Common Reasons to Replace Cables

Burns or Melting

Symptons:

• Burnt or darkened insulation

• Acrid Smell

• Melted or deformed insulation

 

Cause:

• Undersized Cables

• Excessive Cranking

• Proximity to Exhaust Components

 

Solution:

• Replace cable

• Install larger cables

• Use insulating heat sleeving where necessary

 

 

 

Corrosion (Copper Sulphate)

Symptons:

• Greenish White powdery film on exposed copper

• Swelling near ends and crack in insulation

 

Cause:

• Sulfuric acid from the battery

• Cracks in battery casing leaking acidic fumes

• Moisture, particularly in marine applications

 

Solution:

• Replace cable

 

 

 

Cracks in Insulation

Symptons:

• Swelling near cracks

• Corrosion

 

Cause:

• Old, brittle or weathered insulation

• Cuts or abrasions

 

Solution:

• Replace cable

 

 

 

Electrical Problems

Symptons:

• Voltage drop

• Earthing issues

• Overheating cables

 

Cause:

• Undersized cable

• Corrosion

• Unknown defects

• Bad earth point or undersized earth cable

 

Solution:

• Test voltage differential between positive and negative (no more than 0.5V)

• Replace cables, terminals or both

• Use better earth point or earth back to battery

 

 

 

Terminal or Lug Damage

Symptons:

• Corrosion

• Cracked or broken terminals

 

Cause:

• Bolts over tightened

• Poor crimping method

• Exposed strands

 

Solution:

• Replace cable

• Replace terminal only (if no corrosion in cable)