batteries. Remove any metal jewelry. Remember these are lead acid batteries and acid causes some serious damage to you, your skin, your clothes or anything else it touches.

golf cart battery cables

How to Check the battery cables and posts for corrosion.

Is there a lot of dirt or corrosion like the above picture? All that white stuff is corrosion.

Cleaning Golf Cart Battery Cables

cleaning golf cart battery cables

I cleaned the worst battery terminals and cables of my daughter's golf cart with some sandpaper and a wire brush. Reconnected them, tightened the terminals and "voila" the cart started right up again.

You can also clean the terminals with a solution of baking soda and water - but be sure none of the mixture gets into the batteries.  You can apply the baking soda/water mixture as a paste with a tooth brush or put it in a spray bottle to spray on the neutralizing solution.

Before applying, all vent caps need to be tightly closed.

cleaning golf cart battery cables

Make sure the mixture covers all the corroded terminals and cables. Let it sit for at least 15 minutes.  Use a cloth to wipe down the batteries.

cleaner for golf cart battery cables

Battery post cleaners also work well to kill the acid on the posts.

golf cart battery maintenance

A battery terminal cleaner helps to loosen the corrosion. It turns red if acid is there and turns yellow once the acid or corrosion is neutralized. Once it is neutralized just wipe it off with a rag.  Tighten all the terminals. 

You can get yours at Amazon here:

CRC 05023 Battery Cleaner with Acid Indicator

Depending on the use, it's a good idea to check your battery terminals monthly for corrosion and to tighten the lugs.

Golf Cart Battery Terminal Protector

After your battery terminals are clean and free from all corrosion it's a good idea to put something on the terminals to prevent new corrosion from developing.

golf cart battery cable protector

You can apply a thin coat of petroleum jelly to the battery posts or use a commercial product like this Battery Terminal Protector.

Either way, this protection does help to prevent your golf cart batteries from developing corrosion on the terminals and keeping them cleaner longer.

Corrosion is a common cause for golf cart's not starting or stopping suddenly.  Purchase your Battery Terminal Protector from Amazon:

CRC 05046 Battery Terminal Protector

Battery Cable Sets

Cables need to be checked not just for corrosion but to see if they are loose or frayed.  If they are broken or frayed they need to be replaced.

clean golf cart battery cables

Golf cart battery cables can be purchased at on-line golf cart parts stores or Amazon. Some places will sell them as a single cable. The cables are available as 6 gauge or as 4 gauge.

These golf cart parts are specific to a golf cart make, model and year. You will also need to know if you have a set of 36 volt batteries or 48 volt.

Club Car DS 95+ (48 Volt) Golf Cart - Battery Cable Set (4 Guage)

Golf Cart King EZGO TXT Medalist/TXT Battery Cable Set (6-Gauge)

Yamaha G14 G16 Golf Cart - Battery Cable Set (4 Guage)

By performing regular golf cart battery cleaning of your cables and terminals you can improve the performance and reliability of your cart AND extend the life of your batteries.

Go from Golf Cart Battery Cables to Golf Cart Battery Maintenance

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4 Gauge EZGO TXT 48V (1994 and Up) 5pcs

4 Gauge EZGO TXT 36V (Battery + Controller Cables) 13pcs

4 Gauge EZGO Medalist 36V (1986 and 1994) 5pcs

4 Gauge EZGO RXV 5pcs

4 Gauge 5pcs 1994 and Up EZGO TXT, PDS, or Medalist 36V

4 Gauge EZGO TXT 36V (1994 and Up) 7pcs

4 Gauge EZGO TXT PDS 36V (2000 and Up) 10pcs

2 Gauge EZGO TXT 48V (1994 and Up) 5pcs

2 Gauge EZGO TXT 36V (Battery + Controller Cables) 13pcs

2 Gauge EZGO Medalist 36V (1986 and 1994) 5pcs

2 Gauge EZGO RXV 5pcs

2 Gauge 5pcs 1994 and Up EZGO TXT, PDS, or Medalist 36V

2 Gauge EZGO TXT 36V (1994 and Up) 7pcs

2 Gauge EZGO TXT PDS 36V (2000 and Up) 10pcs

1/0 Gauge EZGO TXT 48V (1994 and Up) 5pcs

1/0 Gauge EZGO TXT 36V (Battery + Controller Cables) 13pcs

1/0 Gauge EZGO Medalist 36V (1986 and 1994) 5pcs

1/0 Gauge EZGO RXV 5pcs

1/0 Gauge 5pcs 1994 and Up EZGO TXT, PDS, or Medalist 36V

1/0 Gauge EZGO TXT 36V (1994 and Up) 7pcs

1/0 Gauge EZGO TXT PDS 36V (2000 and Up) 10pcs

2/0 Gauge EZGO TXT 48V (1994 and Up) 5pcs

2/0 Gauge EZGO TXT 36V (Battery + Controller Cables) 13pcs

2/0 Gauge EZGO Medalist 36V (1986 and 1994) 5pcs

2/0 Gauge EZGO RXV 5pcs

2/0 Gauge 5pcs 1994 and Up EZGO TXT, PDS, or Medalist 36V

2/0 Gauge EZGO TXT 36V (1994 and Up) 7pcs

2/0 Gauge EZGO TXT PDS 36V (2000 and Up) 10pcs

Sours: https://www.windynation.com/Welding-Battery-Cable/WindyNation-Inc/EZGO-Golf-Cart-Battery-Cables/-/4484?p=YzE9MTEx
Ez-Go Golf Cart Wiring Explained...

