KNIPEX 97 22 240 Crimping Pliers

1 General

1.1 Notes on operating instructions

These operating instructions are designed to enable safe and efficient use of the tool. The tool must be in technically perfect condition for use. Illustrations and descriptions may differ slightly from the delivered tool due to technical developments. KNIPEX does not accept liability for damage caused by failure to observe these instructions.

1.2 Symbols

Safety instructions are indicated by symbols and signal words that convey the extent of the hazard:

• Danger! Level 1 risk source: Indicates an imminently hazardous situation that will result in death or serious injury if not avoided.
• Warning! Level 2 risk source: Indicates a possibly hazardous situation that may result in death or serious injury if not avoided.
• Caution! Level 3 risk source: Provides important information to prevent damage to property or the environment.

1.3 Copyright

These operating instructions and all supplied documentation are protected by copyright and are the property of KNIPEX. Reprinting, even in extract form, requires written consent from C. Gustav Putsch KG.

1.4 Guarantee and warranty

The manufacturer grants a statutory warranty according to current sales and delivery conditions. The warranty covers defects traceable to material faults or manufacturing errors within the warranty period. Wearing parts are excluded. Repairs or replacements use "as new" parts and do not extend the warranty period. Replaced defective parts become the property of the manufacturer. Warranty claims expire if:

• Damage results from improper operation, use for unintended purposes, or poor maintenance.
• Unauthorized persons perform repairs or conversions.
• Non-original KNIPEX accessories or spare parts are used.
• Defective components are not repaired promptly to minimize damage and ensure safety (obligation to repair).

Refer to current sales and delivery conditions for further liability and warranty regulations.

2 Safety

Observe the following safety instructions when handling the product.

2.1 Intended use

The tool is intended for:

• Cutting cables (up to 6 mm²)
• Stripping cables (0.75 to 6 mm²)
• Crimping insulated terminals and plug type connectors (0.5 to 6 mm²) on fine conductor cables
• Crimping unshielded, open plug type connectors (1.5 to 2.5 mm²) with 6.3 mm width on fine conductor cable
• Cutting copper and brass threaded bolts (M 2.6 to M 5), including recutting the thread

The tool must NOT be used for cutting steel threaded bolts. Any use beyond the intended purpose or unauthorized modification is considered improper, and the operator is liable for resulting damages. Adhering to these operating instructions is part of the intended use and they must be read in full before use.

Warning! Danger from sharp blades! Handling sharp blades is dangerous. Handle tools with care.

Warning! Risk of injury from flying parts! Wear protective goggles when cutting cables and threaded bolts.

3 Design and function

3.1 Design

Illustration of the KNIPEX 97 22 240 Crimping Pliers, showing various crimping profiles for different wire gauges (e.g., 0.5-6 mm², 1.5-2.5 mm²) and threaded bolt cutting holes (M2.6-M5).

The tool features:

• 1. Cable cutter: For cutting cables.
• 2. Crimping points for oval crimp connections: For insulated terminals and cable connectors.
• 3. Threaded holes: For cutting copper or brass threaded bolts (M 2.6, M 3, M 3.5, M 4, M 5) and recutting threads.
• 4. Crimping points for B-crimp connections: For specific crimping applications.
• 5. Blades for stripping cables: For stripping wire insulation.

3.2 Function

The crimping pliers are designed to cut, strip, and crimp cables, cut copper and brass threaded bolts, and recut threads.

4 Operation

4.1 Shortening cables

Illustration for shortening cables: The end of the cable is inserted between the cable cutter blades, and the pliers are closed.

1. Insert the end of the cable to be shortened between the two blades of the cable cutter.
2. Press the crimping pliers closed.

4.2 Stripping cables

Illustration for stripping cables: The cable end is inserted into the appropriate stripping setting on the tool, the pliers are closed, and the cable is pulled out.

1. Select the stripping setting that matches the cable capacity (0.75 to 6.0 mm²) on the tool and place the end of the cable between the two stripping blades.
2. Press the crimping pliers closed.
3. Pull the cable out of the pliers.

4.3 Making an oval crimp

Illustration for making an oval crimp: A terminal/plug connector is selected based on color-coded wire gauge (red for 0.5-1.5 mm², blue for 2.5 mm², yellow for 4-6 mm²), placed in the corresponding crimp profile, the conductor is inserted, and the pliers are closed twice: first on the stripped area, then on the insulated area.

Note: The conductor and connector must match in capacitance values. Stripping length and conductor positioning must meet connector requirements.

1. Select a crimp profile matching the terminal/plug type connector (red = 0.5-1.5 mm², blue = 2.5 mm², yellow = 4-6 mm²).
2. Place the terminal/plug type connector in the selected crimp profile.
3. Insert the conductor into the terminal/plug type connector, ensuring correct positioning.
4. Crimp the stripped area of the conductor by pressing the crimping pliers closed.
5. Crimp the insulated area a second time.

4.4 B-crimp connection

4.4.1 Make the B-crimp correctly

Standard DIN EN 60352-2:1994 + A1:1997 + A2:2002 specifies properties for a perfect crimp connection. The following points are crucial:

Correct crimp connection (A):

1. The conductor core and cable insulation must be visible.
2. The end of the conductor core must be visible.

Possible errors (B):

1. The stripped part of the cable is too long, and the cable is inserted too deep, making insulation support ineffective.
2. The stripped part of the cable is too long, the insulation is not visible, and insulation support is weak.
3. Not enough of the cable has been stripped; the conductor core end is not visible, resulting in a faulty crimp connection.

4.4.2 Making a B-crimp

Illustration for making a B-crimp: A plug type connector (1.5 mm² or 2.5 mm²) is selected, placed in the corresponding crimp profile, the conductor is inserted, and the pliers are closed first on the wire strands and then on the cable insulation using the ISOL crimp profile.

Note: The conductor and connector must match in capacitance values. Stripping length and conductor positioning must meet connector requirements.

1. Select the crimp profile matching the plug type connector (1.5 mm² or 2.5 mm²).
2. Place the plug type connector in the selected crimp profile.
3. Insert the conductor core into the plug type connector, noting correct positioning.
4. Crimp the plug type connector with the wire strands by pressing the crimping pliers closed.
5. Place the plug type connector in the ISOL crimp profile and crimp the connector with the cable insulation.

4.5 Cutting copper or brass threaded bolts

Illustration for cutting copper or brass threaded bolts: The appropriate threaded hole (M 2.6 to M 5) is selected, the bolt is screwed in so the excess protrudes, the pliers are closed to cut the bolt, and then the bolt is unscrewed to recut the thread.

1. Select the appropriate threaded hole (M 2.6, M 3, M 3.5, M 4, or M 5) and open the tool until the hole is fully accessible.
2. Screw the bolt into the threaded hole, allowing the part to be cut away to protrude from the back.
3. Press the crimping pliers closed to cut the bolt.
4. Unscrew the bolt from the threaded hole; the thread is then recut.

5 Maintenance

Oil the joint of the tool regularly.

6 Technical data

7 Disposal

The tool can be disposed of as household waste.

Contact Information

KNIPEX-Werk
C. Gustav Putsch KG
42337 Wuppertal
Tel.: +49 202 – 47 94-0
Fax: +49 202 – 47 74 94
info@knipex.com
www.knipex.com