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)