Should golf cart wires get hot? You may find yourself asking this question during routine maintenance on your golf cart, an entirely common concern and luckily one with a simple answer. Through basic troubleshooting, you will be able to uncover the cause for your golf cart wires getting hot. If they are getting hot, should they be and how hot is too hot?

Should golf cart wires get hot?

Golf cart wires will get hot when you are driving them. This is caused by the resistance in the wires. They should not be too hot to touch for a period of time. If they are, then you may need to check your terminals to make sure they are clean and not causing excessive heat.

By going through a basic checklist of things to look for, you should be able to locate the cause of why your golf cart wires are getting hot. It is important to understand that if your cart or wires get too hot, they can cause your battery cables to melt, which could ultimately cause a fire or short out your batteries causing them to blow up. If you notice your golf cart wires are getting hot, it is highly recommended to take the time to search for the cause.

What Causes Golf Cart Wires To Get Hot?

Cable Corrosion:

Cable corrosion, which is a result of a battery leaking battery acid, can cause overheating in the wires on your golf cart.

The corroded cables will cause a higher resistance while transmitting power which leads to the heating of the terminals, cables, and batteries. This will cause premature failure of your batteries.

Overheating in the wiring of your golf cart can cause sparks and if you are experiencing a leak of battery acid, a spark can cause an explosion to occur.

If you notice your golf cart battery leaking battery acid, be sure to clean the entire area free of any and all battery acid. Battery acid can cause corrosion, melting of cables and casings, and can burn your skin if you come in contact with it.

Corrosion will generally begin where the cable connects to your battery and can consume the entire length of the cable and surrounding areas. It is important to replace any corroded parts with new ones, including cables or batteries in order to prevent any further issues with your golf cart. By using a protecting spray you can reduce the risk of corrosion in your battery, cables, and terminals and help protect your golf cart from overheating.

Dust or Dirt Build-Up:

Older golf carts can acquire a build up of dust and grime in the motor which can cause the wiring in your golf cart to overheat and possibly cause some instances of melting. The build-up of dust, dirt, and grime can put a strain on the wiring and cables in the motor which will overheat them and cause the motor’s efficiency to decline.

Help keep your golf cart and motor clean by using the following techniques (if you know how to breakdown your motor on your own that would give you better access for a better and deeper clean):

  • Exterior: Use a clean, dry rag to wipe any dust or dirt off the exterior of the motor. If you need a little extra help, use a degreaser to assist with those tougher spots. Avoid using water in order to avoid shorting out any electrical components.
  • Wires: Use a very fine sandpaper to brush away any dust or dirt in areas with wiring or cables. Do NOT use water in these areas as water can cause a short to occur and your cart may not run correctly or at all after that.
  • Interior: If you are able to break down your golf cart’s motor then use a clean rag with degreaser to wipe away dust and dirt on the interior parts of your golf cart’s motor. It is important to not use any flammable cleaner in this area and not get any degreaser on the wiring.

By having your motor cleaned on occasion, you will be reducing the possibility of any clogging or overheating that can not only cause your wiring to overheat but your entire motor and battery pack which could ultimately cause your golf cart to blow up.

Low/High Resistance Wires:

If the wiring on your golf cart is overheating, it could be due to its low resistance since a smaller gauge wiring will heat faster than wiring that has a higher gauge. You can use a multimeter to check the wires resistance, if any are low, replace them with a larger diameter wire to decrease the chances of overheating.

The opposite is also true though, the internal resistance of the wire could be too high which could also lead to overheating and/or melting. Use your meter to check the resistance, which should be zero at both ends. If you are experiencing a wire that is too high in resistance, then you will need to replace it with one that is lower in resistance.

Be sure to replace the wiring with one that is within the appropriate limits for the type of golf cart that you own. Welding cables are a popular wire of choice to upgrade your wiring.

Loose Connections:

With the way golf carts are built, you will more than likely have multiple batteries on your golf cart, resulting in multiple cable connections. If any one of these cables have a loose or poor connection, overheating can occur in the one that needs to be tightened or replaced.

Over time, battery connections can become loose, which results in overheating of the cable and wiring within your golf cart. Your cables can also accumulate dust, dirt, or grime over time, making it very important to keep your cables, wiring, and battery clean to prevent overheating and possibly a fire or explosion.

If you notice a loose connection, it is important to tighten it as soon as it is noticed; if dirty cables are noticed, be sure to clean them as soon as possible. By keeping your cables properly connected and clean, you will be decreasing your risk of your wiring getting too hot and possibly melting different components of your golf cart, ultimately costing you more money in the long run.

