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.
How to connect golf cart batteries?
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.
How do you fill the battery in a golf cart?
· 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.
What is the best battery charger for a golf cart?
It is for this reason we suggest strongly that you remove the cables and measure them to get an accurate hole center to hole center length so we can build cables to fit what you need to do. Most carts use 6 gauge cables from the factory and upgrade kits were later offered moving up in size to 4 gauge and 2 gauge.
What kind of batteries does a golf cart use?
4 AWG ( 4 GAUGE ) CUSTOM MADE GOLF CART BATTERY CABLES CHOICE OF RED OR BLACK BATTERY CABLE AND CHOICE OF LENGTHS WITH STANDARD 5/16 CORROSION RESISTANT COPPER RING TERMINALS You choose your length and color from the options above near the purchase buttons. The copper ring terminal lug cable end fits a 5/16 stud common on golf cart …
What gauge wire should I use for battery cables?
Ideally, a 6 gauge cable is the best option for a 12-volt power supply. This automotive wire can sustain a maximum of 60 volts and is ideal for 12-volt electrical systems.
What kind of wire is used for golf carts?
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.
What gauge wire should be used with 12 volt battery?
In practice, we use wires from 16 AWG to as thick as 3/0 AWG for 12V circuits (size depends on the max. wattage and wire length or voltage drop). We have to be quite careful when sizing 12V wires. If we choose a wire with too low an ampacity, the circuit can go up in flames (as well as the battery).
How do I know what size battery cable I need?
Stranded wire gauges should be measured by calculating the equivalent cross sectional copper area. First, measure the bare diameter of a single strand and locate the circular mils value in the row that matches your measurement. Second, multiply the circular mils by the number of strands in the cable.
What is the difference between 4 gauge and 6 gauge battery cables?
6 AWG Gauge battery cable has an amperage capacity of 50 amps at a cable length of 11.8 feet. 6 gauge battery cable i... 4 Gauge AWG Battery Cable has an amperage capacity of 100 amps at a cable length of 9.4 feet.
What is 2 gauge wire?
Breaking Force for Copper WireAWG gaugeConductor Diameter InchesOhms per 1000 ft.20.25760.156330.22940.19740.20430.248550.18190.313339 more rows•May 3, 2022
Can battery cables be too big?
12V battery cables are much thinner. Thicker cables won't cause harm electrically. Mechanically, a larger wire may be harder to route and "might" put stress on the terminal but I doubt it'll be a problem. The starter will only draw the current it needs.
What happens if wire gauge is too big?
using larger wire will not hurt anything or cause any overload. The larger wire will cost more, the pathway or where it has to fit, and the physical size of the connecting means (ie. the size of terminal or clamp it has to fit in), will all be determining factors in just how big is too big.
How do I choose a battery cable?
In summary, when selecting the correct size of battery cable, you need to take into account the total maximum amperage your electrical system requires, the voltage of your system (usually 12 volts), the total length that your cables need to be, and the amount of voltage drop you are willing to accept versus the amount ...
What is 4 AWG battery cable?
This 4 AWG Gauge extreme battery cable is specially designed to meet the demands of various environments while staying extremely flexible. Full AWG sized copper conductor made from 99.9% pure annealed electrolytic copper, will you get maximum power. The insulation and jacket compounds are specially formulated to stay flexible even in cold weather and carry a -49C to 105C temperature rating. The jacket is resistant to chemicals, water, abrasions, oil, sunlight and has a color coded dual extrusion jacket with a white inner insulation which would show any damage to the outer cable more clearly. This cable is rated up to 600 Volts and is suitable for use in automotive applications, solar battery bank wiring, power inverter battery cables, marine battery cables and many other applications calling for a durable yet flexible battery cable. The battery cables meet the requirements of SAE J1127 and J378 making them ABYC and US Coast Guard approved for boat and marine use.
What is CCA cable?
Our cable is Copper...REAL COPPER but watch out for other "CCA Cable" as CCA Means Copper Clad Aluminum so you'd be using Aluminum which is a poor conductor compared to this pure copper cable! You have to use larger sizes of aluminum CCA cable, approximately 2 sizes larger to get close to the same power delivery as real copper cable! If you care about maximum power use our cable!
