KNIPEX 97 22 240 User manual

KNIPEX Quality – Made in Germany
EN Crimping Pliers
for insulated terminals/cable connectors and
non-insulated open plug type connectors
Operating instructions 97 22 240
M4
M5
1.5
1.5
2.5
1.5
2.5
6
1.0
4.0
6.0
0.75
2.5
ISOL
M3
M2.6M3.5
ISO

2Status: 26.10.21
CONTENTS
1 General 3
1.1 Notes on operating instructions 3
1.2 Symbols 3
1.3 Copyright 3
1.4 Guarantee and warranty 4
2 Safety 5
2.1 Intended use 5
3 Design and function 6
3.1 Design 6
3.2 Function 6
4 Operation 7
4.1 Shortening cables 7
4.2 Stripping cables 7
4.3 Making an oval crimp 8
4.4 B-crimp connection 9
4.5 Cutting copper or brass threaded bolts 11
5 Maintenance 11
6 Technical data 11
7 Disposal 11

GENEral
3Status: 26.10.21
1 General
1.1 Notes on operating instructions
These operating instructions are designed to enable you to use your tool
safely and efciently.
The tool may only be used if it is in technically perfect condition.
As a consequence of technical developments, the illustrations and descrip-
tions contained in these operating instructions may differ slightly from the
tool actually delivered.
We do not accept any liability for damage caused by failure to observe these
operating instructions.
1.2 Symbols
All safety instructions in these operating instructions are indicated by corre-
sponding symbols. The signal words at the beginning of each safety instruc-
tion express the extent of the hazard.
Danger!
Level 1 risk source
This combination of symbol and signal word indicates an imminently haz-
ardous situation that will result in death or serious injury if not avoided.
Warning!
Level 2 risk source
This combination of symbol and signal word indicates a possibly hazardous
situation that may result in death or serious injury if not avoided.
Caution!
Level 3 risk source
This combination of symbol and signal word stands for important informa-
tion that will assist in preventing damage to property or the environment.
1.3 Copyright
These operating instructions and all documentation supplied with this tool
are protected by copyright and remain the property of KNIPEX.
The reprinting of these instructions, even in extract form, is only permitted
with the written consent of C. Gustav Putsch KG.

GENEral
4Status: 26.10.21
1.4 Guarantee and warranty
The manufacturer grants a statutory warranty in accordance with the cur-
rent sales and delivery conditions. No further warranties or assurances are
granted.
Within the warranty period, the warranty covers the rectication of all de-
fects that can be traced back to material faults or manufacturing errors.
Wearing parts are excluded from the warranty.
The repair or replacement of a tool shall not result in an extension of the
warranty period. Tools shall only be repaired or replaced with “as new”
parts, whose function corresponds to that of the old parts. All defective and
hence replaced parts are the property of the manufacturer.
Warranty claims shall expire in particular if:
• Damage is caused through improper operation, use for purposes other
than those specied by the manufacturer, or poor maintenance.
• Repairs or conversions are carried out by unauthorized persons.
• No original accessories or spare parts from KNIPEX are used.
• Defective components are not repaired immediately to minimise the
extent of the damage and so as not to impair the safety of the tool
(obligation to repair).
For the rest, reference is made to the liability and warranty regulations
of the current sales and delivery conditions.

SafETy
5Status: 26.10.21
2 Safety
Observe the following safety instructions when handling the product.
2.1 Intended use
The tool is intended for the following uses:
• 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 ne conductor cables
• Crimping unshielded, open plug type connectors (1.5 to 2.5 mm²)
with connector width 6.3 mm on ne 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 the following applications:
• Cutting steel threaded bolts
Any use beyond the intended purpose or any unauthorized modication
shall be considered improper. The operator shall be liable for damages re-
sulting from improper use.
Intended use also includes adhering to these operating instructions. They
must be read in full before use.
Warning!
Danger from sharp blades!
Handling sharp blades is dangerous. For this reason, make sure to handle
your tools with care when working.
Warning!
Risk of injury from ying parts!
Wear protective goggles when cutting cables and threaded bolts!

DESiGN aND fuNCTiON
6Status: 26.10.21
3 Design and function
3.1 Design
M4
M5
1.5
1.5
2.5
1.5
2.5
6
1.0
4.0
6.0
0.75
2.5
ISOL
M3
M2.6M3.5
ISO
1
3
5
1,5 - 2,5 mm2
M2,6 - M5
0,5 - 6 mm2
2
4
Design crimping pliers
1 Cable cutter
2 Crimping points for oval crimp connections
(insulated terminals and cable connectors)
3 Threaded holes for cutting copper or brass threaded
bolts with M 2.6; M 3; M 3.5; M 4 and M 5
4 Crimping points for B-crimp connections
5 Blades for stripping cables
3.2 Function
The crimping pliers can cut, strip and crimp cables, cut copper and brass
threaded bolts and recut threads.