Wiring Gauge Thickness:

How thick or thin gauged your cables and wiring are will determine whether or not they experience excessive overheating as well. Any high current wiring or cables that have a lower gauge thickness can overheat if they are even 10 degrees warmer than surrounding temperatures. By utilizing the following guidelines, you will be able to decrease your possibility of having wiring or cables that get too hot, which could result in a fire, melting, or explosion. The appropriate guidelines for cables to reduce overheating include:

  • Thickness: If you notice a cable that is overheating, it is recommended that it is replaced with a higher gauge thickness, preferably a cable with at least a 4 gauge thickness.
  • Connections: A loose connection can cause battery acid to seep into the crimp, causing corrosion and allowing dust to continuously accumulate and build up.
  • Appropriate Wiring: It is extremely important to use wiring that is the correct size and type to prevent a complete meltdown of your wiring.
  • Type of Connection: Ensure that any and all wiring and cables on your golf cart are specifically meant for a golf cart and NOT an automobile.

By ensuring that you are using a high gauge thickness for your cables and wires, you are preventing a possible overheating issue which can in turn cause a disaster for not only your golf cart but possibly for you as well.

Categories Golf CartsSours: https://www.betterplaygolf.com/should-golf-cart-wires-get-hot/

Cables golf cart

Golf Cart Battery Cables Exposed – Does Size Really Matter?

For gas powered carts, the cables need only be of sufficient size to operate the starter motor, which is only for a few seconds at a time. So that answer is no, the originally installed cables are plenty sufficient in size. For those of us who have the more plentiful, battery powered carts, the answer is somewhat more complicated. The short answer for us is, yes and no, depending upon what we expect from the cart or if modifications to the motor or controller have been made.

If the cart is absolutely bone stock (all original with no upgrades) and is used primarily as originally intended around the local course, the standard 6 AWG (aka 6 gauge or #6) cables are perfectly fine. Wire (cable) size is measured by a standard called American Wire Gauge or AWG and relates to the diameter or cross sectional area of the copper conductor itself. The smaller the AWG number, the larger the diameter, and hence, larger current carrying capacity. For example, a 2 AWG cable is larger than a 4 AWG which is larger than a 6 AWG. Most cart manufacturers use 6 AWG cables. The finest cables we have found so far are made by MaxiLink.com, which are super flexible and made for extreme duty electric vehicle use.

Ok, now for you guys that want better performance, we’ll get a little more technical. The maximum current that will ever go through your cables is when the cart is at rest and you mash the gas pedal to the floor. At that point in time, the controller puts out the max power it is capable of, and the motor experiences what is called “locked rotor” current draw, which can be hundreds of amperes. When the motor is in a stalled state, it requires tremendous energy to get it spinning to the rated RPM. If the motor were to stay in the stalled state (if there was some mechanical restraint that would not allow it to turn) the high current would continue to be absorbed by the motor until it actually burned up the windings. Typically though, the motor begins to spin immediately, and the current drops down to 20 or so amperes within a few milliseconds (on a stock cart). There are four things that limit that maximum current; the resistance of the internal windings of the motor, the current capacity of the battery pack, the controller capacity and the resistance of the battery cables. The Battery Pack and Motor windings are pretty much fixed values. Keep these in mind because we will come back to them.

Aftermarket “high torque” or “high speed” motors installed to increase the carts performance are commonplace these days. Unfortunately, that additional performance requires additional power. The motor is only there to convert electrical energy into kinetic energy (not very efficiently either). High power motors have a lower internal resistance than stock, which in turn draws more current. If you remember from science class, power (in watts) is voltage (E) multiplied by the current (I). Since the voltage cannot go any higher than the battery’s 48volts (or 36volts), the current increases in order to satisfy the power demand of the motor. Unfortunately, this is where the resistance of the battery cables come into play. As the current increases in a conductor, power is lost in the form of heat at a rate of I2R, where R is the cable resistance. In an ideal cable and to transfer max power, the cable resistance (R) should be zero ohms. Unfortunately all cables have some resistance. The cable resistance causes the voltage to drop (E=IR) and results in lost power to the motor. The solution; increase the size of the battery cables (the larger the cable the less the resistance). Of course, the cable diameter can only be increased within reasonable mechanical size limitations, but that is what is required to reap the full benefits of a high power aftermarket motor. Our example used the locked rotor current to explain the worst case effects. They are less drastic at partial throttle, where the current draw is significantly less. If you want to do the drag racing, burnouts, wheelies and such with your cart though, you will need the bigger cables to supply the required massive inrush of current to the motor. Although the resistance of the cables seems tiny (#6 = 0.00047ohms/ft vs. #2 = 0.00015 ohms/ft), the voltage drop is significant when large currents are present, which will reduce performance. So for the high power motor users out there, use large diameter cables and keep them as short as possible. Size will matter to you. Look for other articles by Randy Wade and check out www.digitaloverdrivesystems.com regularly for news, tips and performance products including the new Maxilink Extreme Duty EV cables.



Source

Battery, Cables, Cart, Exposed, golf, Matter, SizeSours: https://clubatthehighlands.com/our-blog/golf-cart-battery-cables-exposed-does-size-really-matter/
Golf cart electrical

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