Installation
Step-by-Step Guide to Upgrading Your Golf Cart to ExxPower Lithium Batteries
Detailed instructions, expert tips, and safety protocols for installing G1 & C1 Series EV-Grade batteries.
Golf carts have evolved from simple course vehicles to essential daily transportation for communities, farms, and campuses. However, the traditional lead-acid battery technology is heavy, inefficient, and requires messy, frequent maintenance. Upgrading to an ExxPower Lithium (LiFePO4) Battery is not just a replacement; it is a transformation of your vehicle's capabilities.
In this comprehensive guide, we will provide you with detailed instructions on how to successfully upgrade your golf cart's battery. Whether you have chosen our G1 Series (High Performance) for extreme terrain or our C1 Series (EV Grade Smart) for reliable daily use, the installation process is straightforward. ExxPower uses Grade A LiFePO4 Prismatic Cells to ensure the highest safety and performance standards in the industry.
1. Why Install ExxPower Lithium to Improve Performance?
Switching from lead-acid to lithium upgrades your entire vehicle's behavior. Here is why performance skyrockets with ExxPower:
- Massive Weight Reduction: A standard lead-acid pack weighs over 350 lbs. An ExxPower 48V pack weighs approx. 83-100 lbs. Removing ~250 lbs of dead weight instantly improves acceleration and braking.
- Consistent Power: Lead-acid batteries lose "pep" as they drain. ExxPower Lithium delivers 100% torque until the very last drop of charge.
- Up to 10 Years Lifespan: With over 4,000+ life cycles (vs 300 for lead-acid), ExxPower batteries are built to last a decade.
- Zero Maintenance: Say goodbye to watering batteries and cleaning acid corrosion.
2. How to Choose the Right ExxPower Battery
Selecting the correct battery is crucial. ExxPower offers two premium series, both using Grade A Prismatic Cells, tailored for different uses.
| Feature | G1 Series (High Performance) | C1 Series (EV Grade Smart) |
|---|---|---|
| Best For | Extreme Terrain: Lifted carts, hunting, steep hills, heavy loads. | Daily Reliability: Golf courses, neighborhoods, smooth commuting. |
| Discharge Power | 250A Continuous (Peak 800A) | 200A Continuous (Peak 1000A) |
| Technology | Self-Heating (-20°C Charging) | Smart BMS (EV Grade Safety) |
| Cell Type | Grade A LiFePO4 Prismatic Cells | Grade A LiFePO4 Prismatic Cells |
3. Preparation: What You Will Need
Before beginning the installation, gather all necessary tools. Having everything within reach will make the process smoother.
Essential Tools Checklist:
- Socket Wrench Set: Standard sizes (1/2" or 13mm) for removing old terminals.
- Torque Wrench: Essential for tightening new terminals to spec.
- Zip Ties: For securing cables and ensuring a clean layout.
- Multimeter: To verify voltage before and after installation.
- Dielectric Grease: To coat terminals and prevent corrosion.
- ExxPower Charger: Only use the dedicated LiFePO4 charger included in your kit.
Preparation Table & Pro Tips
Use this reference table to ensure you are fully prepared.
| Item | Purpose | Professional Tip |
|---|---|---|
| Torque Wrench | Ensures precise tightening. | Tighten M8 terminals to 9-11 Nm (6-8 ft-lbs). Do not overtighten. |
| Baking Soda Kit | Neutralizes acid from old batteries. | Mix with water in a spray bottle. If it bubbles, acid is present. |
| Dielectric Grease | Prevents oxidation on copper lugs. | Apply a thin layer after tightening the bolts. |
| Camera / Phone | Documenting wiring. | Take photos of the old setup before removing any cables. |
4. Safety Precautions
Working with high-amperage battery systems carries risks. Please strictly follow these protocols:
- Wear insulated gloves and safety glasses (PPE).
- Remove all metal jewelry (rings, watches).
- Switch the Golf Cart Tow/Run Switch to TOW.
- Turn the Main Key to OFF.
5. Removing Old Lead-Acid Batteries
Disconnect Main Cables
Once in TOW MODE, locate the Main Negative (-) cable connecting the battery pack to the motor. Disconnect this FIRST. This prevents short circuits if your wrench touches the frame while working on the positive. Then, disconnect the Main Positive (+) cable.
Remove Interconnects & Blocks
Remove all interconnect cables linking the batteries. Unbolt the hold-down brackets.
Warning: Lead-acid batteries weigh 60-80 lbs each. Use a lifting strap or ask for help.
Tray Cleaning
Mix baking soda and water to scrub the tray. This neutralizes any old acid residue that could corrode your frame. Rinse and dry thoroughly.
6. Installing the ExxPower Battery
Mounting and Securing
Place your new ExxPower Lithium battery into the center of the battery well. It is significantly smaller than the old bank, leaving extra storage space.
Use the included mounting brackets to bolt the battery securely to the frame. The battery must not slide during driving.
7. Wiring Connections
Connecting Main Power
Connect the cart's Main Positive (+) cable to the battery's Red terminal and the Main Negative (-) cable to the Black terminal.
Connecting Accessories
Accessory Setup: ExxPower batteries are optimized for pure traction power.
If your cart has 12V lights, radios, or USB chargers, ensure they are connected through a 48V-to-12V Voltage Reducer. Do not connect 12V accessories directly to the 48V battery terminals, as this will damage your accessories.
Installing the LCD Monitor
Route the included LCD communication cable to the dashboard. Mount the screen for real-time visibility of SOC (State of Charge) and Voltage.
8. Maintenance & Charging
- Charger: Use only the provided ExxPower LiFePO4 charger (58.4V output for 48V batteries).
- Winter Charging: The G1 Series features automatic Self-Heating. If plugged in below freezing, it heats itself before charging begins.
- Storage: If storing for >3 months, charge to 50% and turn the battery OFF.
9. Troubleshooting Common Issues
Most issues can be solved with simple checks. Here are common solutions:
Golf Cart Won't Start
Check for loose cables. Ensure Positive (Red) and Negative (Black) are correct. Use a multimeter to check voltage. If 0V, press the Power/Reset button for 3-5 seconds to wake the BMS.
Overheating Issues
If the BMS triggers a "High Temp" alarm (>65°C / 149°F), ensure airflow is not blocked. Let it cool for 30 mins. ExxPower batteries have high heat tolerance, but ventilation is key.
Will it shut down on high speed?
Very Unlikely. ExxPower G1 Series supports 800A Peak (3s) and C1 Series supports 1000A Peak. This easily handles the surge from high-performance controllers like Navitas (600A), preventing the "sudden stop" issues common with cheaper batteries.
BMS Error Codes
If your App or Screen shows codes like "Over Voltage" or "Under Voltage", refer to the user manual. "Under Voltage" simply means it needs a charge.
10. Frequently Asked Questions
Can I mix Lithium and Lead-Acid batteries?
Do I need to change my controller?
How long is the warranty?
How do I safely store the cart?
Ready to Install ExxPower?
Upgrade to the World's 1st EV Grade Golf Cart Battery. Experience faster acceleration, zero maintenance, and a decade of reliability.
Why Choose ExxPower?
- ✅ Grade A LiFePO4 Prismatic Cells for safety.
- ✅ 800A - 1000A Peak Discharge for power.
- ✅ 8-Year Warranty for peace of mind.
- ✅ IP65 Waterproof for durability.
© 2026 ExxPower. All rights reserved. Always refer to the user manual included in your box.