Easy fix for voltage drop(?)

CaptnKingfisher

Petty Officer 1st Class
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May 14, 2017
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I lose about 1 volt from the battery though the harness and in my brain it makes sense that I should just bypass the harness with a jumper wire to the right location and then I'll have full voltage everywhere. Question: where is the right location? I temporarily put a jumper wire to the "key on" power at the starter selenoid and that seemed give me full voltage at coil which is what I was looking for but when I turned the key off the engine keeps running. So I'm gonna try jumper to power in at key. Is it okay to do this? Sorry if it's a dumb question.. most my electrical experience is with AC not DC.. and in AC if I ran a second hot into the circuit I would blow things up.. but it seems to be ok to do this in DC, correct?
1989 OMC Cobra 2.3l
 

Scott Danforth

Grumpy Vintage Moderator still playing with boats
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the leading cause of voltage drop is bad connections. start at the battery, and work your way to the motor and the helm by cleaning every connection with 150 grit sand paper until they are clean and shiny enough your mother in-law would eat off them. this includes the block and starter mounting pad, etc. then when the connections are nice and tight, seal them with marine electrical varnish.
 

alldodge

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In most cases finding a voltage drop location is not easy, just to many places it can be. Meters can also be defective. I have 4 meters and 1 of them reads .3 to .4 V lower then the others.

Can check a cable/wire by using a meter and connecting the probes to each end of the cable. If there is a drop the meter will show a voltage reading

What is the 1 V drop causing?
 

Lou C

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Nov 10, 2002
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I had a couple of electrical problems with my Cobra:
Charging voltage too high, was a known problem according to Arco marine, while the dash gauge didn’t indicate over charging a digital voltmeter on the batteries showed 15.5V. Their recommendation was to disconnect the sense wire at the alt & tape it up in the harness. Then run a jumper from the B+ on the alt to the sense terminal on the alt. This lowered the battery charging voltage to 14.2V but then I had lowered voltage readings in the ignition/gauges circuit. Thought it might be bad grounds so ran a temp extra ground wire from the neg side of the fuse box to the neg terminal of the battery. That didn’t change it. Next I ran a supplemental power lead (8 gauge wire fused from the common terminal on the battery switch to the positive terminal on the fuse box). That seems to have fixed it now have battery voltage at the fuse box both with the ignition on and off. Before the voltage would drop 1.5v from key off to key on at the fuse box. Don’t know if that helps you. I was reluctant to take the harness apart to probe further and it’s been this way about 5 years with no further problems.
I may pick up a spare harness off of eBay to experiment further….
 

Redrig

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Oct 13, 2009
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I had basically the same issue on my Ford. I did basically what Scott said and that fixed the issue.

Clean all of these locations really good and I bet it fixes the problem.

1. Hot - battery to solenoid
2. Hot - solenoid to helm
3. Ground - battery to starter / block.

I was going to run a new thicker gauge wire from the starter to the helm , but after doing this I didn't need to . Claening Those 3 runs fixed my issues.

Again mine is an older Ford, wiring may be a touch different on where that helm wire originates but that worked for me.
 

440roadrunner

Petty Officer 2nd Class
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Aug 6, 2019
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You can ONLY find voltage drop by one or two methods or maybe a combination of methods. First, realize that voltage drop is cause by CURRENT FLOW, and gets worse as current increases. It can be ANYWHERE.......in a connector, where the two halves of the connector "mate," inside a switch CONTACTS, at the switch wire terminals, or even at the junction of a wire -to- terminal point such as the CRIMP on a terminal. And don't be fooled by molded fancy rubber covered ones, they can fail/ corrode internally, as well

1...Shotgun approach. Determine what is the worst symptom, IE the starter, etc, and go over every inch of wire and terminals looking for problems. Either strange appearing insulation as to internal corrosion or signs of previous overheating, "weak" areas which might indicate broken/ corroded wire strands internally, and so on.

2....The methodical approach. Someone mentioned over-charging. MANY times over-charging is cause NOT by bad components such as the VR, but by VOLTAGE DROP. As a long time Mopar guy, this is VERY common on the older "classic" Mopars. Drop in the harness from the battery to the VR, through the ignition switch and various terminals
AND DON'T FORGET THE GROUND side of the circuit

So example, overcharge. Make up a jumper wire, say, no 16 or 18, with alligator clips, long enough to easily reach from the battery to any part of the boat with electrics. If it has to be 30ft, that is fine. Connect the jumper to the battery positive post (you might want to fuse that) and run the wire up to the VR. Connect the jumper wire to one post of your meter, and connect the remaining meter probe to the VR IGN feed terminal, that is the one running to the VR switched power. If you have a separate "sense" terminal, check that too. Turn on the ignition switch to "run" and take a reading

With the meter now connected you are measuring the drop DIRECTLY. For example, if the meter reads .5V that means you have 1/2 volt drop from the battery, through the harness, switch, connections, to the point at the VR that you are measuring, and if this is the SENSE terminal, the VR will ramp the voltage UP 1/2V because of that drop

Example, starter solenoid. Let's say the solenoid won't reliably pull in. You've "thrown money" at it, replaced the solenoid, etc. So the "path" is battery--harness--terminals--etc---key switch starter contacts--neutral safety switch---back through the harness--connectors--etc --to the solenoid and to ground. This of course is just the FUNCTIONAL path, not "electron flow."

So with a helper at the key, or with long enough jumper wires that you can get the meter such that you can read it while operationg the ignition switch, wire to the battery PLUS and to the solenoid S terminal. Crank and take a reading. Whatever you read, again, is the DROP. Now you must "track" along the path that leads from battery to solenoid.

I WOULD START with seemingly obvious culprits------a harness connector or the ignition switch / starter button itself. Measure across the switch terminals, and crank the engine. If you measure .3V across the switch, but ONE VOLT in the previous test, then you have more than one criminal at work.

This stuff is not really as complicated as many seem to think. THE HARD PART is getting documentation and figuring out the wiring.

And I said it before, don't neglect the ground path. Even on vehicles, grounding can "trick" you sometimes
 

CaptnKingfisher

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May 14, 2017
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259
seal them with marine electrical varnish.

Thanks I never heard that before, I'll get some.

What is the 1 V drop causing?
No issues, boat runs fine at the moment.
Next I ran a supplemental power lead (8 gauge wire fused from the common terminal on the battery switch to the positive terminal on the fuse box). That seems to have fixed it now
8 gauge seems like overkill! I might try this with 12 gauge since it's what I have on hand. I suspect I'm losing voltage at the harness plug connection I've already cleaned most of my connections shiny and new with no improvement
1. Hot - battery to solenoid
2. Hot - solenoid to helm
3. Ground - battery to starter / block.
I'll double check these
You can ONLY find voltage drop by one or two methods...
Thanks for taking the time to write all that I'll spend some time going through your suggestions when I'm back at the boat
 

Lou C

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Nov 10, 2002
Messages
13,045
I had the 8 gauge left over from a project (installing roof rack lights on our '98 Jeep). My thought was that this problem probably existed due to undersized wiring so going bigger would address that.
garmin 441s.JPG'88 FW instrument panel.jpg
first pic is before I ran the supplemental feed (notice voltmeter reading, only 11.5V, second is after, voltmeter is reading 14V.
 
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