TROJAN BATTERY
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4.1 INSPECTION AND 12V ACCESSORIES CONTINUED
To prevent damage to 12V accessories in the cart, first verify the voltage requirement of accessories like lights or others
items in the vehicle. Then, if needed, the installer can use a voltage reducer to reduce the 48V battery voltage
to 12V or as required. To ensure you install your batteries properly and safely, please use the following guidelines.
4.2 TERMINALS AND TORQUE VALUES
Both the positive and negative terminals of the battery are M8-1.25 x 18mm threaded studs. Ensure that the nuts are
tightened to the proper dry torque of 80-90 in•lbs (9-10Nm). OVER-TIGHTENING TERMINAL CONNECTIONS CAN
CAUSE TERMINAL BREAKAGE, AND LOOSE CONNECTIONS CAN RESULT IN TERMINAL MELTDOWN OR FIRE.
4.3 CORRECT HARDWARE INSTALLATION
If using flat or lock washers, it is very important to ensure the battery cable lug is contacting the top surface of the
terminal, and the washer is placed on top of the lug. DO NOT PLACE A WASHER BETWEEN THE BATTERY TERMINAL
AND THE LUG, AS THIS WILL CREATE HIGH RESISTANCE AND CAUSE EXCESSIVE HEATING OF THE CONNECTION,
WHICH CAN RESULT IN FIRE. If assistance is needed in determining the appropriate hardware configuration, contact
Trojan Battery technical support.
4.4 CABLE SIZE
Battery cables should be sized to handle the expected load and be of sufficient length and flexibility to avoid applying
undesirable mechanical loads on the battery terminals. Refer to Table 1 for the maximum amperage based on
the cable/wire gauge size.
WARNING! USE AN INSULATED WRENCH WHEN MAKING
BATTERY CONNECTIONS.
TABLE 1
Table values are from NEC Table 310.15(B)16 for copper cables
rated at 167°F (75°C), operating at an ambient temperature of no
more than 86°F (30°C). Lengths in excess of 6 feet (1829mm)
may require heavier gauge wire to avoid unacceptable voltage
drop. In parallel battery banks, it is preferable for all cables to be
the same length.
For more information refer to the National Electrical Code for
correct cable/wire size, which can be located at www.nfpa.org.
CABLE/WIRE GAUGE SIZE, AWG mm2 AMPACITY (Amps)
14 (2.08) 20
12 (3.31) 25
10 (5.26) 35
8 (8.36) 50
6 (13.3) 65
4 (21.1) 85
2 (33.6) 115
1 (42.4) 130
1/0 (53.5) 150
2/0 (67.4) 175
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