If your carts still run on six 8V lead-acid batteries and you’re tired of watering, corrosion and short lifespan, a 48V LiFePO4 golf cart lithium conversion is one of the most impactful upgrades you can make.
But converting from 6×8V flooded or AGM batteries to a 48V lithium pack is more than a simple battery swap. You’re changing:
- The energy storage technology
- The charging system
- The weight distribution
- And often the electrical protection and monitoring
This guide walks you through the full process—from evaluating your cart to selecting a 48V pack, installing it safely, and commissioning the system.
Quick Overview: What a 48V Golf Cart Lithium Conversion Involves
A typical 48V golf cart with lead-acid uses one of these layouts:
- 6 × 8V batteries in series → 48V
- Sometimes 8 × 6V or 4 × 12V → also 48V
In a lithium conversion, you usually replace that entire string with:
- One 48V LiFePO4 pack, or
- Two 48V packs in parallel for more capacity, engineered as a system
At a high level, a 48V golf cart lithium conversion follows these steps:
- Confirm your cart’s voltage, controller and space
- Choose a conversion approach – single pack vs full kit
- Size the pack for voltage, capacity and current
- Plan the mechanical layout in the battery compartment
- Upgrade wiring, fusing, main switch and grounding
- Replace or integrate a lithium-compatible charger
- Integrate with controller, meter and accessories
- Commission the system with a structured test checklist
- Document safety and compliance aspects
We’ll assume your cart is 48V with 6×8V lead-acid and use that as the main example.
Step 1: Check If Your Cart Is a Good Candidate for Lithium Conversion
Before choosing any kit or pack, you need to understand what you’re starting from.
Confirm system voltage and existing layout
- Count the batteries and read their labels:
- 6 batteries × 8V each → 48V
- 8 × 6V or 4 × 12V are also common 48V layouts
- Verify on the cart’s nameplate/manual that it’s a 48V system.
This guide focuses on converting a 48V 6×8V pack to a 48V LiFePO4 pack, but the principles apply to other 48V layouts.
Gather controller and motor information
Look at:
- Controller rating – nominal voltage, continuous and peak current
- Motor type and power – stock vs upgraded, any high-performance modifications
- Accessories – extra loads like lift kit, big tyres, sound systems, lights
This tells you how much continuous and peak current your new 48V lithium pack must safely deliver.
Understand your usage profile
Different usage patterns need different designs:
- Private / weekend use – light duty, occasional use
- Golf course fleet – daily use, predictable routes
- Resort / hotel / community – stop-and-go, shuttle service
- Utility carts – heavy loads, hills, work-duty usage
The more demanding the routes and loads, the more carefully you need to size capacity and current and consider parallel packs.
Check battery compartment space and structure
Measure:
- The available footprint, height and clearances in the battery bay
- The strength and condition of the existing battery racks/trays
- Any obstacles: cross-braces, covers, seat supports
You’ll use this information to choose a pack form factor and design mounting brackets or trays for a safe installation.
Step 2: Choose Conversion Approach – Single 48V Pack vs 48V Lithium Kit
Once you know your cart and usage, you decide how to implement the conversion.
Single 48V LiFePO4 pack
This approach uses:
- A single 48V lithium pack engineered for golf cart duty, with:
- Integrated BMS
- Pack-level protections (fuse/contactor)
- Clearly specified continuous/peak current and cycle life
Advantages:
- Simplified wiring – one main pack instead of multiple batteries
- Easier to manage and monitor
- Typically more robust for fleets and commercial users
This is the most common approach for B2B projects, fleets and engineered solutions.
48V lithium golf cart conversion kit
A 48V lithium golf cart conversion kit typically includes:
- One or more 48V LiFePO4 pack(s)
- Mounting brackets or trays
- Pre-made cables and lugs
- A matched 48V lithium charger
- Often: main fuse, main switch, basic SOC gauge
Advantages:
- Faster, more standardized installation
- Reduced risk of mismatched components
- Easier to repeat across a small fleet
For smaller customers or dealers who want a structured solution, kits can work very well.
Multi-12V “drop-in” lithium batteries in series
Some conversions use:
- 4 × 12V LiFePO4 batteries in series → 48V
This can work for small projects when:
- All batteries are the same brand, model and BMS version
- They are installed with proper balancing and cabling
- The installer understands lithium charging and protection
However, managing multiple independent BMS units in series can be more complex. For fleet projects, a correctly engineered single 48V pack or kit is usually more robust and easier to support.
Step 3: Size Your 48V LiFePO4 Pack – Voltage, Capacity and Current
Voltage is fixed (48V), but capacity and current must match your application.
