Hydraulic cable crimping

Hydraulic cable crimping tools deliver controlled compression force to attach cable lugs and connectors onto electrical conductors in industrial installation and maintenance work. This product range spans battery-powered and hydraulic-drive units offering 62 kN to 130 kN crimping force, handling cable cross-sections from 6 mm² to 400 mm². Models such as 106652 and 106665 feature rotating crimping heads—180° and 270° respectively—enabling flexible operation inside crowded switchgear cabinets. The MultiPro system, anchored by unit 106345, accepts interchangeable crimping and cable-cutting heads to serve multiple applications from a single power base. Hexagonal crimping insert sets like 106896 and 106900 support copper and aluminum cable lugs according to DIN standards. Series 22 crimping inserts from 105711 through 105721 provide 5 mm crimping width, forming uniform hexagonal profiles for secure electrical connections. The collection also includes the indenting-die crimper 106656, which handles tubular lugs and connectors in the 10–300 mm² range without die changes.

Force ratings and cable cross-section coverage

Crimping force determines the maximum cable cross-section a tool can reliably compress and the mechanical integrity of the finished joint. Units in this range divide into two primary force classes: 62 kN and 130 kN. The 62 kN tier suits small to medium cable sections, while the 130 kN tier addresses heavy-duty conductors up to 400 mm².

The 62 kN category includes 106345 and 106656. Unit 106345 forms the foundation of the MultiPro system, pairing with head 106350 to crimp lugs and pin terminals. Unit 106656 crimps tubular lugs, standard connectors, and DIN 46234 lugs across 10–300 mm² without die swaps. Its 180° rotating head improves access in confined spaces.

The 130 kN tier is represented by 106665, which handles 10–400 mm² cable sections. The C-shaped crimping head opens 38 mm and rotates 270° around its axis, reaching cable ends inside switchgear panels. This force level ensures full compression of large aluminum and copper conductors, meeting the mechanical and electrical requirements of high-current installations.

Rotating crimping heads and workspace access

Rotating heads enable technicians to position the crimping jaw without repositioning the entire tool body. This feature proves essential when working inside electrical cabinets where cable routing and adjacent equipment limit movement. Two rotation angles appear in the range: 180° and 270°.

Unit 106652 incorporates a detachable 180° rotating head. The head swivels halfway around the tool axis, allowing the operator to align the crimping jaw with the cable lug while keeping the handle clear of cabinet walls. This design reduces the need to reposition cables or remove adjacent components during termination work.

Unit 106665 extends rotation to 270°, covering three-quarters of a full circle. The C-shaped jaw opens 38 mm, accommodating large lugs and thick insulation jackets. Combined rotation and jaw geometry permit crimping in corners and along cabinet edges where straight-head tools cannot reach. Both models support quick head removal for maintenance or replacement.

MultiPro modular system architecture

The MultiPro platform separates the hydraulic power unit from the working head, enabling one battery-powered base to drive multiple interchangeable attachments. This modularity reduces the number of complete tools required on site and simplifies inventory management for maintenance teams.

Base unit 106345 houses the 18 V battery, hydraulic pump, and quick-change coupling. It delivers 62 kN force to any compatible head. The basic kit includes the power unit, two batteries, a charger, and a carrying case. Operators select the appropriate head for each task and attach it via the coupling mechanism.

Crimping head 106350 pairs with 106345 to crimp cable lugs and pin terminals. The head accepts interchangeable crimping jaws tailored to specific lug types and cross-sections. Robust construction and secure jaw retention ensure consistent crimp geometry across repeated cycles. The complete set 106354 bundles the power unit with both crimping and cable-cutting heads, covering termination and cable preparation in one package.

Hexagonal crimping insert sets for standard lugs

Hexagonal crimping produces a six-sided compression profile that distributes mechanical stress evenly around the conductor and lug barrel. This geometry meets DIN specifications for tubular cable lugs and connectors, ensuring reliable electrical contact and pull-out resistance in power distribution systems.

Set 106896 contains six pairs—twelve individual inserts—designed for tool 106652. Each pair crimps copper and aluminum tubular lugs to standard dimensions. The 5 mm crimping width forms uniform hexagons, preventing lug deformation and conductor strand damage. The set ships in a transport box for organized storage and field deployment.

