The Club Car Carryall 500 utility cart uses a 48V battery system, typically with lead-acid or lithium-ion batteries. OEM models often feature 8×6V flooded lead-acid batteries (group GC2 size) for 48V operation. Lithium-ion alternatives like 48V 30–100Ah LiFePO4 packs are drop-in replacements, offering 2–3x longer lifespan and 50% weight reduction. Always confirm terminal positions and dimensions (L: 10.25″–12″, W: 7″–7.5″, H: 10.5″–11″) to ensure compatibility.
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What is the OEM battery specification for the Club Car Carryall 500?
The original equipment lead-acid batteries are 6V units arranged in series (8×6V = 48V). Each GC2-sized battery delivers ~180–190Ah, supporting 8–10 hours of continuous operation. Dimensions must fit factory trays: 10.3″ L × 7.1″ W × 10.5″ H. Pro Tip: Replace all lead-acid batteries simultaneously—mixing aged and new cells accelerates degradation.
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Deep Dive: The OEM setup relies on GC2 flooded lead-acid batteries, which weigh ~63 lbs each. Their 1,000–1,200 cycle lifespan demands replacement every 3–5 years under daily use. Lithium upgrades, however, can hit 3,000–5,000 cycles. For example, a 48V 60Ah LiFePO4 battery reduces weight by 230 lbs compared to lead-acid while doubling the cart’s range. Transitioning to lithium? Ensure the BMS supports Club Car’s regenerative braking, which can induce voltage spikes up to 56V. Practically speaking, even a 10% undersized battery can leave you stranded on hills—always prioritize capacity over cost savings.
| Parameter | Lead-Acid (OEM) | LiFePO4 |
|---|---|---|
| Weight per Battery | 63 lbs | 15–22 lbs |
| Cycle Life | 1,200 | 3,500+ |
| Peak Power | 1.2 kW | 3 kW |
Can lithium-ion batteries replace lead-acid in the Carryall 500?
Yes, lithium-ion batteries are compatible if voltage (48V) and dimensions match. LiFePO4 models require a 16S configuration (3.2V cells ×16) and a 50–100A BMS. Benefits include faster charging (2–3 hours vs. 8–10 hours) and no maintenance. Pro Tip: Disable the cart’s voltage-based “fuel gauge”—lithium’s flat discharge curve confuses lead-acid-calibrated systems.
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Deep Dive: Swapping to lithium demands more than just physical fit. Club Car’s onboard computer expects a specific voltage range (42–54V for lead-acid). Lithium packs maintain ~51V until depletion, which could trigger false low-battery warnings. A battery communication module (BCM) adapter solves this. But what if your cart lacks regenerative braking? Simplified installs bypass BCM tweaks. Take Redway’s RLFP-48-60: this 60Ah pack includes auto-sleep mode to prevent deep discharge during storage. On the flip side, using generic lithium batteries risks damaging the motor controller—always verify peak current ratings exceed the cart’s 300A surge draws.
How does battery group size affect compatibility?
Group size (GC2, GC8, etc.) defines physical dimensions and terminal placement. The Carryall 500 uses GC2 trays—any replacement must align with 10.3″×7.1″×10.5″ space. Lithium options like Battle Born 100Ah GC2 fit seamlessly, while GC8-sized packs (12″ long) require tray modifications. Pro Tip: Measure clearance around terminals; reversed polarity layouts demand custom cables.
Deep Dive: Think of group sizes like engine blocks in cars—wrong dimensions mean no fit, regardless of power. GC2 lead-acid batteries have front-terminals 5.5″ apart, whereas some lithium models use top terminals. For instance, Dakota Lithium’s DL+ 48V 60Ah mimics GC2 footprints but adds a handle for easier swaps. Transitioning between chemistries? Double-check weight limits—lithium’s 65% mass reduction might necessitate securing brackets to prevent rattling. Beyond physical specs, cold weather performance diverges: lithium retains 85% capacity at -20°C vs. lead-acid’s 40% drop.
| Group Size | Length | Width | Height |
|---|---|---|---|
| GC2 | 10.3″ | 7.1″ | 10.5″ |
| GC8 | 12″ | 7.5″ | 10.5″ |
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FAQs
1,000–1,200 cycles (~3–5 years) with proper watering and equalization charging. Letting cells sit discharged slashes lifespan by 60%.
Can I use third-party lithium batteries?
Only if BMS parameters match Club Car’s 48V (±2%) requirements. Non-programmable BMS units risk controller errors during regenerative charging.
Does upgrading to lithium void the warranty?
Yes, unless using Club Car-approved packs. Aftermarket installs require independent battery warranties (typically 3–10 years).