Using your existing lead-acid pack as a reference
Start from what you know:
- Original pack: 6 × 8V, often in the 150–170Ah range at 20-hour rate.
- Real-world runtime:
- How many holes or kilometres do you get today?
- Is that enough, or are you looking for more range?
Remember that lithium:
- Maintains voltage better across the discharge
- Allows more of the rated capacity to be usable
- Offers higher round-trip efficiency
So a 48V 100–120Ah LiFePO4 pack can often match or exceed the range from a much larger lead-acid pack, depending on your usage.
Choosing capacity (Ah / kWh)
Consider:
- Daily route length – distance or hours per shift
- Typical load and terrain – flat course vs hills, light vs heavy loads
- Desired depth of discharge – target around 50–80% DOD for best life
- Reserve margin – weather, detours, second round
For example:
- Light private use may be fine with a 48V 80–100Ah pack
- Golf course fleets commonly use 48V 100–120Ah packs
- Heavy-duty or long-route carts might need 150Ah+ or parallel packs
A battery manufacturer can help translate your current usage + lead-acid experience into an appropriate lithium capacity.
Continuous and peak current
Your pack must support:
- Continuous current at least equal to what your controller and motor draw under normal acceleration and cruising
- Peak current for hills, loaded starts, or short bursts
Check:
- Controller specs – e.g., 48V, 250A or 350A controller
- Any performance upgrades – motors, bigger tyres, lift kits
A 48V pack for golf cart use is typically designed so that:
- Continuous current rating ≥ typical cruise/hill current
- Peak current rating ≥ controller peak, for a limited number of seconds
Oversizing current capability improves reliability and reduces stress on the cells.
When to use two 48V packs in parallel
In some cases you might install two identical 48V packs in parallel:
- For significantly greater range, or
- To share current between packs in high-demand carts
If you parallel packs:
- They must be designed and approved for parallel use
- They should be same brand, model, capacity and age
- Cables between packs and the bus must have matched lengths and sizes
- Ideally, the BMS and firmware are coordinated for parallel operation
For fleets, parallel packs should always be implemented with manufacturer guidance, not as a DIY experiment.
Step 4: Mechanical Layout – Replacing 6×8V with a 48V Pack
A lithium pack is usually more compact and lighter than the original lead-acid string, but that doesn’t mean you can just “drop it anywhere.”
Positioning the pack
Plan the new layout to:
- Maintain a reasonable center of gravity
- Avoid interfering with seat mounts, covers and service access
- Allow room for cables, fuse, main switch and inspection
Often the pack is placed:
- In the center of the original battery tray, or
- Across the tray with a custom bracket that bolts to existing mounting points.
Mounting and restraint
Ensure the pack is:
- Securely mounted to withstand bumps, vibration and emergency stops
- Supported by a strong tray or brackets that can handle its weight
- Restrained so it cannot move or tilt into cables or sharp edges
Soft spacers or rubber pads can reduce vibration and protect the enclosure.
Ventilation and ingress protection
LiFePO4 packs do not vent gas like flooded lead-acid batteries, but you still need to consider:
- Air flow around the pack and controller for cooling
- Protection from water and dirt – splashes, rain, wash-down
Depending on pack IP rating, you may want:
- A protective cover with drainage holes and airflow, not a fully sealed box that traps heat.
Service access
When planning the layout, leave space to:
- Read the pack label and serial number
- Reach key connectors, fuses and the main switch
- Access diagnostic ports, CAN connectors or Bluetooth antennas (if present)
Good service access saves time for future maintenance and troubleshooting.
Step 5: Wiring and Protection – Cables, Fuses, Main Switch and Grounding
The conversion is a good time to upgrade the high-current wiring and protection.
Choose appropriate cable sizes
Select cable sizes based on:
- Maximum continuous and peak current
- Length of each run
- Acceptable voltage drop and heating
Use high-quality, flexible cable designed for mobile DC applications, and crimp the lugs with suitable tooling.
Install a main fuse or circuit breaker
Place a high-current fuse or breaker:
- As close as practical to the positive terminal of the pack
- Rated to protect the cable and pack from faults, while allowing normal operation
This is a critical safety element in any high-current DC system.
Main switch or contactor
Your system should include a main disconnect that:
- Allows safe shutdown for service
- Lets operators isolate the pack in emergencies
The switch or contactor must be rated for the system voltage and current, and installed in a location that is accessible but protected from accidental operation.
