Mechanical Cable Lugs for Flexible Cable Termination

WISETREE supplies mechanical cable lugs for cable termination in switchgear, transformers, power distribution equipment and industrial electrical systems. The current range includes mechanical bolt and shear-bolt designs such as BMLC, BMCL, BMCL-N, BMCL-A, TMCL and other configurations for different conductor ranges and equipment interfaces.

Unlike conventional compression lugs, mechanical cable lugs create the conductor connection through a bolted structure. Selected designs can also cover a defined conductor range, reducing the need to match every cable cross-section with a separate compression lug and crimping die.

Select the correct model according to conductor material, conductor range, conductor construction, bolt configuration, stud hole, equipment interface and application requirements.

For conventional crimp termination products, browse our complete Cable Lugs, including Copper Cable Lugs, Aluminum Cable Lugs and Bimetallic Cable Lugs.

When to Choose a Mechanical Cable Lug

Mechanical cable lugs are suitable where the installation or project specification calls for a bolted cable termination rather than a conventional compression connection.

They are particularly useful when one or more of the following conditions apply:

• A defined conductor range must be covered by one lug design

• Mechanical or shear-bolt installation is specified

• Dedicated compression dies are not preferred for field installation

• Different cable sizes are used across the same project

• Copper or aluminum conductor compatibility must be considered

• Installation takes place in switchgear, transformer or cable accessory systems

• Equipment-side dimensions require a specific palm or stud-hole configuration

Do not select a mechanical lug only because its conductor range includes your cable size. Confirm conductor material, conductor construction and the equipment-side interface as well.

Mechanical Cable Lug Types

WISETREE offers several mechanical cable lug configurations for different installation requirements.

Standard Mechanical Cable Lugs

Standard mechanical lugs use a bolted connection to secure the conductor.

Confirm:

• Conductor material

• Minimum and maximum conductor range

• Number of bolts

• Bolt dimensions

• Stud hole

• Palm dimensions

The exact installation procedure depends on the selected product series.

Shear Bolt Cable Lugs

Shear-bolt cable lugs use bolts designed to operate according to the specified installation method for the individual product.

WISETREE's current range includes several mechanical lugs with shear-bolt configurations.

For product matching, confirm:

• Conductor range

• Conductor material

• Number of shear bolts

• Bolt head size

• Equipment-side dimensions

• Installation requirements

Do not apply one shear-bolt installation procedure to every product series. Use the technical information provided for the specific model.

Mechanical Cable Lug Selection Guide

Use this table for initial selection. Confirm the final product against the individual model specification.

Key Specifications for Mechanical Cable Lug Selection

Use the following information when comparing product series or preparing an RFQ.

Standard Mechanical Bolt vs. Shear Bolt Lug

Mechanical bolt and shear-bolt cable lugs use different installation approaches.

Select the bolt design according to the cable system and installation requirements.

Do not apply torque values or installation sequences from one product family to another without checking the applicable technical documentation.

Mechanical vs. Compression Cable Lugs

Mechanical and compression lugs can both be used for cable termination, but their selection logic is different.

If your project uses conventional copper compression termination, see Copper Cable Lugs.

For aluminum compression termination, see Aluminum Cable Lugs.

For aluminum conductor termination onto a copper connection point, review Bimetallic Cable Lugs.

Custom Mechanical Cable Lugs

Standard mechanical lug designs do not fit every conductor range or equipment interface.

WISETREE can review project-specific mechanical cable lug requirements according to manufacturing feasibility.

• Conductor range

• Body dimensions

• Palm width

• Palm thickness

• Stud hole

• Overall length

• Number of bolts

• Bolt type

• Bolt head dimensions

• Shear-bolt configuration

• Insert configuration

• Material requirement

• Surface requirement

• Product marking

• Packaging

For custom evaluation, send:

• Conductor specification

• Required conductor range

• Equipment terminal dimensions

• Installation method

• Drawing or sample

• Estimated quantity

If no formal drawing is available, provide clear dimensions and application information for initial review.

Typical Applications

Mechanical cable lugs can be used for cable termination in applications such as:

• Switchgear

• Transformers

• Power distribution equipment

• Cable accessory systems

• Substations

• Industrial electrical equipment

• Renewable energy power distribution

• Utility infrastructure

• Indoor and outdoor electrical installations

The actual application and voltage suitability depend on the selected product series.

For conductor-to-conductor mechanical joining, browse Mechanical Cable Connectors.

For related electrical connection products, visit Terminals & Connectors.

Frequently Asked Questions

What is the difference between a mechanical cable lug and a compression cable lug?

A mechanical cable lug secures the conductor with bolts or shear bolts. A compression lug is crimped onto the conductor using a compatible tool and die. Select the connection method according to the cable system and project installation requirement.

How do I select the correct conductor range for a mechanical cable lug?

Confirm the actual cable size and compare it with the minimum and maximum conductor range of the specific mechanical lug. Also check conductor material and construction before selecting a model.

Can one mechanical cable lug fit several cable sizes?

Some mechanical lug designs cover a defined conductor range. The exact range depends on the specific product series. Confirm that every cable size you intend to use falls within the compatible range.

Can mechanical cable lugs be used with both copper and aluminum conductors?

Compatibility depends on the specific product series. Do not assume universal Cu/Al compatibility. Confirm the conductor material against the technical information of the selected model.

What is a shear bolt cable lug?

A shear-bolt cable lug uses a bolt design intended to be installed according to the specified shear procedure. The conductor range, bolt design and installation method should be confirmed for the individual product.

How do I select the correct number of shear bolts?

Bolt quantity is determined by the product design and conductor range. Select the mechanical lug according to its specified conductor range rather than choosing bolt quantity independently.

Do mechanical cable lugs require crimping tools?

Mechanical cable lugs do not use the conventional compression-lug crimping process. They require the mechanical installation tools specified for the bolt or shear-bolt design.

Can mechanical cable lug dimensions and bolt configurations be customized?

Project-specific dimensions and connection configurations can be reviewed according to manufacturing feasibility. Send the conductor range, equipment-side dimensions, bolt requirement, drawing and estimated quantity for evaluation.

Send Your Mechanical Cable Lug Specification

If you already know the required model, send the product series, conductor size and quantity for quotation.

If you are still comparing BMCL, BMLC, TMCL or other mechanical lug options, provide your conductor material, actual cable size, required conductor range, bolt type, stud size and application.

For equipment-specific or non-standard connections, attach a drawing or reference sample.

Contact WISETREE to request mechanical cable lug specifications, samples or a quotation.