This can't be right...

[86 inches]

This is from the Evinrude E-TEC G2 Installation & Predelivery Guide on page 26 concerning battery connections. When I installed my G2, I was very careful to follow the recommendations in this guide but this always bothered me. Why would Evinrude recommend installing a star washer on the threaded battery post UNDER the lug of the outboard cable setting up a high resistance situation that could lead to a potential critical event? Typo?

"Install a starwasher on the threaded battery post. Stack cables from the outboard, then cables from accessories. Finish this connection with a hex nut."

[DaleH]

I do not have a G2 nor slept at a Holiday Inn last night, but I believe that is correct, as there are no threads at the bottom of the battery post and a cable placed there could be loose!

See my simple sketch I had made many years ago, for my Classic Parker website, when many Yummie owners were complaining of weird OB electrical-related issues.

I only have a DI 2-stroke motor but have setup every electric start OB motor with either a SS star (internal or external) toothed or split washer on the post 1st over the last 40-50-years. With non-G2 motors, I've also known many who have fried sensitive OB electronics or have lost their stators as they have had loose battery connections and/or God forbid ... just wing nuts on top!

[86 inches]

This is from Trojan Batteries...



This is from U.S. Battery...

"It is also important to consult the battery manufacturer’s recommendations for the proper type and assembly of the terminal hardware. Most manufacturers provide stainless steel nuts and lock washers or plated bolts, nuts, and lock washers with the batteries depending on the type of terminal used. The correct method is to position a lock washer between the nut and the connector (never between the connector and the lead terminal) and apply the recommended torque to completely compress the lock washer without deforming the lead terminal."




And here is a link to an article written by a ABYC Certified Marine Electrical Systems Specialist where he is discussing a near-meltdown situation.

https://marinehowto.com/battery-melt...rowly-averted/

"Here’s the other half of this problem. The first half was caused by improper torquing of the Nyloc nut with pair of pliers. Please DO NOT use pliers to tighten and torque battery terminals.

The second problem arose because the person who connected these batteries left the flat SS washer on top of the lead battery post. This means the SS washer was sandwiched between the lug and the lead of the battery post. Stainless steel is a horrible conductor, one of the worst.

In battery installations flat washers should never be placed between the lug and battery post. They can only ever reside on top of the lug compressing it not being compressed.

Here’s the relevant ABYC standards from E-10 Storage Batteries:

“10.8.3 Battery cables and other conductors size 6 AWG (13.3 mm²) and larger shall not be connected to the battery with wing nuts.

10.8.4 Multiple conductors connected to a battery shall be installed with the highest ampacity conductor terminal closest to the battery, followed by successively smaller ampacity conductor terminals.

10.8.4.1 A maximum of four conductor terminals shall be permitted to be installed on a single battery stud.

10.8.5 Flat washers, if used, shall only be installed immediately under the split lock washer and nut of the attachment stud.”


Not a pro but putting the star washer on first never has seemed right to me.




.

[ELGIN]

This is from the Evinrude E-TEC G2 Installation & Predelivery Guide on page 26 concerning battery connections. When I installed my G2, I was very careful to follow the recommendations in this guide but this always bothered me. Why would Evinrude recommend installing a star washer on the threaded battery post UNDER the lug of the outboard cable setting up a high resistance situation that could lead to a potential critical event? Typo?

"Install a starwasher on the threaded battery post. Stack cables from the outboard, then cables from accessories. Finish this connection with a hex nut."

That is the way engineering wanted the cable and washer connected, this is like the transom saver thing, ask 10 people get ten different answers.

[alli ss]

Youre quoting flat washer placement from the battery people. Nothing to do with the star washer they are recommending to dig into the lead of the terminal. I agree with the battery companies- do not put a flat washer between the cable and terminal. I also agree with brp- yes install a star washer between the terminal and cable.

here you go

https://www.albanycountyfasteners.co...l-p/109000.htm

[yam911]

I would suspect that a star washer offers less resistance than a flat washer. Points digging in should offer better conductivity.

Might do a test.

No mention of soldering the terminal on a battery cable. Both Yamaha and Mercury Marine suggest that be done. Also to minimum voltage drop.

[86 inches]

That is the way engineering wanted the cable and washer connected, this is like the transom saver thing, ask 10 people get ten different answers.

So... not a typo.

[86 inches]

Youre quoting flat washer placement from the battery people. Nothing to do with the star washer they are recommending to dig into the lead of the terminal. I agree with the battery companies- do not put a flat washer between the cable and terminal. I also agree with brp- yes install a star washer between the terminal and cable.

here you go

https://www.albanycountyfasteners.co...l-p/109000.htm

I don't know what I don't know so I'm not arguing... especially with Evinrude Engineers... but it still seems odd to me. Why would you want to "dig in" with a SS star washer with poor conductivity. Though not a flat washer, the principal is the same. Perhaps you're right and Evinrude has determined that the the star washer does not have the resistance of a flat washer and that the pros out weigh the cons.

