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Professional automotive electrical connectors and cable
Understanding Cable Lugs & Terminals
Choosing the correct cable lug ensures safe, reliable electrical connections. The wrong size can cause poor contact, voltage drop, overheating, and connection failure.
Types of Cable Lugs
Ring Terminals: Most secure - complete circle around bolt. Best for permanent installations
Fork Terminals (Spade): U-shaped, can install without removing bolt. Quick connections
Battery Terminals: Heavy-duty lugs for battery posts. Often tinned copper
Bootlace Ferrules: For multi-strand wire into screw terminals. Control panels
Cable Size to Lug Size Chart
Cable Size (mm²)
AWG Equivalent
Lug Hole Size
Bolt Size
Max Current
1.5mm²
16 AWG
M4-M5
M4-M5
15A
2.5mm²
14 AWG
M5-M6
M5-M6
20A
4mm²
12 AWG
M5-M6
M5-M6
25A
6mm²
10 AWG
M6-M8
M6-M8
35A
10mm²
8 AWG
M6-M8
M6-M8
50A
16mm²
6 AWG
M8-M10
M8-M10
70A
25mm²
4 AWG
M8-M10
M8-M10
100A
35mm²
2 AWG
M10-M12
M10-M12
150A
50mm²
1/0 AWG
M10-M12
M10-M12
200A
70mm²
2/0 AWG
M12
M12
250A
95mm²
3/0 AWG
M12
M12
300A
Automotive Cable Lug Applications
Application
Current
Cable Size
Lug Type
Interior Lights
5-10A
1.5-2.5mm²
Ring, M5-M6
Auxiliary Lights
10-20A
2.5-4mm²
Ring, M6
Fuel Pump
15-20A
4-6mm²
Ring, M6-M8
Radiator Fan
20-30A
6-10mm²
Ring, M8
Winch Motor
150-300A
35-70mm²
Battery, M10-M12
Alternator Output
80-150A
25-35mm²
Ring, M10
Starter Motor
200-400A
50-95mm²
Battery, M12
Battery Ground
300-500A
70-120mm²
Battery, M12
Crimp Terminal Color Codes
Insulated crimp terminals use color coding for cable size:
Red: 0.5-1.5mm² (22-16 AWG) - Light duty, signal wires
Blue: 1.5-2.5mm² (16-14 AWG) - Standard automotive circuits
Yellow: 4-6mm² (12-10 AWG) - Higher current accessories
Clear/Uninsulated: Heavy duty applications (10mm²+)
Pro Tip: Always match the lug barrel (crimp area) to your cable size. The hole size determines bolt compatibility. A 35mm² cable might use M10 or M12 depending on your bolt.
Proper Crimping Technique
Use correct tool: Ratcheting crimper ensures proper compression
Strip correctly: Remove only enough to fill barrel completely
Insert fully: Wire should be visible at inspection hole
Crimp in center: Not too close to entry or terminal end
One crimp only: Multiple crimps weaken connection
Heat shrink protection: Especially in harsh environments
Test pull: Terminal shouldn't pull off with firm pressure
Bolt Size and Torque Settings
Bolt Size
Torque
Max Cable
M5
2-3 Nm
4mm²
M6
3-5 Nm
10mm²
M8
8-12 Nm
25mm²
M10
15-20 Nm
50mm²
M12
20-30 Nm
95mm²+
Common Installation Mistakes
Wrong tool: Pliers don't work - use ratcheting crimper
Under-crimped: Terminal pulls off, poor contact
Over-crimped: Damages strands, reduces capacity
Exposed strands: Creates short circuit risk
Mismatched sizes: Too small = poor crimp, too large = loose
No anti-oxidant: Critical for aluminum lugs
Battery Terminal Guidance
Use battery-grade lugs: Heavier construction, better contact
Tinned copper preferred: Resists acid corrosion
Use terminal grease: Prevents corrosion, improves conductivity