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How to Assemble a Battery Cable

By Royal Brass and Hose Marketing July 31, 2024

Royal Brass and Hose is a prime dealer of QuickCable brand battery cables, connectors, tools, and accessories. We also specialize in assembling battery cables to custom lengths and specifications. 

In this blog: 

Watch our Step-by-Step Video 

 

Does this sound familiar? You get in your car on a cold, winter Monday morning only to discover it won’t start because the battery died during the night. The kids are already loaded in their seats, your cup of coffee is piping hot, and you are on time for work. As you try fervently to crank your vehicle’s engine all you hear is the whirling sound of power loss to the system. Next thing you know, the kids are crying, your coffee is cold, and you are late for work as you wait to have someone come give you a boost. 

We’ve all been there before, and chances are we will all be there again one day. It’s easily one of the most frustrating ways to start a work week. Disregarding the personal aspect of this situation, let’s think about it from a business standpoint. We all know that in business, time is money. Whenever a power loss like this happens to a work truck, maintenance vehicle, tractor or construction implement it could lead to a loss of business and the loss of bottom-line dollars. 

While it is inevitable that vehicle batteries will need to be charged or replaced over time, we recognize the importance of having the proper components needed to sustain and improve the life of your battery.

A close-up of a battery cable end with a crimped clamp, covered with heat shrink tubing. The cable end is securely attached to a metal terminal, which is designed to connect to a battery. In the upper left corner, there is a smaller inset image showing a similar battery cable with a crimped clamp. The text on the image reads, "COMPLETE CABLE END WITH HEAT SHRINK TUBING," and the logo of Royal Brass and Hose is visible in the top right corner.

There are five major QuickCable product types we distribute and use for assemblies: 

  1. Connectors - Clamps and Lugs 

  2. Battery and Welding Cable 

  3. Heat Shrinkable Tubing 

  4. Assembly Protection Products 

  5. Crimpers and Cutters 

Through this tutorial, we will examine the details of those five categories and show how they are correctly assembled. 

Copper Die Cast Connectors 

Three different types of metal clamps used for battery cables, each labeled with its configuration. From left to right, the clamps are labeled "STRAIGHT," "ELBOW," and "FLAG." The straight clamp is oriented vertically, the elbow clamp has a 90-degree bend, and the flag clamp has a perpendicular extension. Each clamp has a copper connection point and is branded with the Royal Brass and Hose logo, which is also displayed in the top right corner. The title at the top of the image reads "CLAMP CONFIGURATIONS."

Connectors refer to the clamp or lug used to attach the battery cable to the battery terminal. A clamp is joined together by a bolt and a nut whereas a lug is a one-piece circular end that fits around the terminal of which it’s attached. All our clamps, lugs, and fasteners are tin-plated with a cast copper alloy to resist corrosion. 

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  Two types of cables and their corresponding lugs and clamps. A black cable labeled "BLACK" is shown with a matching lug, while a red cable is displayed with a matching clamp. The lug and clamp are color-coded to correspond with the cables. The text at the bottom of the image reads, "LUGS AND CLAMPS ARE COLOR CODED TO CORRESPOND TO THEIR MATCHING CABLE." The setup is placed on a wooden surface, and the connectors are arranged to highlight the color-coding system.

How to Read a Battery Clamp

Two metal clamps side by side, each annotated to explain how to read the information on a clamp. The left clamp features a red marker indicating it is for positive connections, while the right clamp has a black marker indicating it is for negative connections. Annotations highlight that the black clamps note negative connections and the red clamps note positive connections. The image also points out the cable gauge, which indicates the size of the cable the clamp fits, and explains that gauge color codes make crimping easy. Additionally, the part number of each clamp is noted. At the bottom of the image, the text reads, "HOW TO READ A CLAMP," and the Royal Brass and Hose logo is displayed in the top right corner.

The connectors are color-coded (gray, green, pink, black, orange, purple and yellow) for easier cable gauge, size, identification and to denote positive or negative polarity. They are also imprinted with die codes that match the crimping tools necessary to complete an assembly. 

These are the steps to attach the connector to the cable: First measure the length of the hollow end of the connector and mark that amount on the end of the cable. Using a utility knife or cutting tool remove the insulation and place the connector over the exposed wire. The connector should match firmly against the remaining insulation. Be sure the end is pushed all the way on before crimping. 

