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16-06-2019, 17:07
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#1
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Registered User
Join Date: Dec 2016
Posts: 254
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Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
While my crimping with FTZ Power Lugs normally works like a charm, but I have started using #2 AWG cable and am having challenges. My FTZ power lugs and crimper come from Bay Marine Supply, so I believe they are both genuine, and the cable is Ancor.
The common power lugs available for #2 cable are marked #1-2. With #2 cable, it is definitely a loose fit before crimping. And after crimping with at the H-H (pink) setting, I can easily pull the cable out by hand. Even after re-crimping after rotating the lug 90 degrees, I can still wiggle out the cable.
2/0 cable in 2/0 power lugs, and #6 cable in #6 lugs both work fine.
Any ideas?
Thanks,
Allan.
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16-06-2019, 17:15
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#2
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Senior Cruiser
Join Date: Jan 2016
Boat: Bathtub
Posts: 889
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
That doesn't look like #2 AWG cable. Looks like #6 or #4 at the most.
FT1 or FT2 is not a wire "size" but an insulation rating.
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16-06-2019, 17:18
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#3
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Registered User
Join Date: Aug 2013
Location: Florida
Boat: 2000 Searay 380 Sundancer
Posts: 1,087
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
Quote:
Originally Posted by ayates
The common power lugs available for #2 cable are marked #1-2. With #2 cable, it is definitely a loose fit before crimping. And after crimping with at the H-H (pink) setting, I can easily pull the cable out by hand. Even after re-crimping after rotating the lug 90 degrees, I can still wiggle out the cable.
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As you've stated, the ID for the cable is too large.
Either the lug is defective, with the ID too large, or the wire is defective, with the OD too small. Can the lug bore ID and the wire OD be measured?
The crimp tool might be wrong, but the fit should be snug, so my guess is not focusing on the tool yet.
__________________
2000 SeaRay 380 Sundancer Mercruiser
454 MAG MPI Horizon 380hp / Westerbeke 7.0KW BCGB
many cool mods
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16-06-2019, 17:23
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#4
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cruiser
Join Date: Jan 2017
Boat: Retired from CF
Posts: 13,317
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
#2 uses different sizes depending on the different lug types, heavy-duty wall thickness etc
Try J-H (Brown).
If Alan is your supplier for everything give him a buzz in the morning, very responsive.
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16-06-2019, 17:29
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#5
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Registered User
Join Date: Aug 2013
Location: Florida
Boat: 2000 Searay 380 Sundancer
Posts: 1,087
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
Quote:
Originally Posted by john61ct
#2 uses different sizes depending on the different lug types, heavy-duty wall thickness etc
Try J-H (Brown).
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The Gray J-H lug is rated for 4AWG.
__________________
2000 SeaRay 380 Sundancer Mercruiser
454 MAG MPI Horizon 380hp / Westerbeke 7.0KW BCGB
many cool mods
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16-06-2019, 17:37
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#6
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cruiser
Join Date: Jan 2017
Boat: Retired from CF
Posts: 13,317
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
I usually use Pacer rather than Ancor, from bestboatwire.com
the O.D. of their #2 is close to a 1/2"
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16-06-2019, 17:38
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#7
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Registered User
Join Date: Dec 2016
Posts: 254
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
Quote:
Originally Posted by BlackHeron
That doesn't look like #2 AWG cable. Looks like #6 or #4 at the most.
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Fair question. The markings on the insulation do claim it to be #2 cable.
Thanks,
Allan.
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16-06-2019, 17:38
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#8
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cruiser
Join Date: Jan 2017
Boat: Retired from CF
Posts: 13,317
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
Quote:
Originally Posted by wingless
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Are you looking at the FTZ terminal catalog?
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16-06-2019, 18:01
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#9
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cruiser
Join Date: Jan 2017
Boat: Retired from CF
Posts: 13,317
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
Ancor specs
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16-06-2019, 18:08
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#10
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Registered User
Join Date: Dec 2016
Posts: 254
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
Quote:
Originally Posted by wingless
As you've stated, the ID for the cable is too large. Either the lug is defective, with the ID too large, or the wire is defective, with the OD too small. Can the lug bore ID and the wire OD be measured?
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Wire OD (#2) is 5/16" and the power lug ID (#1-2) is 3/8"
Thanks,
Allan.
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16-06-2019, 18:13
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#11
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cruiser
Join Date: Jan 2017
Boat: Retired from CF
Posts: 13,317
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
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16-06-2019, 18:36
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#12
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cruiser
Join Date: Jan 2017
Boat: Retired from CF
Posts: 13,317
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
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16-06-2019, 18:56
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#13
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cruiser
Join Date: Jan 2017
Boat: Retired from CF
Posts: 13,317
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
What was your source for the Ancor wire? Link?
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16-06-2019, 19:52
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#15
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cruiser
Join Date: Jan 2017
Boat: Retired from CF
Posts: 13,317
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Re: Crimping issue with FTZ 1-2 AWG Power Lugs & 2 AWG Cable
Yes I always thought them trustworthy.
Try a pulltest using the next setting down with the existing supplies, following MS' technique outlined in the links I posted.
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