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12/07/2025
Visit your local site for the relevant product catalog, pricing, service and events
Not all crimping tools are created equal – and for good reason. While some are built for light-duty tasks like bootlace and pre-insulated terminals, others need to handle large conductor sizes and heavy-duty lugs in industrial environments. Some jobs require manual flexibility, while others demand the power and consistency of hydraulic force.
That’s why HellermannTyton offers a comprehensive range of crimping tools, from ergonomic ratchet tools to robust hydraulic crimpers. All designed for secure, high-quality connections no matter the application.
Whether the application is in electrical installation, automotive wiring, or industrial panels Hellermanntyton’s ratchet crimpers produce a uniform and secure crimp for pre-insulated terminals or bootlace ferrules. The ratchet mechanism releases when the correct amount of pressure has been applied to the terminal. This helps prevent under or over crimping and significantly reduces the amount of force required to crimp the terminal, it also reduces user fatigue.
Your advantages:
Both feature clear colour-coded markings for accurate terminal size allocation: Red (0.5mm2 – 1.5mm2), Blue (1.5mm2 – 2.5mm2), Yellow (4mm2 – 6mm2).
Bootlace ferrule crimp tool HYAC5, for conductor size range of 0.5mm2 – 6mm2
Bootlace ferrule crimp tool HYAC6, for conductor size range of 6mm2 – 16mm2
Bootlace ferrule crimp tool HYAC10, for conductor size range of 0.5mm2 – 16mm2
Many crimpers come with interchangeable dies, allowing users to work with a range of cable lug and connector sizes. HellermannTyton’s cable crimpers feature integrated rotary dies, enabling quick and easy transitions between cable sizes without the need to manually change dies. This built-in design reduces reliance on multiple loose die sets and saves valuable time when working with various lug dimensions.
Engineered for demanding electrical installations, the HYCP400 hand held hydraulic crimping tool delivers a powerful 12-tonne output for precise and secure crimping across a wide conductor range of 16 mm² to 400 mm².
Featuring interchangeable C-type dies and a robust hydraulic mechanism, it ensures consistent performance with minimal manual effort. Designed for flexibility and reliability, it’s ideal for industrial, utility, and onsite applications.
Automatic high/low pressure conversion improves crimping efficiency by shifting seamlessly between speed and power modes
A built-in pressure relief valve protects the tool and user by preventing overload during operation
The 180° rotating head provides excellent manoeuvrability in confined or angled workspaces
Manual operation, therefore can be used anywhere and so there no reliance on batteries or power sources
Designed with ergonomic handling and durable construction for comfort and longevity in tough environments
Delivers consistent high-quality crimps, enhancing connection reliability and electrical safety
The hexagonal crimp dies are specifically designed for use with the 12-tonne hydraulic crimper (HYCP400). These dies form a uniform six-sided crimp that ensures excellent electrical conductivity and mechanical strength. The interchangeable C-type dies are available for both copper and aluminium conductors, they’re easily designed to slot into the HYCP400 head and ram which allows for a quick and efficient set up when working with different materials.
| Part No. |
For conductor sizes of (mm2) |
|---|---|
| DIECU16 | 16 |
| DIECU25 | 25 |
| DIECU35 | 35 |
| DIECU50 | 50 |
| DIECU70 | 70 |
| DIECU95 | 95 |
| DIECU120 | 120 |
| DIECU150 | 150 |
| DIECU185 | 185 |
| DIECU240 | 240 |
| DIECU300 | 300 |
| DIECU400 | 400 |
| Part No. |
For conductor size ranges of (mm2) |
|---|---|
| ALDIE6-35 | 6 - 35 |
| ALDIE50-70 | 50 - 70 |
| ALDIE95-120 | 95 - 120 |
| ALDIE150-185 | 150 - 185 |
| ALDIE240-300 | 240 - 300 |
1. Strip the Cable: Remove just enough insulation to expose the conductor this is typically around 5–10mm depending on the terminal size. Take care not to nick or damage the wire strands.
2. Insert the cable connector: Slide the non-insulated cable lug onto the stripped wire. Ensure all strands are fully inside the barrel.
3. Select the Correct Crimp Profile: Choose the appropriate die size or jaw setting on your crimping tool to match the terminal and conductor size. All HellermannTyton cable lugs and links are designed for hex-style crimping.
4. Position the cable lug in the Tool: Place the lug or link into the crimping jaws, aligning it correctly with the crimp zone (usually the centre of the barrel).
5. Crimp the cable lug: Squeeze the handles firmly until the tool completes the full crimping cycle. For ratchet-type crimpers, the tool will release only once the proper pressure is applied.
6. Inspect the Crimp: Check for a tight, even crimp. Tug lightly on the wire to ensure its securely held. A good crimp should not deform the terminal excessively or leave gaps, it should form nicely sharp corners of a hexagon.
The number of crimps required depends on the size of the cable lug and the type of crimping tool being used. As a general guideline, we recommend making the first crimp 5mm from the top of the barrel (nearest the palm). If the barrel length allows for multiple crimps, maintain a 5mm spacing between each crimp, and leave 5mm from the end of the barrel uncrimped. A minimum distance between crimps is usually recommended to ensure proper crimp formation and prevent interference with other parts of the lug. Always ensure the crimps are evenly spaced and fully compressed for a reliable connection.
Choosing the right tool is dependent on the terminal type and conductor size. It’s important to select a tool that matches the connector you’re working with and supports the desired crimp profile for a secure connection. Ensure that the tool covers the right conductor size range and is compatible with any necessary dies or inserts. For consistent results, we recommend our ratchet crimping tools for all HellermannTyton pre-insulated terminals and bootlace ferrules. For all cable lugs and links we have a few options available from indent crimpers through to hand hydraulic crimpers.
Ratchet crimping tools are ideal for smaller terminals like pre-insulated and bootlace ferrules. They deliver consistent crimping force and only release when the correct pressure is applied, reducing the risk of over or under crimping. Hydraulic crimping tools, on the other hand, are built for heavy-duty applications. They use hydraulic pressure to crimp larger conductors, typically from 16 mm² up to 400mm2 they are perfect for copper lugs and links.
Crimping cable lugs, also known as wire terminals, requires a tool that delivers both strength and precision. HellermannTyton’s heavy-duty manual tools are a reliable choice for conductor sizes up to 120 mm². However, for larger cables or more demanding applications, our hydraulic crimping tools provide a superior solution—delivering significantly higher crimping force with minimal physical effort to ensure strong, consistent crimps every time. Aluminium dies are also available for use with our HYCP400, allowing safe and effective crimping of aluminium lugs and links, ensuring the correct compression profile for aluminium conductors.
While our heavy-duty crimping tools are suitable for a wide range of copper cable lugs, HellermannTyton’s hydraulic crimping tools are specifically designed to reduce the physical effort required during installation. Hydraulic crimpers offer greater crimping force, making them ideal for larger conductor sizes and ensuring consistent, high-quality terminations with minimal operator fatigue.
Crimping without an incompatible crimping tool may deform the terminal or wire, resulting in poor connections. Improper crimps can lead to loose connections, overheating or even system failure. Crimping tools are designed to apply the correct amount of pressure and form the correct crimp profile. To ensure safe, secure and reliable connections it’s best to use the right HellermannTyton tool for the job.