Other Features of QuickCable Connectors: 

  • Thick wall 
  • Centered barrel and bolt hole 
  • Clamps the full height of a battery post for maximum electrical contact 

For tight spots, connectors are offered in a 45- and 90-degree angle as well as in a flag design.

 Three different types of metal lugs used for battery cables, each labeled with its configuration. From left to right, the lugs are labeled "90 DEGREE," "STRAIGHT," and "45 DEGREE." The 90-degree lug is bent at a right angle, the straight lug is oriented vertically, and the 45-degree lug is angled halfway between the other two. The title at the top of the image reads "LUG CONFIGURATIONS."

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A metal flag connector with a perpendicular extension. The connector has red markings on the clamp portion, indicating it is for positive connections. The body of the connector features several labels, including "Quick Connect," "Made in USA," and other specifications. The text in the bottom left corner of the image reads "FLAG CONNECTOR."

Copper tubing butt splices are available to match the cable size in question. 

Four copper butt splicers of varying sizes arranged in a row from smallest to largest. These splicers are cylindrical and are used to connect or splice electrical cables. The text at the bottom of the image reads "COPPER BUTT SPLICERS," and the Royal Brass and Hose logo is visible in the top right corner. The background is a dark, smooth surface, highlighting the metallic appearance of the splicers.

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MagnaLugs 

A good connector to use for farming, construction, trucks and buses is the MagnaLug. 

Two connectors side by side, comparing a Magnalug connector to a standard copper lug. The Magnalug connector, labeled "MAGNALUG," is on the left and features the "Quick Connect" branding, specifications, and "Made in USA" label. The standard copper lug, labeled "STANDARD," is on the right and has a simpler design with a slightly flared end for cable insertion. The text at the top of the image reads "MAGNALUG CONNECTOR COMPARED TO A STANDARD COPPER LUG," and the Royal Brass and Hose logo is visible in the bottom right corner. The background is a plain, smooth surface that highlights the connectors.

The benefits of a MagnaLug connector: 

  • Made of 100 percent copper 
  • Tin plated twice as thick as industry standards 
  • Longer, thicker, wider and stronger than standard lugs 
  • Exceeds SAE conductivity standards 

Quick Compression Connectors with compression nuts are ideal for small and medium sized users such as tow trucks, maintenance vehicles, and field repairs. They can be installed with common hand tools, just strip 7/8” of insulation from the cable end then insert the bared wire into the compression nut and thread that with the connector. Grip the compression nut with a wrench and turn until the nut seats. 

Battery and Welding Cable 

A disassembled battery cable assembly with labeled components, arranged sequentially from left to right. The components include a cable with exposed copper at the end, followed by a piece of heat shrinkable tubing, a nut, and a lug. Each component is clearly labeled to show its function: the cable is identified with "CABLE" and "EXPOSED COPPER," the tubing with "HEAT SHRINKABLE TUBING," the nut with "NUT," and the lug with "LUG." The text at the bottom of the image reads "BATTERY CABLE ASSEMBLY WITH COMPRESSION END." The components are laid out on a wooden surface, clearly highlighting each part of the assembly.

Battery cable is insulated with flame retardant PVC and is resistant to fuel, oil, acid, and salt. It is the OEM standard in the industry. Like connectors, battery cable is color-coded for identification. This way it’s easy to quickly identify gauge, connectors, and crimper needed. The generally accepted industry practice is to use black insulated cable for negative (ground) and red for positive posts. 

When replacing cable, always install a heavier gauge cable, never lighter. In cold climates, a heavier gauge can also be used to improve starting. To find the gauge size, measure the bare conductor wire only, not the insulation. 

An assortment of metal clamps organized by gauge size, each labeled with a different color and gauge number. From left to right, the clamps are labeled 2, 1, 8, 6, 4, 1/0, 2/0, 3/0, and 4/0. Each clamp has a distinct color-coded band indicating its gauge: green for 2, pink for 1, black for 8 and 6, yellow for 4, red for 1/0, orange for 2/0, brown for 3/0, and purple for 4/0. The title at the top of the image reads "ASSORTMENT OF CLAMPS BY GAUGE," and the clamps are laid out on a dark, smooth surface to clearly display their size and color coding.

