IWISS AWG24-12 JST Open Barrel Crimper and Wire Cutter Instruction Manual

1. Introduction

This manual provides detailed instructions for the safe and effective use of the IWISS AWG24-12 JST Open Barrel Crimper (Model IWS-2412M) and the accompanying Wire Cutter (Model ICP-206). These tools are designed for precision electrical work, specifically for crimping non-insulated open barrel terminals and cutting various types of electrical wires.

The IWS-2412M crimper is suitable for JST ZH, Dupont, and Molex open barrel terminals, covering a wire gauge range of AWG 24-12 (0.21-3.31mm²). The ICP-206 wire cutter is designed for cutting copper and aluminum cables, including single conductor and multiple stranded wires, up to 4AWG aluminum and 3AWG copper.

2. Product Overview

The IWISS crimper and wire cutter set includes two essential tools for electrical wiring tasks. Understanding the components and features of each tool is crucial for proper operation.

2.1. IWISS IWS-2412M Open Barrel Crimper

Image Description: A close-up view of the IWISS IWS-2412M crimper highlighting its key features. The image points out the angled head for maximum leverage, the tool latch for preventing dust when closed, and the ergonomically designed two-component handles for comfortable use.

• Angled Head: Designed for maximum leverage during the crimping process.
• Tool Latch: Secures the tool jaw when closed, protecting it from dust and accidental opening.
• Ergonomically Designed Handle: Two-component handles provide a comfortable grip and reduce hand fatigue during prolonged use.
• Crimping Dies: Multiple die sizes ranging from 2.2mm to 3.4mm, suitable for AWG 24-12 (0.21-3.31mm²) wires.

2.2. IWISS ICP-206 Wire Cutter

Image Description: A detailed view of the IWISS ICP-206 wire cutter, illustrating its main features. The image highlights the CR-V steel body with a rust-resistant black oxide finish, the high tenacity holding spring that returns the blades to their original position after shearing, and a safety lock for secure storage.

• CR-V Steel Body: Constructed from CR-V steel with a rust-resistant black oxide finish for durability.
• High Tenacity Holding Spring: Ensures the blades return to their open position after each cut, facilitating repetitive tasks.
• Safety Lock: A mechanism to keep the cutter blades securely closed when not in use, enhancing safety during storage.

3. Setup and Preparation

Before beginning any crimping or cutting task, ensure you have a clean and well-lit workspace. Inspect both tools for any signs of damage or wear. Always wear appropriate personal protective equipment, such as safety glasses, when working with hand tools.

3.1. Crimper Preparation

• Unlock the tool latch to open the crimper jaws.
• Select the appropriate crimping die size based on the wire gauge and terminal size. The die sizes are marked on the crimper jaw (e.g., 2.2, 2.5, 2.8, 3.1, 3.4).

3.2. Wire Cutter Preparation

• Release the safety lock to open the cutter blades.
• Ensure the blades are clean and free of debris.

4. Operating Instructions

4.1. Using the IWS-2412M Open Barrel Crimper

Follow these steps for proper crimping of open barrel terminals:

1. Prepare the Terminal: Select the correct open barrel terminal for your application.
2. Place the Barrel: Place the paralleled barrel of the terminal into the upper die of the crimper. It is recommended to guide the barrel from the reverse side of the crimping die for optimal positioning.

   Image Description: A two-part image demonstrating the initial steps of crimping. The top part shows an open barrel terminal being placed into the crimper's die, with an arrow indicating it should be guided from the reverse side. The bottom part illustrates a stripped wire being inserted into the terminal's barrel, showing the conductor barrel and insulation barrel.

3. Strip the Wire: Carefully strip the insulation from the end of your wire to the appropriate length, exposing the conductor. Ensure the stripped length allows the conductor to sit fully within the conductor barrel and the insulation to be secured by the insulation barrel.
4. Insert the Wire: Insert the stripped wire into the terminal barrel. Ensure the conductor is fully seated in the conductor barrel and the insulation is positioned correctly in the insulation barrel.
5. Crimp the Conductor Tab: Squeeze the crimper handles firmly until the conductor tab of the terminal is securely crimped around the exposed wire conductor.

