ABB - Installation Products 60178 - Aluminum One-Hole Lug, Long Barrel, Blind End, Max 35kV, 750 kcmil Wire, 900 Compact, 5/8 Inch Bolt Size, Tin Plated, Die Code 115H, Die Color Code Yellow
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ABB - Installation Products

60178

UPC: 786210601786


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Installation InstructionsSpecification SheetManufacturer Product Website

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Overview

The ABB 60178 Aluminum One-Hole Lug is a high-conductivity electrical connector designed for 35kV applications with 750 kcmil stranded aluminum or copper conductors. This lug features a long barrel and blind end design, ensuring secure cable retention and protection against moisture ingress and environmental contaminants. The thick-walled wrought aluminum construction with a tin-plated finish delivers superior corrosion resistance in harsh industrial environments. Key specifications include a 5/8-inch bolt size, die code 115H (color-coded yellow), and compatibility with Panduit and specified competitor crimping tools. The 900 series compact design optimizes space utilization in power distribution systems, substations, and industrial machinery where installation efficiency is critical. The enclosed barrel design inhibits corrosive material entry, and when used with compatible systems, the pre-filled joint compound enhances long-term electrical performance by improving conductivity and reducing oxidation at the connection point. Ideal for power utilities, renewable energy installations, and heavy industrial applications requiring reliable high-voltage terminations, the 60178 ensures durability and performance in both indoor and outdoor settings. The lug’s design and materials make it a versatile choice for critical electrical connections in demanding environments, including high-voltage power distribution, substations, and industrial machinery where reliable terminations are essential.
  • Designed for 35kV applications with 750 kcmil stranded aluminum or copper conductors
  • Long barrel and blind end design for secure cable retention and moisture protection
  • Tin-plated finish for superior corrosion resistance in harsh environments
  • Compatibility with Panduit and specified competitor crimping tools (die code 115H, yellow)
  • Compact 900 series design optimizes space in power distribution and industrial systems
  • Compatible with Panduit and specified competitor crimping tools (die code 115H)
  • Color-coded yellow for easy identification and die selection
  • Compact 900 series design optimizes space in high-voltage installations

Specifications

Cable Size
750 kcmil
Color
Yellow
Insulation
None
Material
Aluminum
Number Of Holes
1
Standard
UL E9809
Standard
UL E9809 / UL E9809
Stud Size
5/8 in
Type
Long Barrel
Voltage Rating
35 kV
Package Dimensions (L x W x H)
5 IN x 4.5 IN x 3 IN
Package Dimensions (L x W x H)
12.7 cm x 11.43 cm x 7.62 cm
Package Weight (Imperial)
0.700 L
Package Weight (Metric)
0.318 kg
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How to Install the 60178 Aluminum Lug

Instructions for installing and crimping the 60178 aluminum lug, ensuring a secure electrical connection.

Estimated time: 15m

Tools needed:

Wire strippers, Crimping tool (appropriate die), Wire brush or emery cloth, Safety gloves, Safety glasses

Supplies needed:

Joint compound (for aluminum cable), Belleville compression washer (for bolting to pad)

  1. Prepare the Cable

    WARNING: Risk of shock, disconnect power before installation. Strip the insulation from the cable to the length specified in the product's table. Avoid nicking the cable strands. Remove the plastic protective cap from the wire barrel of the lug.

  2. Apply Compound and Insert Cable (Aluminum Cable Only)

    WARNING: Do not remove compound from barrel. Smear a thin layer of joint compound onto the aluminum cable. Brush the cable with a wire brush or emery cloth. Insert the cable into the connector barrel until it stops. The insertion length should approximate the stripped cable length.

  3. Perform Crimp

    CAUTION: Using an improper installing die may result in a defective connection. Select the appropriate installing die and the number of compressions required as per the product's table. Insert the lug into the die and compress it between the specified markings, starting near the tongue of the connector. Refer to the product's table for the correct die code and number of compressions for your specific cable size and lug model.

  4. Clean Up Crimp

    After crimping, remove any sharp edges, flash, or burrs resulting from the crimping process.

  5. Insulate the Connection

    Insulate the connection using one of the methods specified in the product's table (e.g., shrink tubing or adhesive pad).

  6. Bolt Lug to Pad

    Important: Bolting the lug to a pad is critical for a good connection. Use a Belleville compression washer to compensate for expansion and contraction due to temperature changes. Turn the bolt until the compression washer is flat.

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