Size 8, 6, 4: Garden Tractor 

Size 6, 4: Compact Car, RV 

Size 4: Standard Car 

Size 1, 2: Full-size Car, Van 

Size 1/0: Tractor, Light Truck, Construction 

Size 2/0, 3/0: Heavy-Duty Tractor, Truck, Bus, Construction 

Size 4/0: Extra Heavy Duty 

As an alternative, welding cable is made with a very fine copper wire and insulated with synthetic rubber. It is more flexible than battery cable, especially in cold temperatures and it is easier to route in tight spaces. 

Heat Shrinkable Tubing 

Four pieces of heat shrinkable tubing, with two in red and two in black. The tubes are cylindrical and positioned on a dark surface, slightly angled to display their hollow interiors. The text at the bottom of the image reads "HEAT SHRINKABLE TUBING," and the Royal Brass and Hose logo is visible in the top right corner.

This tubing creates a corrosion resistant seal around the area where the connector covers the wire and meets the insulation on the battery cable. The inside surface is lined with a sealer which melts when heated and permanently seals the link. 

The tubing is rated for -65 °F to 340 °F and is resistant to: 

  • Flame 
  • Acid 
  • Fuel 
  • Abrasion 

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Battery Protectors 

Four protective terminal covers, with two in red and two in black. These covers are designed to fit over electrical terminals to provide insulation and protection. They are arranged on a dark surface, showcasing their shape and size. The text at the top of the image reads "PROTECTIVE TERMINAL COVERS," and the Royal Brass and Hose logo is visible in the bottom right corner. The covers have warning labels molded into the material for safety information.

Battery Terminal Protectors reduce the possibility of shorts to the electrical system while lowering the chances of sparks and battery explosions. They cover the battery post cable connection area and are also color-coded black for negative and red for positive.  

As for the cables themselves, they can be covered with an extremely flexible nylon loom for extra protection. It is slit on one side for easy install. 

This shields the cables against: 

  • Heat (rated for 409 degrees F) 
  • Abrasion 
  • Electrical shorts 
  • Corrosion 

Use a Quickcote Protective Compound to guard connectors and terminals. 

Guards against corrosion from: 

  • Water 
  • Oils 
  • Damaging Gases 

It has an easy brush-on application and can be used on all exposed electrical connectors. Doing this can prevent threaded fasteners from seizing. Protective washers can also prevent corrosion.  

Crimpers and Cutters 

A selection of tools used in battery cable assembly, each labeled with its specific function. From left to right, the tools include a red-handled stripping tool, a pair of red-handled cable cutters, a crimping tool with red handles, and a blue brute hammer tool. These tools are arranged on a wooden surface, showcasing their importance in the assembly process. The text at the top of the image reads "TOOLS USED IN BATTERY CABLE ASSEMBLY," with the Royal Brass and Hose logo visible in the top right corner.The connectors are crimped to the cables using a hand-held or bench mounted lever-style crimping tool. A Brute Hammer style crimping tool for use with a hammer or vise is available as well. Copper cable cutters are also offered in bench mounted or hand-held models. Battery cable insulation strippers can save time and energy during production. Another accessory we provide is Booster Cable sets in case you need a jump-start.  

A close-up of a quick cable crimper tool and a cable clamp, illustrating the color-coded system for matching cable ends and crimper teeth. The crimper tool, positioned on the left, has pink crimper teeth, labeled "CRIMPER TEETH (PINK)." On the right, a cable clamp with pink color coding is labeled "COLOR CODING (PINK)." The text at the top of the image reads, "CABLE ENDS AND CRIMPER TEETH ARE COLOR CODED. THIS EXAMPLE SHOWS 1 GA. CLAMP (PINK) WITH PINK CRIMPER TEETH SET." The title at the bottom of the image reads, "QUICK CABLE CRIMPER," and the Royal Brass and Hose logo is visible in the top right corner. The setup is arranged on a wooden surface to clearly show the components and their color-coded system.

Whether you need components to produce battery cables for your own operations or custom-made assemblies at Royal Brass and Hose, we have you covered. From connectors to protectors to wire we have the products available to get your vehicles started and keep your business thriving.

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Need Help Selecting the Right Battery Terminal or Lug?  

When it comes to battery terminals and lugs, we’re trusted experts. Contact us or call 800-669-9650  to speak with a member of our customer service team at any of our 11  locations  (Knoxville, TN; Marietta, GA; Orlando, FL; Charlotte, NC; Little Rock, AR; Fort Worth, TX; Benton, IL; Madisonville, KY; Princeton, WV; Birmingham, AL; Calvert City, KY).  

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