Set 106900 targets aluminum cable lugs and connectors conforming to DIN 46329 and similar standards. It includes six pairs of half-round inserts that create hexagonal profiles with 7 mm crimping width. The wider crimp accommodates the larger barrel diameters typical of aluminum lugs, which require greater compression area to achieve equivalent contact resistance compared to copper.

Series 22 crimping inserts for tubular lugs and connectors

Series 22 inserts support axial crimping of tubular cable lugs and connectors per DIN 46234 and DIN 46230, as well as tubular lugs for stranded flexible conductors. Axial crimping compresses the lug barrel along its length, forming a hexagonal cross-section that locks the conductor strands in place.

Insert 105711 handles 6 mm² cross-sections with 5 mm crimping width. Insert 105712 serves 10 mm², 105713 covers 16 mm², and 105714 addresses 25 mm². Each insert matches a specific conductor size to prevent over-compression or under-compression, both of which degrade joint performance.

Mid-range inserts include 105715 for 35 mm², 105716 for 50 mm², 105717 for 70 mm², and 105718 for 95 mm². Larger sections are served by 105719 at 120 mm², 105720 at 150 mm², and 105721 at 185 mm². All maintain the 5 mm crimping width standard.

Insert 105764 crimps 50 mm² cable lugs and pin terminals according to DIN 46234 and DIN 46230, plus tubular lugs for multi-strand flexible wire. Axial crimping creates secure joints that resist vibration and thermal cycling in industrial power circuits. Proper insert selection ensures the crimp meets pull-out force and contact resistance specifications.

Indenting-die crimping without die changes

Indenting-die crimpers use a pointed die to press the lug barrel into the conductor, forming multiple indentations around the circumference. This method eliminates the need to swap dies when moving between cable sizes within the tool's rated range, speeding up termination work on mixed-gauge installations.

Unit 106656 crimps tubular lugs, standard connectors, and DIN 46234 lugs from 10 mm² to 300 mm² without die changes. The indenting die adapts to varying lug diameters by adjusting penetration depth automatically. The 180° rotating head allows the operator to orient the tool for optimal access in tight quarters.

This approach reduces the number of accessories carried to the job site and shortens setup time between terminations. The tool maintains consistent crimp quality across the entire cross-section range, provided the lug barrel thickness and material fall within design limits. Indenting-die crimping suits field service and maintenance scenarios where cable sizes vary unpredictably.

Battery power and hydraulic actuation

Battery-powered hydraulic crimpers combine the portability of cordless tools with the force multiplication of hydraulic systems. An electric motor drives a hydraulic pump, which pressurizes fluid to move the crimping piston. This architecture delivers high force without requiring manual pumping or external power sources.

Units 106652, 106665, 106345, and 106656 all operate on 18 V lithium-ion batteries. Battery capacity determines the number of crimps per charge, which varies with cable size and crimp force. Larger cross-sections and higher forces consume more energy per cycle.

Hydraulic actuation ensures smooth, controlled compression that stops automatically when the programmed force is reached. This prevents over-crimping, which can fracture conductor strands or crack lug barrels. Consistent force application across all crimps improves joint reliability and reduces the risk of field failures due to improper termination.

Selecting the appropriate tool and insert combination

Choosing the correct crimper and insert depends on cable cross-section, lug type, applicable standards, and workspace constraints. Start by identifying the conductor size range for the project. Match that range to a tool with adequate force rating and compatible inserts or dies.

For installations involving multiple cable sizes and both crimping and cutting tasks, the MultiPro system offers flexibility. Base 106345 with head 106350 handles crimping, while additional heads address cable cutting. The complete set 106354 provides both functions in one kit.

When working in confined cabinets or near obstacles, prioritize rotating-head models. Unit 106652 with 180° rotation suits moderately tight spaces, while 106665 with 270° rotation and a C-shaped jaw addresses the most challenging access scenarios. For rapid termination across a wide size range without accessory changes, 106656 offers indenting-die convenience.

Verify that the selected inserts or dies comply with the relevant DIN or equivalent standards for the lugs and connectors in use. Hexagonal sets 106896 and 106900 cover standard copper and aluminum lugs, while Series 22 inserts provide precise size matching for tubular lugs per DIN 46234 and DIN 46230. Matching tool, insert, and lug ensures mechanical and electrical performance meets design specifications.