Cable Replacement Guide

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)