Battery Cable Corrosion

RLS7201 wrote:
If your charge algorithm is correct and the batteries are not overfilled you will not have corrosion problems.

My 50+ years under the hood of cars disagrees with you.

If your charge algorithm is correct and the batteries are not overfilled you will not have corrosion problems. Could it be that your auto filler has failed and overfilled a cell or two?

Richard

SGTJOE wrote:
My hot lead to my 6v batteries (1 of 4) has battery corrosion on the wire just before the hook up clamp. This is the primary positive cable that supports the 4 Duracell GC2 Golf Cart Batteries. Any thoughts as to why this happened?

Any lead acid battery, but especially flooded lead acid out gas (produce bubbles, boil) as they are charged/discharged even at very low rates. That out gas a small amount of sulfuric acid (gas). This is reacting to any exposed copper.

Clean with backing soda and water. Clean the entire base case.

There are a couple of ways you can prevent this from happening.

1) Use "tinned" (marine) battery cable wire. The individual copper strands are coated in a material that will not react with the sulfuric acid (gas).
2) Apply dual wall (marine) heat shrink while the cable is being assembled.
3) If you missed step 1) or 2) put a good "gob" of grease (Vaseline) on the clamp and covering any exposed copper. You will have to repeat this every time you wash the outside of the battery.