   Image Description: A two-part image showing the result of proper crimping. The top section displays a close-up of a wire terminal with the conductor tab securely crimped around the wire's exposed conductor. The bottom section shows the insulation tab crimped around the wire's insulation, providing strain relief.

6. Crimp the Insulation Tab: Reposition the terminal if necessary and squeeze the crimper handles again to crimp the insulation tab around the wire's insulation. This provides strain relief and protects the connection.
7. Inspect the Crimp: Visually inspect the crimp for proper formation. The conductor should be fully enclosed and secure, and the insulation crimp should hold the insulation firmly without cutting it.

4.2. Using the ICP-206 Wire Cutter

The ICP-206 wire cutter is designed for clean and smooth cuts on various cables.

• Identify Cable Type: The cutter is suitable for stranded cable, communications cable, and copper cable.

  Image Description: An image illustrating the types of cables compatible with the ICP-206 wire cutter. It shows examples of stranded cable, communications cable, and copper cable, each marked with a checkmark to indicate compatibility.

• Position the Cable: Place the cable to be cut between the open blades of the cutter. Ensure the cable is fully seated in the cutting area.

  Image Description: A split image demonstrating the ICP-206 wire cutter in action. The left side shows the cutter cutting a thick battery cable. The right side shows the cutter cutting an armored cable, illustrating its versatility.

• Make the Cut: Squeeze the handles firmly and steadily to cut through the cable. The high tenacity spring will assist in returning the blades to the open position.
• Capacity: The cutter can handle up to 4AWG aluminum and 3AWG copper cables. Do not use for cutting steel wire, ACSR, or hard-drawn copper conductors.

5. Maintenance

Proper maintenance ensures the longevity and optimal performance of your tools.

• Cleaning: After each use, wipe down both the crimper and cutter with a clean, dry cloth to remove any dust, debris, or residue. For stubborn grime, a mild solvent can be used, followed by thorough drying.
• Lubrication: Periodically apply a light machine oil to the pivot points and moving parts of both tools to ensure smooth operation and prevent rust.
• Storage: Store the tools in a dry environment to prevent corrosion. Engage the safety latch on the crimper and the safety lock on the wire cutter before storage.
• Inspection: Regularly inspect the crimping dies for wear or damage. Check the wire cutter blades for nicks or dullness. Replace tools if significant damage is observed.

6. Troubleshooting

If you encounter issues while using your IWISS tools, consider the following common solutions:

• Poor Crimp Quality:
  • Ensure the correct die size is selected for the terminal and wire gauge.
  • Verify the wire is stripped to the correct length and properly seated in the terminal.
  • Apply sufficient pressure during crimping.
• Difficulty Cutting Wire:
  • Check if the cable type and gauge are within the cutter's specified capacity (max 4AWG aluminum, 3AWG copper).
  • Ensure the safety lock is fully disengaged.
  • The cutter is not designed for steel wire or hard-drawn conductors.
• Stiff Tool Operation:
  • Clean any accumulated dirt or debris from the pivot points.
  • Apply a light lubricant to the moving parts.

7. Specifications

7.1. IWISS IWS-2412M Open Barrel Crimper

Image Description: A visual representation of the IWISS IWS-2412M crimper alongside a table detailing its specifications. The table lists the model, length, weight, capacity (AWG and mm²), crimping tool material, and crimping handle material.

7.2. IWISS ICP-206 Wire Cutter

Image Description: A close-up image of the IWISS ICP-206 wire cutter, prominently displaying its cutting capacity of 3AWG and blade material as CRV13.

8. Warranty Information

IWISS products are manufactured to high-quality standards. Specific warranty details may vary by region and retailer. Please retain your proof of purchase for any warranty claims. For detailed warranty information, refer to the documentation included with your purchase or visit the official IWISS website.

9. Customer Support

If you have any questions, require technical assistance, or need to report an issue with your IWISS tools, please contact IWISS customer support. Contact information can typically be found on the product packaging or the official IWISS website.

Online Resources: For additional information, product guides, and FAQs, visit the IWISS Store on Amazon.