AWC battery cables comply with SAE J-112 and are heavy-gauge single core cables designed for robust automotive applications, such as connecting vehicle batteries to essential power circuits such as starters, alternators, and main fuse boxes. These cables feature stranded pure copper wire and durable insulation capable of withstanding harsh automotive environments, including exposure to fuel, oils, and chemicals. Allied Wire & Cable battery cables adhere to stringent SAE J-1127 standards, as well as meeting Ford and Chrysler specifications, ensuring exceptional quality and reliability for your automotive electrical system.
Additional Information
What is battery cable?
Battery cable refers to heavy-duty single-core cables used in automotive applications to connect vehicle batteries to critical power circuits such as starters, alternators, and main fuse boxes. These cables are engineered to handle high currents and endure the demanding conditions of automotive environments, including exposure to fuel, oils, and chemicals. Battery cables typically feature stranded pure copper conductors for flexibility and durable insulation to ensure electrical safety and reliability.
What kind of wire gauge do I need for battery cable?
The appropriate wire gauge for battery cables depends on the current requirements of your vehicle's electrical system. Generally, heavier wire gauges (lower AWG numbers) are used for higher current applications. Commonly used wire gauges for battery cables range from 4 AWG to 1/0 AWG (0 AWG). For standard automotive battery connections, smaller gauge sizes like 4 AWG or 2 AWG are sufficient, while heavier gauge sizes like 1/0 AWG are used for heavy-duty applications in high-performance vehicles or heavy machinery.
What are common battery cable insulation options?
Battery cables are available with various insulation options to provide protection against electrical shorts and environmental factors. Common insulation materials used for battery cables include:
PVC (Polyvinyl Chloride) Insulation
Basic insulation offering protection against moisture and abrasion. Suitable for standard automotive applications. PVC is typically economical and versatile but may have limited temperature and chemical resistance.
Cross-Linked Polyethylene (XLPE) Insulation
Provides enhanced resistance to high temperatures, chemicals, and abrasion. Ideal for applications requiring increased durability and performance.
Ethylene Propylene Diene Monomer (EPDM) Insulation
Offers excellent resistance to heat, cold, and weathering. Suitable for extreme weather conditions and heavy-duty applications.
Chlorinated Polyethylene (CPE) Insulation
Combines flexibility with resistance to oil, chemicals, and abrasion. Suitable for automotive and industrial environments requiring durability.
Choosing the right insulation option depends on specific application requirements, including temperature range, chemical exposure, flexibility needs, and environmental conditions. At Allied Wire & Cable, we offer a comprehensive selection of battery cables with various insulation options to meet diverse automotive wiring needs.
Types of Battery Cable
There are three types of car battery cables in common use: SGT, SGX and STX
SGT Wire
SGT battery wire has polyvinyl chloride (PVC) insulation that’s suitable for use in temperatures between -40 to 105 degrees Celsius. Available in gauges between 6 American Wire Gauge and 4/0 AWG, SGT wire has fewer and thicker conductor wire strands, making this a relatively stiff wire that holds its shape after installation. It's suitable for all automotive heavy current applications.
SGX Wire
SGX battery wire has a heat-resistant cross-linked polyethylene (XLPE) insulation. The insulation can withstand high under-bonnet temperatures up to 125 °C. This wire is more flexible than other types because of the higher number of smaller wire strands used in its construction. Applications are similar to SGT, although this cable needs to be fully supported.
STX Wire
STX battery wire has XLPE insulation and is a relatively rigid wire with a similar number and size of wire strands to SGT wire. It is suitable for heavy current automotive applications and the high under-bonnet temperatures found in modern vehicles. Its work temperature range is from minus 40 °C to 125 °C.
What’s the Difference Between Battery Cables, Welding Cables and DLO Locomotive Cables?
The primary difference between battery cables and welding and locomotive cables is that battery cables have a lower voltage rating of 50 volts. Class K welding cables can withstand 600 volts AC, and the maximum voltage for locomotive cables is 2,000 volts. Apart from that, battery cables aren't as flexible as welding cables. You can't use battery cables for welding, but you can use welding cables and DLO locomotive cables in place of battery cables, especially for jumper cables. Watch this video on AWC battery cables for more information.
Battery Cable Ratings
When selecting a battery cable, you need to consider two key factors: Ampacity and voltage drop. Because automotive systems run at 12 volts, even a small voltage drop can cause problems, especially with battery charging circuits. You must select a cable with an ampacity greater than the maximum current in the circuit by checking ampacity tables or speaking to one of our experts. Then use our voltage drop calculator to establish the optimal size cable for your circuit.
Battery Cable Specifications
| Conductors: | Single-core stranded pure copper (tinned copper available upon request) |
| Insulation: | PVC or XLPE |
| Minimum Temperature: | -40°C |
| Maximum Temperature: | PVC: +105°C XLPE: +125°C |
| Sizes: | 6 AWG - 4/0 AWG |
| Voltage: | 50 volts |
| Colors: | Red, Black, other colors upon request |
| Chemical and Oil Resistance: | Good |
Battery Cable Standards
AWC battery cables comply with the following specifications
- SAE J-1127
- Ford automotive standards
- Chrysler automotive specifications
Battery Cable Customization
Contact our Custom Cable Department for information on non-standard battery cables. For special manufacturing requirements such as fitting a ring terminal and making cable sets, contact AWC's Value Added Services.
Have Questions about Automotive Battery Cable? View our Battery Cable FAQs or watch our All About Battery Cable Video below.