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Old 08-22-2013, 04:02 PM   #1
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What size do I need? Size DOES matter!

Alright friends, dumb question that all ya smart types know off the top of your head.

Ok, I need to replace the battery cables on my house batteries. Why? The ends are falling off and they look "cheap." I don't like ugly cables....

I have 16 220AH 6V AGMs wired in series/parallel. They are in two eight battery banks feeding two Xantex SW3012 inverters in a stacked configurations. Please, don't ask why... (Hint...DW like POWER)

Normally, this should be easy, EXCEPT Monaco failed to use battery cable that was labeled. They probably save money by buying it without the proper markings.... :-)

OK, this is big stuff but how big I don't know. I'm guessing 2/0 or 3/0 SGT.

Am I close? As you know, some of these are real short cables so I can't go lo large or I will never be able to bind them enough to install them.


Thanks in advance for the wisdom.....
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Old 08-22-2013, 08:49 PM   #2
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What size do I need? Size DOES matter!
Especially when dealing with battery or electric cables. With that many batteries you have a bunch of cables. I would suggest you take them to NAPA and have them make new ones. Even if you get the correct AWG of the cables you still have to deal with crimping on the connectors at each end. If the connectors are not installed correctly they might become loose and create heat and eventually will corrode. I always put a high quality heat shrink over the barrel of the connector and an inch or so over the cable end to keep moisture out. JMHO
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Old 08-22-2013, 08:58 PM   #3
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Take several pictures and create a drawing before taking anything apart.

Agree with having the new cables professionally made by someone with the proper tools.
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Old 08-22-2013, 09:09 PM   #4
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Hello I am replacing mine as well and I am going with 3/0. Main cables should be nothing less then 3/0. Bigger is better and going with that size will give you good flow and should carry the current without heating up.
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Old 08-23-2013, 03:51 AM   #5
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Originally Posted by thrushl View Post
Alright friends, dumb question that all ya smart types know off the top of your head.

Ok, I need to replace the battery cables on my house batteries. Why? The ends are falling off and they look "cheap." I don't like ugly cables....

I have 16 220AH 6V AGMs wired in series/parallel. They are in two eight battery banks feeding two Xantex SW3012 inverters in a stacked configurations. Please, don't ask why... (Hint...DW like POWER)

Normally, this should be easy, EXCEPT Monaco failed to use battery cable that was labeled. They probably save money by buying it without the proper markings.... :-)

OK, this is big stuff but how big I don't know. I'm guessing 2/0 or 3/0 SGT.

Am I close? As you know, some of these are real short cables so I can't go lo large or I will never be able to bind them enough to install them.


Thanks in advance for the wisdom.....
3/0 can safely handle about 225 amps 4/0 about 260 amps.

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Old 08-23-2013, 04:44 AM   #6
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Besides NAPA another place that makes battery cables is a shop that repairs HI-LO's.
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Old 08-23-2013, 04:48 AM   #7
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Hi-Lo s ???
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Old 08-23-2013, 04:54 AM   #8
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Besides NAPA another place that makes battery cables is a shop that repairs HI-LO's.

but that is one HECK of a big dog!!!
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Old 08-23-2013, 04:57 AM   #9
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Take several pictures and create a drawing before taking anything apart.
When taking ours out to service I took photos and marked the cables and batteries with a Sharpie 1 on all cable ends 1 on the battery post, 2 on all cables 2 on post... you get the idea. Makes life much easier when reassembling.
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Old 08-23-2013, 09:47 AM   #10
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Originally Posted by STLNLUV View Post
Especially when dealing with battery or electric cables. With that many batteries you have a bunch of cables. I would suggest you take them to NAPA and have them make new ones. Even if you get the correct AWG of the cables you still have to deal with crimping on the connectors at each end. If the connectors are not installed correctly they might become loose and create heat and eventually will corrode. I always put a high quality heat shrink over the barrel of the connector and an inch or so over the cable end to keep moisture out. JMHO
Great Suggestion. I did not realize that NAPA or any other parts store made cables.

Thanks for the idea....
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Old 08-23-2013, 09:50 AM   #11
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Originally Posted by HD4Mark View Post
When taking ours out to service I took photos and marked the cables and batteries with a Sharpie 1 on all cable ends 1 on the battery post, 2 on all cables 2 on post... you get the idea. Makes life much easier when reassembling.
Great idea... Makes sense. Thanks
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Old 08-24-2013, 05:05 AM   #12
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Hi-Lo s ???
Yea, you know. The machines they use in warehouses to move stuff around.
[high-low]
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Old 08-24-2013, 05:06 AM   #13
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but that is one HECK of a big dog!!!
That's why I need a hi-lo. [Or high-low.]
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Old 08-24-2013, 11:43 AM   #14
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Welding supply stores would be a good place to get heavy duty custom cables made. I know none of the auto part stores in my area make cables.
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