How many strands of copper is in a 4 AWG cable?
THIS WELD CABLE HAS 392 STRANDS OF COPPER AND A EPDM JACKET THAT IS RESISTANCE TO FLAME,OIL,GREASE SOLVENTS,OZONE AND ABRASION AND HAS A 600V HIGH DIELECTRIC STRENGTH INTEGRITY AND IS UL AND ROHS COMPLIANCE. ALL CUSTOM BUILT
Do you measure cables before buying?
before you buy any cables for your cart please measure your cables first.
Series vs. Parallel
Two simple statements govern the rules for series versus parallel battery bank wiring. In a series circuit, the current through each of the batteries is the same. Also, the voltage across the circuit is the sum of the voltages across each component. In a parallel circuit, the voltage across each of the components is the same.
36V Battery Bank
If connected properly in a series circuit as shown, you should be able to test across the battery bank main positive and main negative terminals with a voltmeter and get a reading equal to the sum of each battery. In this example, your reading should equal 36 volts (6×6 = 36).
48V Battery Bank
A 48 volt golf cart battery bank wired in a series circuit is also very common in this industry. However, there are several combinations of individual battery voltages which can provide 48 volts. These combinations include the following:
How powerful is a golf cart battery?
Let’s take a close look at Voltage in a battery pack. For comparison, we like to take a look at cars since we are familiar with horsepower and miles per gallon (MPG). Therefore, voltage in a battery pack inside of an electric golf cart has to do with power. It does not have to do with fuel. Therefore, voltage in a battery pack within a golf cart will be comparable to the horsepower in a car. With this knowledge in place, we can determine a 72 volt system can be more powerful than a 48 volt system, and a 48 volt system can be more powerful than a 36 volt system. If you took notice, we said that it “can” be more powerful. The reason for this is due large in part to the controller inside the vehicle. A controller determines how much amperage is delivered from the batteries to the controller.
How to tell 12 volt golf cart battery?
A 12 volt battery can be identified by seeing batteries with 6 cell caps on top of the battery indicating 2 volts per cell. A single 12 volt golf cart battery will have the least amperage capacity and is commonly used in 72 volt battery systems which are not terribly common among golf carts. EZGO golf cart batteries are known to be use 4-12 volt battery systems in some of their golf cart models.
How long is a golf cart battery warranty?
Now, one of the best and longest battery warranties we have seen is at 2 years full replacement. This type of warranty will not be offered everywhere, however if you call around enough, then you may find a golf cart dealer that offers it. Do not confuse this with a 4 year limited warranty though. A 4 Year limited warranty has fine print details such as hours of use and cycles attached to it in addition to a residual payout based on time. This means that if the batteries go bad after 3.5 years and meets the hours of use addendum, then you would receive 25% of the value you paid for the batteries back instead of a full replacement pack or equivalent.
Do golf carts use lead acid batteries?
Most golf courses with electric cart fleets use lead acid batteries because they get a great price by buying in quantity, they have cart barn employees to perform all the maintenance and with newer carts they have state-of-the-art chargers that will keep a trickle charge going when the carts are not being used and prevent any overcharging.
Why are golf cart batteries so expensive?
Simply put, Golf Cart Batteries are expensive because you aren’t visiting the gas station every week. When you purchase them, you are essentially pre-paying for fuel. Yes, you still have to charge the vehicle, however the electricity cost usually breaks down to pennies per mile. In some studies, it was shown a golf cart costs less than $.02 per mile to operate in terms of electricity cost. Buying higher quality batteries versus cheaper ones will be better in the long run and will actually cost you less since you are replacing them less frequently.
Which is the least expensive battery for a golf cart?
Of the 48 Volt systems, the 4-12 Volt system is typically the least expensive (not always) since only 4-12 Volt deep cycle batteries are required. However the 4-12 Volt system has the least range. The more lead and the heavier the battery pack as a whole typically leads to a more expensive but higher quality battery pack. And a higher quality battery pack will have a longer life for your golf cart and generally better performance in terms of range.
How much does it cost to replace a golf cart battery?
