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Unread 04-17-2019, 12:05 PM   #1
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Question Thinking out loud here

Everyone is always talking about upgrading their cables and such on their carts but not many of us upgrade the battery terminal bolt that attach's the cable to the battery.
I'm curious has anyone ever wondered how much juice the standard battery terminal bolt can handle? The 00# cable can handle about anything a normal cart controller can send it but what about the bolt in the battery. How much amps does it really pass through it without burning are melting it off?

This is even more so on a old Club Car F/R cam that has the smaller 3/16" screw that hold the cable to the stock cam. I always put a H/D Ezgo in them myself if I upgrade the cart. How many amp's you think that little bitty screw can take?
Just thinking about this today and wondering about what one could do to off set this. Are the cables really making that much of a difference in the way it runs?As we all know the system is only as good as the weakest link which would be the terminal bolt.
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Unread 04-17-2019, 12:47 PM   #2
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Default Re: Thinking out loud here

The posts or "screws" are not intended to carry current, their only purpose is to provide a firm connection between the cable lug and the surface of the device, or in the case of a battery, the lead surface.

Technically the smaller screws allow for more surface contact area.
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Unread 04-17-2019, 01:01 PM   #3
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Default Re: Thinking out loud here

I was thinking about a similar thing this morning. Has anyone ever put a cart on a Dyno machine and measured amps delivered to the motor under identical conditions with cable size difference being the only variable. Run the cart 3 times with #6 cables, then swap to #2 and see if more amps are delivered to the motor.
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Unread 04-17-2019, 01:07 PM   #4
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Default Re: Thinking out loud here

You should not see any measurable difference, current is not limited by the gauge of the cable and there is not enough resistance on the cable lengths used to cause problems due to voltage drop.
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Unread 04-17-2019, 07:56 PM   #5
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Default Re: Thinking out loud here

Quote:
Originally Posted by R.Boyd View Post
I was thinking about a similar thing this morning. Has anyone ever put a cart on a Dyno machine and measured amps delivered to the motor under identical conditions with cable size difference being the only variable. Run the cart 3 times with #6 cables, then swap to #2 and see if more amps are delivered to the motor.
A series drive with 6x8V battery pack has roughly 25' of high current cables and there are no perfect conductors, so the smaller the conductor' diameter, the greater the power loss.

6Ga - 98.8W per 100A
2Ga - 39.1W per 100A
00Ga - 19.5W per 100A.

Not sure how much the Torque and RPM will change at the motor with the different gauge cables, but I suspect it would be measurable and if the cart was put on a dyno, the differences would be magnified by a factor of 16.59 with 12.44:1 gears and 18" tall tires.
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