I think I know what I need to do...

[KenLDavis]

but would like a little confirmation from people with more experience.

I have a power sense battery box (has an LED meter on it to tell me how charged my battery is before we go out) connected to the battery. The box then has connectors on the outside of it, for the power leads to the engine starter and accessories. http://www.overtons.com/modperl/product ... on&i=25600

Had the boat out yesterday, ran fine - we went out, and anchored in a quiet cove; spent the day hanging out. While we were out there, I unscrewed the power cables at the battery box connection, just long enough to add a connector cable for a solar maintainer (a smart one that won't overcharge the battery, since where our boat is parked, there is no power for a trickle charger).

Tightened everything back down; we had the stereo playing and power to all accessories. When we got ready to leave... "click". Engine wouldn't spin over. So I went back, checked my connections - everything was tight, wing nuts were good. Tried it again... "click" - no starter. So - I loosened the wing nuts slightly, and moved the cables - there was still pressure on the connectors, but loose enough I could move them - then tightened everything back down, hit the starter and it spun over just fine.

I had this happen a few weeks back when I was doing some work on the boat in the driveway - trim unit stopped responding - had power to starter, though.... Same story - loosened the connector, moved the cables slightly, tightened it back down and all was fine.

This boat sat for two years, in the water, no use. I was looking at the connectors last night and they are not shiny silver, but dark grey - they seem to be very oxidized (not corroded - just turned dark). Thinking the best thing to do at this point is to take some very fine sandpaper or emery cloth, clean the oxidation off of them, and then put a light coating of die-electric grease on them before I tighten everything back down. If I get the connectors cleaned, thinking it should solve the problem and the grease will at least significantly reduce the oxidation returning, especially since the boat is now being used regularly. Worst thing in the world for electrical connections is for them to sit idle, outside.

Thoughts or recommendations? Is my train of thought logical and is it running on the right track?

Thanks, guys - much appreciated.

Ken

[Cycleman07]

You are on the right track with cleaning them up some and adding grease. I had this same scenario happen with my G3 i had before my current boat. Also, dont over tighten the wing nuts back down. Just tighten them down enough that the cables wont move a whole lot.

[rockhound]

Just enough so the cables won't move a whole lot?

This is bad, let me say that again, this bad advice, an electrical connection be it in your house or in your car or in your boat should not move at all ever. An electrical connection that moves can cause arcing, an arc causes heat and a hot electrical connection causes fires, melted wires and can ignite fumes. That wire should be tight to the point you are absolutely sure it will not come loose unles you make it come loose.

i have seen battery connections that were not tightened properly create enough heat to melt the studs off a car battery from just making a small arc as they went along

[LocoCoco]

...i have seen battery connections that were not tightened properly create enough heat to melt the studs off a car battery from just making a small arc as they went along

Yup. This happened to the stud on the alternator in my truck. Connection was loose and it was arcing and eating away at the metal. Lucky I caught it before it broke right off.

I clean up the wires and terminals on my boat every spring just using files and sandpaper. I don't bother with grease since corrosion doesn't take over in one season on freshwater and I don't want grease accidentally getting spread to other things.


LC.

[KenLDavis]

I think the key is to not over-tighten them. But agreed - the cable connectors should not be able to spin under the wing nut. By the same token, you don't want to strip the stud off, or the wing nut out, or bend the connectors. But tight is good.

[rockhound]

yeah, don't take a monkey wrench to it, but tighten her down, the vibrations of trailering and running a boat can loosen connections for sure

[babock]

If you are using those battery wing nuts, throw them in the trash and replace with stainless nyloc nuts.

[KenLDavis]

Great idea!! Thanks! (Note to self - trip to Lowe's before this weekend...)