Zupper 18V-Battery Hydraulic Crimping Tool 400mm2 ED-400

The termination of large cross-sectional cables on commercial M&E projects using manual hydraulic pumps is a primary reason why operators become fatigued, project schedules are extended, and crimp profiles are irregular. The Zupper ED-400 battery hydraulic crimping tool is developed to eliminate these inefficiencies. This tool is utilized to offer fast, automated hexagonal crimping for copper conductors up to 400mm2 and aluminum conductors up to 300mm2, utilizing a 120KN electro-hydraulic power unit coupled with a dedicated 18V lithium-ion platform. It is the standard heavy-duty solution for switchboard fabricators, underground cable jointers, and power grid maintenance contractors.

Technical specifications

The following output parameters should be verified by procurement officers and electrical engineers to ensure they are in accordance with local electrical termination standards.

Resolving issues in M&E terminations

Electrical contractors undergo strict inspections by local authorities. The ED-400 is mechanically engineered to resolve the most frequent field problems that cause inspection failures.

Reducing manual fatigue in volume terminations

Pumping a 12-ton hydraulic crimper manually on a 400mm2 cable requires tremendous physical effort. Fatigued operators often fail to fully compress the dies, leading to high-resistance joints that produce heat and cause serious fire hazards. The ED-400 makes use of an internal micro-pump powered by a high-torque DC motor. The operator simply presses a trigger to provide the full 120KN force. When the peak pressure is achieved, the piston is automatically retracted by the internal micro-valve, ensuring that the entire compression cycle is complete and uniform each time without physical strain.

Movement through narrow switchboard areas

Long manual pump handles can hardly be manipulated in cable trenches or main switchboards (MSB). To overcome this space limitation, the ED-400 features a robust C-shape crimping head that rotates a full 360 degrees along its longitudinal axis. This enables the operator to pre-load the cable lug, push the tool between tight copper busbar layouts, adjust the trigger grip to an ergonomic position, and then initiate the crimp.

Pressure and thermal safety measures

Power tools constantly used in tropical climates are prone to thermal overload. The ED-400 has a built-in heat dissipation system and an electronic control board to monitor motor temperature. Moreover, the mechanical safety valve acts as a definitive fail-safe; the hydraulic circuit cannot over-pressurize, and the internal seals are protected from rupturing in case the tool is accidentally switched on without a die set installed.

Standard die sets and accessories

The Zupper ED-400 is provided as a complete operational package, contained in a high-density, impact-resistant polymer enclosure to facilitate instant deployment upon delivery.

• Hexagonal die set included: 16, 25, 35, 50, 70, 95, 120, 150, 185, 240, 300, and 400 mm2.

• Power supply: Two (2) 18V Lithium-ion batteries to ensure continuous operation across extended shifts.

• Charging unit: One (1) AC rapid charger.

• Maintenance kit: High-pressure cylinder O-ring replacement set.

Note: Always select the die size that exactly matches the cable cross-section and the lug specifications. Improper die selection will result in flash (metal extrusion) or an incomplete cold weld.

Order today

Ready to upgrade your toolkit? Contact our team directly through the A.P.E website to verify stock, get a clear pricing quote, and arrange fast local delivery. Let us equip you with the right tools to get the job done safely and efficiently.

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