Foot-operated swaging for repeat wire rope assembly
AM-116 turns repetitive hand squeezing into foot-controlled pneumatic crimping. Build batches of cable loops and end stops with compatible copper or aluminum sleeves in the listed 1/16–3/16 in. range (approximately 1.6–4.8 mm). A fixed workstation is a practical choice when the same verified cable-and-sleeve combination is assembled repeatedly.
The jaws mechanically compress a metal sleeve around the wire rope. This is cold swaging, not welding, and it is different from crimping electrical terminals or wire-end ferrules.
Is AM-116 right for your job?
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Repeated workshop batches: pneumatic actuation reduces repeated hand-grip effort compared with manual swagers.
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Loop and stop assembly: use matched oval/duplex sleeves for loop terminations and matched stop sleeves for end-stop applications.
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Foot control: operate the cycle without squeezing long handles; keep hands clear of the jaw area before pressing the pedal.
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Existing compressed-air workstation: best suited to a stable bench with an adequate regulated air supply.
For occasional jobs or work away from compressed air, compare a manual swaging tool instead. A pneumatic cycle improves workflow but does not automatically verify connection strength.
Applications to evaluate
These are candidate applications for a correctly matched and tested assembly, not blanket approvals for every cable system.
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Fishing tackle and marine accessory workshops: repeat steel leader and tether assemblies within the supported range. Confirm sleeve material for saltwater exposure; do not assume suitability for monofilament or fluorocarbon.
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OEM cable assembly: small wire-rope loops, retaining cables and equipment tethers made to a specified drawing.
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Agriculture and horticulture: preparation of compatible trellis, fence and support-cable terminations.
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Display and fabrication workshops: custom cable loops and end stops for fixtures and assemblies with a defined load requirement.
Safety-critical work needs a qualified connection system. This listing does not establish approval for lifting slings, fall protection, overhead safety cables, aircraft controls or structural cable railings. Stainless steel threaded railing fittings require specifically matched tooling and are not established as compatible with these copper/aluminum sleeve jaws.
Check these details before ordering
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Cable: outside diameter, material, construction (for example 7×7 or 7×19), coating and required service load.
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Sleeve: manufacturer/part number, copper or aluminum, oval/duplex or stop design, dimensions and intended cable size.
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Tooling: confirm the correct groove and the sleeve supplier's compression sequence, number of presses and acceptance dimensions. Nominal diameter alone does not prove a fit.
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Environment: match sleeve and rope materials for indoor, wet, outdoor or saltwater use.
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Production: share pieces per day and available air pressure/flow so the workstation can be assessed.
A stop sleeve is not interchangeable with a load-rated eye splice. A thimble supports the inside of a cable eye; the sleeve is the part being compressed. For coated cable, follow the sleeve supplier's preparation instructions rather than crimping over a coating by assumption.
Specifications and package
| Listed swaging range |
1/16–3/16 in. (≈1.6–4.8 mm); confirm actual cable, sleeve and groove combination |
| Sleeve materials |
Compatible copper and aluminum oval/duplex and stop sleeves |
| Working pressure |
102–138 psi / 7–9.5 bar / 0.7–0.95 MPa, per AM-116 instructions |
| Output force |
Manual designation: 6T. This is tool output, not the working-load limit of a finished cable assembly. |
| Control |
Pneumatic drive with foot pedal |
| Length × width |
49 × 14 cm (≈19.3 × 5.5 in.), per manual |
| Tool weight |
13 kg (≈28.7 lb), per supplied AM-116 manual; confirm packed shipping weight separately |
| Manual packing list |
1 main body, 1 pedal control, 3 air tubes and 2 spare quick connectors. Compressor not included. |
Inch-to-metric conversions are approximate references, not approval for a differently dimensioned metric sleeve. Confirm the supplied jaw markings and sleeve specification before production.
Air supply: what compressor do I need?
The tool requires 102–138 psi at its inlet during operation. A compressor limited to 90 psi is below the stated working range. Check regulated delivery pressure while cycling, not only the storage-tank gauge.
- Use clean, dry, regulated compressed air and pressure-rated hoses and fittings suitable for the maximum operating pressure.
- Account for pressure loss through hoses, connectors and other tools sharing the supply.
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Air consumption in CFM or L/min is not specified in the supplied manual. Ask for confirmed consumption and duty-cycle data before choosing compressor horsepower, tank size or a multi-machine air system.
- Follow the current model-specific instructions for air preparation and lubrication; do not copy the setup of another pneumatic crimper.
How to obtain a reliable crimp
- Prepare a clean cable cut with a suitable wire-rope cutter. Select the specified sleeve and form the loop or stop according to its supplier's instructions.
- With the air isolated, check installation and hose connections against the AM-116 manual. Keep clear when connecting air; the correctly connected jaws should open at startup.
- Place the sleeve squarely in the correct groove. Keep fingers outside the closing area, then press the pedal until the jaws fully close. Follow the sleeve's specified press sequence.
- Inspect the first piece for damage, alignment and required dimensions. Use the specified gauge where applicable and perform the required sample pull test before releasing a batch.
- Recheck after changing cable, sleeves, settings or tooling. Isolate the air before cleaning or maintenance.
One operator only: the same person positions the work and operates the pedal. Never let another person activate it while hands are near the jaws.
Frequently asked questions
Will it crimp stainless steel wire rope?
The sleeve must be a compatible copper or aluminum type, and the complete rope/sleeve/groove combination must be checked. Stainless steel rope and stainless steel sleeves are different compatibility questions; this listing does not establish stainless steel sleeve or railing-stud capability.
Does 6T mean the finished loop can hold 6 tons?
No. Assembly performance depends on the rope, sleeve, tooling and process. Use the connection supplier's tested ratings and the required design factor; do not derive a working-load limit from tool force.
Can I use any sleeve with the same size label?
No. Wall thickness, length, material and profile can differ. Send the sleeve drawing or part number with your cable specification for a fit check.
What makes pneumatic operation useful?
It reduces repeated manual squeezing during batch assembly and gives a foot-controlled workstation. Actual production rate depends on cable preparation, positioning, the number of presses and inspection; no fixed cycles-per-minute claim is made.
Can the tooling be customized?
For qualifying order quantities, ask about application-specific tooling. Send cable and sleeve samples or drawings, the required acceptance criteria and estimated quantity. Feasibility, minimum order and validation requirements are confirmed before quoting.
Complete your workstation
CWR60 wire rope cutter — check the cable construction and diameter. Manual bench swaging alternative — compare its separate capacity before choosing.
Need a fit check? Email sales@iwiss.com with cable diameter/construction, sleeve part number or drawing, application, daily quantity and available air supply. Request the current AM-116 instructions with your configuration.
