Crimping Lugs as per UL 486A-486B Simplified!

Installation Process of Cable Lugs

Note: Before starting, please ensure that you use proper tools, procedures and personal protective equipment to avoid injury. Also kindly follow these do’s and don’ts suggested by UL 486A-486B.

Do’s

Always confirm that cable strands have entered fully into the barrel.
After removing the cable insulation do not remove or cut any wire strands. Use the complete barrel for crimping.
Ensure that all wire strands are inserted in the long barrel.
Use only the recommended size of lug for recommended size of cable.
If multiple crimps are required, make the first crimp when crimping lugs closest to the Lug Palm.

Don’ts

Do not strip cable insulation more than recommended.
Do not use crimping dies for crimping lugs that don’t match, for example using a 35 mm² die for the first crimp and a 50 mm² die on the second.
Do not use any other tool for crimping than the recommended one by the manufacturer.
Do not insert multiple smaller cables into a lug designed for a single larger cable, such as two 35 mm² cables in a 70 mm² lug.

Accessories & Tools for Proper Installation

Wire Brush
Marker
Oxide Inhibiting Compound (For Aluminium lugs only)
Cable Insulation Stripper
Crimping Tools & Dies
Measuring Tape

Talk to our engineers!

Installing a Single Hole Cable Lug

Pre-requisites

Choose the crimping tool and dies with the exact dimensions recommended by the cable lug manufacturer. Check the markings on the connector or the labels on the packages to verify.

Cable Preparation

Step 1: Measure the distance of the insertion depth of the lug to be used. In this case, the strip length will be the Barrel length + 6 mm.
Step 2: Once measured, mark the distance on the cable using a marker.
Step 3: Using a suitable stripper, cut and remove the cable insulation leaving sufficient extra allowances. Approximately 3mm to 5mm.
Step 4: Clean or brush the surface of the conductor using a wire brush to remove any oxidation.
Step 5: Apply Oxide Inhibiting compound recommended for aluminium on the cable strands.

Note: Axis Aluminium Cable Lugs are supplied with factory-filled oxide inhibiting compounds.

A) Using Battery-Operated Crimping Tool

Step 1: Insert the cable or conductor into the barrel of the cable lug.
Step 2: Use the crimping tools & dies for the crimping process as specified in the Instruction sheet.
Step 3: Complete the crimping process as shown.

B) Using Hand Held Hydraulic Crimping Tool

Step 1: Insert the cable or conductor into the barrel of the cable lug.
Step 2: Use the crimping tools & dies for the crimping process as specified in the instruction sheet.
Step 3: Pull the switch on the crimping tool to insert and place the dyes correctly.
Step 4: Complete the crimping process as shown.

Note: Once the crimping is done, remove the excess material and clean the connection surfaces to avoid resistance and corrosion.

Watch this video to understand it better:

Congratulations you have now successfully crimped your single hole cable and lug using the crimping tool.

I hope you have a clear understanding of crimping lugs and connectors. At Axis, we have a team of 50+ engineers to design and support your project needs for Lugs & Connectors, Earthing & Lightning Protection, and many more.