OTOH, Generally, the lock washer or star is there to prevent the nut from loosening. But it's not doing that if it is between the terminal and the lug. Evinrude doesn't mention a lock washer under the nut or even a Nyloc. So what's keeping "their" nut from loosening? Appropriate torque, I guess?

I have plenty of star washers. In fact, until just recently I followed the recommendations in the Installation and pre-delivery guide. But I just got a new battery - an X2 (Northstar) and it does not have the lead terminals and putting the star washer on first feels strangely odd. I don't know how much digging in is going on unless it is into the lug, itself. The Northstar came with split locking washers.



Now that I know the pic in the guide is not a typo, I guess I'll go back to that....

[86 inches]

I would suspect that a star washer offers less resistance than a flat washer. Points digging in should offer better conductivity.

Might do a test.

No mention of soldering the terminal on a battery cable. Both Yamaha and Mercury Marine suggest that be done. Also to minimum voltage drop.

Solder. Say it's not so!

[ELGIN]

Do what you want, I have never seen warranty coverage denied due to the location of a washer on a battery cable.

[DaleH]

Damn ... now I’m confused ...

[SEAHORSE]

According to engineering, the top of a battery post is not flat but rounded. A battery cable terminal is flat and fastened to the rounded battery post leaves little area for a substantial connection between the two.

A star washer (toothed lock washer) is moderately flexible and provides a flatter surface for the cable terminal end as it will "bite into" the curvature of the post plus the height of the teeth help compensate for the top of the post's radius by providing a flatter surface.

In addition, the sharp-edged teeth give a solid bite into both the post and terminal for a secure connection. The hex nut also provides additional surface area for the high current that travels through the terminal and post during starting.

[alli ss]

I don't know what I don't know so I'm not arguing... especially with Evinrude Engineers... but it still seems odd to me. Why would you want to "dig in" with a SS star washer with poor conductivity. Though not a flat washer, the principal is the same. Perhaps you're right and Evinrude has determined that the the star washer does not have the resistance of a flat washer and that the pros out weigh the cons.

OTOH, Generally, the lock washer or star is there to prevent the nut from loosening. But it's not doing that if it is between the terminal and the lug. Evinrude doesn't mention a lock washer under the nut or even a Nyloc. So what's keeping "their" nut from loosening? Appropriate torque, I guess?

I have plenty of star washers. In fact, until just recently I followed the recommendations in the Installation and pre-delivery guide. But I just got a new battery - an X2 (Northstar) and it does not have the lead terminals and putting the star washer on first feels strangely odd. I don't know how much digging in is going on unless it is into the lug, itself. The Northstar came with split locking washers.



Now that I know the pic in the guide is not a typo, I guess I'll go back to that....

i think your brass terminals are an exception. And the star washers lock it by keeping the cable from moving which would loosen the nut. It gets a better grip between lead and copper instead of copper and stainless if it was on the top.

[86 inches]

According to engineering, the top of a battery post is not flat but rounded. A battery cable terminal is flat and fastened to the rounded battery post leaves little area for a substantial connection between the two.

A star washer (toothed lock washer) is moderately flexible and provides a flatter surface for the cable terminal end as it will "bite into" the curvature of the post plus the height of the teeth help compensate for the top of the post's radius by providing a flatter surface.

In addition, the sharp-edged teeth give a solid bite into both the post and terminal for a secure connection. The hex nut also provides additional surface area for the high current that travels through the terminal and post during starting.

Holy cow! The lead surface of the threaded studs on my interstate flooded cell batteries are indeed rounded... and not just a little. I never would have guessed that. Thanks for the why behind the how. That totally makes sense. I always find it frustrating when any manufacturer - not just Evinrude - doesn't include the reasoning behind their recommendations.

[86 inches]

i think your brass terminals are an exception. And the star washers lock it by keeping the cable from moving which would loosen the nut. It gets a better grip between lead and copper instead of copper and stainless if it was on the top.

Yeah, maybe. I need to look and see if Evinrude addresses the connection at a battery selector or cut off switch. The terminals there are similar to the terminals on the higher end TPPL batteries. My Blue Sea switch has always been lug directly in contact with the terminal then a star washer and then the nut.

[alli ss]

Not sure how youd do that, keeping it tight to their specs i should say

[DaleH]

Good info here ... I myself have 'updated' my Sketch to show a toothed/star lock washer only down against the lead terminal. I guess even old dogs are never too old to learn!