Quick Cable 800 User Manual

880000 AAmmpp BBoooosstteerr CCllaammppss

Booster Clamps

CCaabbllee AAsssseemmbbllyy aanndd SSaaffeettyy IInnssttrruuccttiioonnss

How to Make Booster Cables Using 800 Amp Booster Clamps

These instructions are designed for the professional mechanic who wishes to make or repair a set of booster cables using 800 amp booster clamps, Nos. 602070-002, 602071-001 and 602072-001.

These booster clamps can be used with 1, 1/0, 2/0, and 3/0 gauge cable. The gauge of the cable you select is dependent on two factors, the length of your booster cable and the amperage draw of the equipment you are jump-starting.

Once you have selected the cable gauge, then you know which No. 4800 series heavy wall copper lugs you should use. These booster clamps are made to be used with 1, 1/0, 2/0, or 3/0 gauge heavy wall copper lugs. The lugs are clamps; they should be purchased separately. See #6 page 2

1. No. 602070-002 booster clamp kits contain the following:

not included with the booster

No. 602071-001 Kit

1 – 800 amp Solid Copper Clamp

2 – 3-3/4” (95mm) Handle Grip Tube - Black

1 – 5/16” - 18 x 5/8” Round Head Screw

1 – 5/16” - 18 Hex Nut

1 – 800 amp Solid Copper Clamp

2 – 3-3/4” (95mm) Handle Grip Tube - Red

1 – 5/16” - 18 x 5/8” Round Head Screw

1 – 5/16” - 18 Hex Nut

No. 602072-001 Kit

No. 602070-002 Kit

2 – 800 amp Solid Copper Clamp

2 – 3-3/4” (95mm) Handle Grip Tube - Red

2 – 3-3/4” (95mm) Handle Grip Tube - Black

2 – 5/16” - 18 x 5/8” Round Head Screw

2 – 5/16” - 18 Hex Nut

Items not included in the booster cable kit: copper cable and heavy wall copper lugs.

Cut cable to the length of the booster cables you desire. This cable should either be twin conductor or two separate

2. conductors, one for the positive and one for the negative. We strongly recommend finely stranded welding-type cable, with a neoprene or synthetic rubber insulation, as this will remain flexible in cold weather and give you maximum conductivity. See #5 (page 2)

3. Red for Positive, Black for Negative. Use red insulated or red marked cable for the positive booster cable and use black insulated cable for the negative booster cable.

4. Length and Gauge. Generally, the longer the booster cables, the larger the gauge cable you need to use. Likewise, the larger the displacement of the engine you are jump-starting, the larger the gauge cable you should use. If you expect to use the booster cables in very cold conditions, where the temperature may be below 0° F or –20° C, use a large gauge cable, as batteries will not be operating at their peak capability.

Battery Efficiency and Starting Power Requirements Depend on Temperature

Temperature

Degrees F

80° F

Temperature

Degrees C

26° C

Starting Power

Available from Battery

100 %

Starting Power

Required by Engine

100 %

32° F

0° F

-20° F

0° C

-20° C

-29° C

65 %

40 %

18 %

155 %

210 %

268 %

. Guideline for Cable Gauge. For the proper gauge booster cable for your vehicle, please check your owner’s manual.

If this information is not available, use the following as a guideline. Important: the gauge size of your booster cables should be larger than the largest and longest cable in your vehicle.

able Carrying Capacities

25’ (7.6M) Booster Cables

For Intermittent Duty

Only (Not Continuous Duty)

Copper Cable

auge

1 Gauge

1/0 Gauge

2/0 Gauge

3/0 Gauge

Note: For longer booster cables, increase the gauge of the cable.

Made of

elding Cable

Up to 400 Amps

500 Amps

600 Amps

700 Amps

Made of

attery Cable

300 Amps

325 Amps

375 Amps

425 Amps

ypical Vehicle

Full-size Car or Van

Light Truck, Light Construction, Small Tractor

Tractor, Truck, Bus, Construction

HD Tractor, Off Highway

6. Heavy Wall Copper Lugs. Based on cable selected, use the appropriate heavy wall copper lugs below One lug is required for one booster clamp. Four lugs are required for the typical set of booster cables. (The part numbers below are for a box with five lugs.)

The size bullets (left) will help

ou determine the gauge (size)

Part Number

4801-005F

4810-005F

4820-005F

4830-005F

Fits Cable Gauge

1 Gauge

1/0 Gauge

2/0 Gauge

3/0 Gauge

f an unmarked cable.

easure the bare conductor

M only, not the insulation. Actual diameters vary depending on the

pecific stranding of the wire.

Fig. 1

7. Slide the handle grip onto and away from the end. Strip 7/8” to 1” (22 - 25 mm) of insulation from end of cable. Insert bared wires into barrel of lug. Crimp lug on to cable. Use two crimps on barrel for best connection. See Figure 1.

8. One handle of the booster clamp is formed so that the heavy wall lugs will nest inside. Bolt the lug into place according to Figure 2.

9. Slide the 3-3/4" (95mm) handle grip down over the handle and lug, according to Figure 2.

The handle grip tube will seal the cable, reducing corrosion, and it will also act as a strain relief for the cable, extending the life of your booster cable.

10. Push the other handle grip onto the other handle. Make certain the grips are the same color on both handles. See Figure 2.

For a typical set of booster cables, install a second clamp on the other end of the cable. Make certain the same color

11. handle grip is used for both clamps on the same length of cable. Use black grips for the negative booster cable. Use red grips for the positive cable. See Figure 3.

Fig. 2

Fig. 3

+ 2 hidden pages