Good routing and strain relief
When routing cables:
- Avoid sharp edges, moving parts and hot surfaces
- Use grommets, clamps and loom to prevent chafing
- Provide strain relief at terminals to avoid stressing lugs and studs
Label the main cables clearly, especially when multiple packs or accessories are involved.
Step 6: Charger and Charging Port – Moving from Lead-Acid to Lithium Charging
A lithium conversion almost always requires a new charger.
Replace the lead-acid charger
Traditional 48V lead-acid chargers:
- Use voltage and taper profiles optimised for flooded or AGM batteries
- Often include equalisation or long absorption phases that are not suitable for LiFePO4
You should replace them with a charger designed for:
- 48V LiFePO4 chemistry
- Correct target voltages and termination logic
- Appropriate maximum charge current for your pack
On-board vs off-board chargers
You can choose between:
- On-board charger
- Mounted in the cart, plug in an AC cord
- Convenient for users, but must consider cooling and space
- Off-board charger
- Remains in the garage or charging bay
- Lighter cart, but less convenient for ad-hoc charging
For fleets, off-board chargers on fixed bays can work well; for private owners, an on-board charger is often preferred.
Charging port integration
Decide whether to:
- Reuse the existing charging socket, adapting it to the new charger, or
- Install a new charging port that matches your charger connector
Ensure the:
- AC and DC portions are clearly separated and safe
- Charging connector is robust and weather-resistant for your environment
Opportunity charging guidance
Lithium allows for opportunity charging, but:
- Avoid repeated high-current charging at very high temperatures
- Follow pack manufacturer guidelines on maximum daily charge cycles
- Consider how opportunity charging fits into your overall lifecycle and warranty plan
Step 7: Integrate with Cart Electronics – Controller, Meter and Accessories
A good conversion respects all the electronics around the battery.
Controller compatibility and settings
Check with the controller documentation or supplier:
- Supported input voltage range
- Low voltage cut-off and how it is set
- Any regen braking settings and their impact on pack charging
LiFePO4 has a different discharge curve from lead-acid. You may want:
- To ensure low-voltage thresholds match the pack’s BMS protections
- To adjust any settings that assume lead-acid behavior
DC-DC converter and 12V loads
Most carts use a DC-DC converter to feed:
- Lights
- Horn
- Accessories
- Audio / accessories
During conversion:
- Confirm the DC-DC converter’s input range works with the LiFePO4 pack
- Check wiring and fusing on the 12V side
- Upgrade any undersized wiring if you’re adding extra accessories
State of charge (SOC) indication
Lead-acid style “battery meters” that simply read voltage are not accurate for LiFePO4.
Options include:
- A pack-specific SOC gauge provided with the kit
- A display driven via CAN bus or RS485
- A Bluetooth app that reads the pack BMS
Choose an SOC indication method that matches your user and maintenance team’s expectations.
Step 8: Commissioning Checklist – Testing After a Lithium Conversion
Before handing the cart back to users, run through a structured test.
Pre-power checks
With the main switch OFF:
- Verify all connections are tight, correctly polarised and insulated
- Confirm the fuse and main switch ratings and torque
- Inspect cables for proper routing and strain relief
First power-up
Turn the system on and:
- Check pack voltage and BMS status (via display/app if available)
- Confirm the controller powers up without faults
- Verify no abnormal noises, smells or heating
Do a no-load test: a short motor run with wheels off the ground or at low speed.
Road test
Conduct a controlled test:
- Start with light acceleration on flat ground
- Gradually include normal driving and moderate hills
- Monitor for:
- Unexpected BMS trips
- Unusual voltage sag or performance drops
- Excessive heating of cables, controller or pack
Record key observations such as maximum current, temperature and any warnings.
Record and label
After a successful test, document:
- Pack model, capacity and serial number
- Charger model and settings
- Installation date and responsible technician
- Any configuration changes in the controller
Clear labels and records are particularly valuable for fleets and future service work.
Safety, Compliance and Documentation for Lithium Conversions
Conversions should respect both safety and regulatory requirements.
Transport and compliance
Lithium packs must comply with applicable standards for:
- Transport (e.g. UN38.3 test report for shipping)
- Relevant IEC / UL standards for motive power, where applicable
For fleet projects or export, you may need:
- MSDS / SDS
- Test summaries
- Packing and handling instructions
A manufacturer should be able to provide these documents.
Installation records and labelling
Maintain:
- Installation reports for each cart
- Drawings or photos of wiring and component locations
- Clear labels for pack voltage, disconnects, and emergency contact information
This supports both safety audits and future troubleshooting.