OpEraTiON
7Status: 26.10.21
4 Operation
4.1 Shortening cables
6.0
4.0
2.5
1.5
ISOL
2.5
1.5
1.5
2.5
6
1.0
0.75
ISO
M3.5
M4
M2.6
M3
M5
2.5
1.5
6
ISO
M3.5 M2.6
1.
2.
Cutting cables
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
2.5
1.5
6
ISO
M3.5
M4
M2.6
M3
M5
2.5
1.5
6.0
4.0
2.5
1.5
1.0
0.75
ISOL
3.
2.
1.
Stripping cables
1. Select the stripping setting that matches the capacity of the cable
(0.75 ... 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.

OpEraTiON
8Status: 26.10.21
4.3 Making an oval crimp
6.0
4.0
2.5
1.5
ISOL
2.5
1.5
1.5
2.5
6
1.0
0.75
ISO
M3.5
M4
M2.6
M3
M5
1.5
2.5
6
ISO
M3.5 M2.6
1.5
2.5
6
ISO
M3.5 M2.6
1.
2.
3. 4.
Making an oval crimp
Note:
The conductor and connector must match each other in terms of their ca-
pacitance values. The stripping length and positioning of the conductors
in the connector must meet the respective requirements of the different
connectors.
1. Select a crimp prole that matches the (insulated) 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 prole.
3. Insert the conductor into the terminal / plug type connector. Note the
correct positioning.
4. First crimp the stripped area of the conductor by pressing the crimping
pliers closed.
5. Next crimp the insulated area a second time.

OpEraTiON
9Status: 26.10.21
4.4 B-crimp connection
4.4.1 Make the B-crimp correctly
Standard DIN EN 60352-2:1994 + A1:1997 + A2:2002 species the proper-
ties that a qualitatively perfect crimp connection must satisfy.
The following gure shows the most important points to consider when
making a B-crimp.
AB
1
1
2
3
2
Notes on making a B-crimp connection
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 far too long and the cable is inserted
too deep. The insulation support is ineffective.
2. The stripped part of the cable is too long and the insulation is not
visible. The insulation support is not sufciently strong.
3. Not enough of the cable has been stripped. The end of the conductor
core is not visible. The crimp connection is faulty.

OpEraTiON
10 Status: 26.10.21
4.4.2 Making a B-crimp
6.0
4.0
2.5
1.5
ISOL
2.5
1.5
1.5
2.5
6
1.0
0.75
ISO
M3.5
M4
M2.6
M3
M5
6.0
4.0
2.5
1.5
ISOL
2.5
1.5
1 0
M3.5
M4
M2.6
M3
M5
6.0
4.0
2.5
1.5
ISOL
2.5
1.5
1 0
M3.5
M4
M2.6
M3
M5
2. 1.
3. 4.
Making a B-crimp
Note:
The conductor and connector must match each other in terms of their ca-
pacitance values. The stripping length and positioning of the conductors
in the connector must meet the respective requirements of the different
connectors.
1. Select the crimp prole that matches the plug type connector
(1.5 mm² or 2.5 mm²).
2. Place the plug type connector in the selected crimp prole.
3. Insert the conductor core into the plug type connector. Note the correct
positioning.
4. First crimp the plug type connector with the wire strands by pressing
the crimping pliers closed.
5. Next place the plug type connector in the ISOL crimp prole and crimp
the connector with the cable insulation.

MaiNTENaNCE
11 Status: 26.10.21
4.5 Cutting copper or brass threaded bolts
6.0
4.0
2.5
1.5
ISOL
2.5
1.5
1.5
2.5
6
1.0
0.75
ISO
M3.5
M4
M2.6
M3
M5
6
ISO
M3.5
M4
M2.6
M3
M5
2.5
1.5
ISOL
1.
2.
Cut off the threaded bolts
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 threaded hole is completely accessible.
2. Screw the bolt into the threaded hole and let the part to be cut away
protrude from the back.
3. Press the crimping pliers closed.
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
Technical data Unit
Article number –97 22 240
Length mm 240
Weight g300
Properties –Pliers black-lacquered, handles with
multi-component grips
Application –insulated terminals + cable connectors,
non-insulated open plug type connectors
(plug width 6.3 mm)
Capacity mm² 0,5 ... 6,0
7 Disposal
The tool can be disposed of as household waste.

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