Important - Check Your Battery Cable!!

[jsalley]

While changing my engine oil today I happened to notice that the large positive cable (think it's 1-0) from the batteries to the starter was contacting the edge of the engine's oil pan and lower block on the port bottom of the engine, about 3-4 inches from where the cable emerges from its conduit in front of the engine. There were particles of red cable insulation stuck to the engine, and when I moved the cable I could see a section about 1/4 inch long where the insulation was worn off just shy of the conductor! This cable has the potential to carry several hundred amps, it's not fused as delivered from the factory (mine soon will be). Had that last bit of insulation worn off, this would likely have caused a fire in the engine compartment with catastrophic consequences. I temporarily fixed it by holding the cable off the engine with a wire tie connected to the front port engine mount.

I don't know if this is a problem unique to my boat, to only early-build boats (I'm #14), or to all 309's. I'd suggest checking your cable at the earliest opportunity.

 

[GKuffner]

John,

Thanks for the heads-up. I'll definitely check my cables again the next time I visit my boat. I would be interested to learn more on how you intend to fuse the main battery cable.

Gary
Glory Days #136

 

[jsalley]

I plan to install a Blue Sea high amp fuse, though not sure what amperage to use - need to research that further. I have a 150 amp fuse on the positive side of my inverter - probably don't need that for the starter, but will need something close.

 

[Maine Sail]

Your battery

Your house battery should already be fused by the factory as this part of the ABYC standard. If the 309 is anything like my 310 you should find an ANL fuse block in the battery compartment usually with a 250 amp ANL fuse..

I would still double check though just to be safe..

 

[jsalley]

Re: Your battery

Maine -

I haven't seen any fusing in my travels through the battery compartment or behind the panel. I have the 309 manual on the page with the battery/12V electrical schematic open in front of me, and it doesn't show a fuse either (though does show every other component of the 12V system). Seems like a pretty risky way to save a couple of bucks; and, as you point out, it doesn't conform to ABYC. I plan to contact Catalina about it, if only to prevent a problem on future hulls.

 

[Maine Sail]

Maine -

I haven't seen any fusing in my travels through the battery compartment or behind the panel. I have the 309 manual on the page with the battery/12V electrical schematic open in front of me, and it doesn't show a fuse either (though does show every other component of the 12V system). Seems like a pretty risky way to save a couple of bucks; and, as you point out, it doesn't conform to ABYC. I plan to contact Catalina about it, if only to prevent a problem on future hulls.

Please do contact Catalina. ABYC suggests battery fuses within 7" of the battery, at least on the house bank. If it is not there, call Catalina they are pretty good about handling these sorts of complaints, especially where you could have started a fire..

 

[jsalley]

Tried to call Catalina Customer Service today, but didn't get a callback yet. I decided to go ahead and order a pair of Blue Sea terminal fuse blocks, P/N 5191 and appropriate 225A fuses, from Defender. These should be simple to install (they mount between the positive battery terminal and the cable lug) and will give the needed protection from shorts anywhere downstream from the batteries. I plan to install one on my house bank (2 X 4D AGM's in parallel) and one on the reserve battery (1 X Group 31 AGM). I also plan to reroute the cable to the starter where it contacted and chafed on the engine block. Will continue to pursue this with Catalina, especially the lack of any battery fusing.