Emergency procedures
Make sure operators and maintenance staff know:
- How to disconnect the main switch in an emergency
- How to recognise electrical faults or abnormal heating
- Who to contact if the BMS repeatedly trips or if there is physical damage
Lead-acid removal and recycling
The old lead-acid batteries are hazardous waste and must be:
- Removed carefully (acid, corrosion and weight hazards)
- Sent to a qualified recycling facility or through an approved waste handler
Never abandon or dump old batteries; proper recycling recovers lead and reduces environmental impact.
Common Mistakes to Avoid in Golf Cart Lithium Conversions
Some of the most common and costly mistakes include:
- Undersizing capacity
- Choosing too small a pack so that daily use runs near 100% DOD, shortening life.
- Mixing battery types or brands
- Combining different lithium brands, capacities or ages in series/parallel, leading to imbalance.
- Keeping an incompatible lead-acid charger
- Using the old charger and damaging the pack or causing BMS trips.
- Ignoring fusing and cable upgrades
- Reusing undersized cables and missing fuses, creating overheating and safety risks.
- Bypassing or modifying the BMS
- Attempting to override protections for “more power,” risking cells, pack and warranty.
Avoiding these pitfalls is one of the main reasons to follow a structured conversion process and, for larger projects, to involve an engineering team.
When to Work with a Professional or Manufacturer
Not every conversion has to be a DIY project.
When a kit and local installer may be enough
For:
- Single carts or a few carts
- Standard models with no special modifications
- Users comfortable with using a 48V lithium conversion kit built for that cart type
A kit plus a qualified local cart shop can work well.
When you should involve a manufacturer or engineering partner
You should involve a professional battery manufacturer or engineering team when:
- You run a fleet (golf course, resort, industrial site)
- Carts have been heavily modified (lift kits, bigger motors, heavy loads)
- You plan to convert many carts over time
- You need documentation, compliance and consistent performance
For a manufacturer like SAFTEC, useful information to prepare includes:
- Cart brand, model and system voltage
- Controller type and maximum current
- Existing battery layout and Ah rating
- Daily route length, terrain and typical load
- Climate (temperature extremes)
- Fleet size and whether conversions will be phased
With this data, a technical team can propose appropriate 48V LiFePO4 packs, chargers and safety components, and help you design a conversion plan that balances performance, lifespan and cost.
FAQs – Golf Cart Lithium Conversion and 48V Conversion Kits
Q1. Do I need to replace the charger when converting my golf cart to lithium?
In almost all cases, yes. Lead-acid chargers use charging profiles that are not suitable for LiFePO4 and can shorten lifespan or cause BMS trips. A 48V lithium golf cart conversion should include a charger specifically designed for 48V LiFePO4, with the correct voltage limits and current rating for your pack.
Q2. Can I keep my existing 48V controller and motor when I switch to a 48V LiFePO4 pack?
Often you can, as long as the controller is compatible with the voltage range and the pack can supply the required continuous and peak currents. Many conversions retain the original 48V controller and motor but you may need to adjust low-voltage thresholds or other settings so they align with the lithium pack’s behaviour and BMS protection limits.
Q3. Is one 48V lithium pack enough to replace six 8V lead-acid batteries, or do I need two packs in parallel?
A single 48V lithium pack is usually enough to replace a 6×8V string, provided it has suitable capacity and current ratings. Two packs in parallel are considered when you need significantly more range or current than one pack can safely provide. Parallel packs must be specifically designed and approved for parallel use and installed with proper cabling and protections.
Q4. What wiring and safety components should always be checked or upgraded during a lithium conversion?
You should at least review and, if necessary, upgrade: high-current cables (size and condition), main fuse or breaker, main disconnect switch, lugs and terminations, DC-DC converter wiring for 12V loads, and the routing and securing of all cables. A thorough safety check is as important as selecting the right lithium pack.
Q5. Can I do a golf cart lithium conversion myself, or should it be done by a professional installer?
If you are experienced with DC wiring and follow a well-designed 48V lithium golf cart conversion kit with clear instructions, a DIY installation may be possible on a private cart. For commercial fleets, heavily modified vehicles or any project involving higher currents and parallel packs, working with a professional installer or directly with a battery manufacturer is strongly recommended.
Q6. Will converting my cart to lithium void the original golf cart warranty or lease agreement?
It may. Many OEM warranties and lease agreements assume the original battery type and configuration. Before converting, check the terms with your cart supplier or leasing company. Even if the original warranty is no longer in effect, it is good practice to document the conversion, use compliant components, and follow best practices so that safety and liability are properly managed.