Pricing varies from pack to pack. The general consensus for golf cart battery replacement ranges from $600 on the low end to $1600 on the high end. If you are buying batteries in the lower end of the price range, then they are most likely cheap golf cart batteries that will not last as long (you really do get what you pay for when it comes to batteries). Some packs cost as much as $2500 when you start dealing with 72 Volt systems and sealed for lithium batteries. But, for the typical lead acid battery pack, $900 to $1500 is about the norm. This price range is assuming you are working with a local golf cart dealer.
How to wire golf cart batteries?
1. Open the battery compartment of your golf cart by lifting the seat out of the cart. Golf cart battery banks are normally located beneath the seat of the cart. 2.
How many batteries are in a golf cart?
A) How to Wire a Golf Cart Battery. Electric golf carts are normally run by a bank of six batteries, depending on what model car you have purchased. The batteries are designed to provide a sustained charge to support propulsion of the cart over the duration of a playing day.
Where is the battery bank on a golf cart?
Golf cart battery banks are normally located beneath the seat of the cart. 2. Remove the black negative cable from the first battery in the bank followed by the subsequent positive wire. You will do this for each battery in the bank in the same order moving from forward to rear in the battery bank. 3.
Why are my golf cart cables melting?
The most common cause for melting your golf cart cables, is not ensuring that the terminal connectors on the golf cart cables are tight. A loose connection with your golf cart cables will cause the current to encounter resistence, causing heat to build up and then melting your golf cart cables .
How to remove battery from battery bank?
Lift the batteries that require removal from the battery bank. Some battery banks are designed to hold each battery in place with a battery clip that will require a basic wrench to remove the securing nut and washer from the bracket.
What wire should I use for a 4 cylinder engine?
We recommend #2 wire for 4 cylinder and small 6 cylinder automotive engines, hi-power accessories (like winches, power converters), and alternators over 160A.
What is SGX battery cable?
Sometimes we use SGX battery cable. SGX uses a high-grade XLP (Cross-Linked Polyethylene) insulation which has a higher temperature rating and is more abrasion-resistant. The trade-off is the insulation is thicker and stiffer. Often it has a higher strand count. If you need a higher temp rating, it’s a good choice.
What gauge is used for low power alternators?
8 gauge works for accessory leads and low power alternators.
What does a fuse link look like?
Think of a fuse link as a very slow-acting (“slow-blow”) fuse that looks like a piece of wire. Fuse link wire has special very high-temp insulation that won’t burn even if the wire becomes so hot that it fuses open.
Is wire stiff enough to stay in place?
It usually has a fairly low strand count (meaning the strands are larger), making the wire stiff enough to stay where you put it but is still flexible enough to bend around tight corners.
What is the difference between OFC and standard wire?
What’s different about it? Standard wire is AT LEAST 99.90% pure copper. OFC is 99.95% pure copper. An extra 0.05% copper sounds good. What’s the downside? COST. OFC is often TWICE the price for the same size of standard cable. So you are paying DOUBLE for 0.05% more copper. There is NO measurable electric difference (source Wikipedia ).
What is SGT wire?
SGT is a thermoplastic PVC (polyvinyl chloride) insulation rated at 50 volts. It’s typically rated for 85 or 105 degrees C. It usually has a fairly low strand count (meaning the strands are larger), making the wire stiff enough to stay where you put it but is still flexible enough to bend around tight corners. Buy SGT Battery Cable.
How to change the battery in a golf cart?
Step 1. Open the battery compartment of your golf cart by lifting the seat out of the cart. Golf cart battery banks are normally located beneath the seat of the cart. Step 2. Remove the black negative cable from the first battery in the bank followed by the subsequent positive wire.
Why are batteries used in golf carts?
The batteries are designed to provide a sustained charge to support propulsion of the cart over the duration of a playing day. Because the batteries are installed in a battery bank, their wiring differs from an automobile.
What to put on before removing battery?
Put on your acid-resistant work gloves before starting the battery removal process.
How to remove battery from battery bank?
Lift the batteries that require removal from the battery bank. Some battery banks are designed to hold each battery in place with a battery clip that will require a basic wrench to remove the securing nut and washer from the bracket.
How to disconnect battery from bank?
Remove the connection from the first battery in the bank's positive terminal that is connected to the subsequent battery's negative terminal. Then, move to the next battery and follow the same steps until all of the batteries in the bank are disconnected from each other.
