How to Crimp Cable Lugs?

General Information

Compression connections require matching of compression cable lugs, conductors and tool size. That will provide best results: a durable, reliable connection.

Preparation

  • All compression cable lugs are stamped with cross section specification.
  • Select the compression tool die corresponding to this size.
  • The hexagon compressions are carried out by means of mechanical, hydraulic or electrical tools.
  • “Cu” marked dies have to be used for copper compression cable lugs.
  • “Al” dies are used for aluminum or aluminum alloy compression cable lugs.
  • In the case of hydraulic tools differentiation regarding the conductor materials is not necessary.

Assembly instruction:

1. Strip conductor to sleeve length a+10%

    

2. Remove all tapes/yarn/powder or similar conductor filling materials before mounting

3. Erase dirt and oxide layers from the conductor using a metal brush

4. Insert conductor into compression sleeve up to the stop or inspection hole

5. Before compression verify the die code with the size mark on the lug

6. Start compression from the palm side to the barrel end

    

7. The number and position of the compression points is indicated by marking lines. Attention: All markings must be compressed

8. Final Check: The extension length of the sleeve is about 5 % by correct compression with correct conductor – cable lug – die – combination

9. Remove excess grease