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                                                                                   ELECTRICIAN - CITS



           EXERCISE 11 : To practice crimping of lugs on PVC wire



           Objectives

           At the end of this exercise you shall be able to
           •  identify the crimping tool and different types & size of lugs
           •   select the suitable die in crimping tool as per size of wire & lugs
           •  skin the insulation of wire and crimp the lug with crimping tool.




           Requirements

           Tools/Equipments
           •  Combination plier (150 mm, Insulated) -1 No.     •  Screw driver set (150mm, 5 Blades)  -1 Set.
           •  Wire stripper Automated                          Materials/Components
              (1.5 sq.mm - 4.0 sq.mm)           -1 No.         •  PVC copper multi strand wire
           •  Crimping tool                                       (1.5/2.5/4.0 sq.mm)          - Each 1 meter.
              (1.5 sq.mm - 4.0 sq.mm)           -1 No.         •  Copper lugs
           •  Neon tester (75mm, 500V)          -1 No.            (1.5/2.5/4.0 sq.mm)                    - Each 2 No’s.
                                                               •  Insulation tape (19mm)       -1 role.

            Procedure


           TASK 1 : Identify the crimpimg tool and lugs
           1  Check and identify the types & size of copper lugs and PVC wire.
           2  Check and identify the parts of crimping tool, and practice to operate the crimping tool.

           3  Similarly, check and identify the parts of automated wire stripper and practice its usage.



           TASK 2 :  Crimping of lugs on PVC wire
           1  Take the PVC copper multi strand wire of required length and suitable size of lug.

           2  Remove the insulation of 10mm on both sides of PVC copper wire with automated wire stripper.
           3  Insert the skinned part of PVC copper wire into the barrel of copper lug (Ensure that all strands of PVC copper
              wire inserted properly into the barrel of lug)
           4  Place the wire and lug carefully  into suitable die of crimping tool.

           5  Ensure that both lug & wire are properly placed in the die, and crimp the lug by pressing the handle of crimping
              tool.
           6  After lug is fully crimped release the handle of crimping tool which turns back automatically.

           7  Remove the crimped wire from the die of crimping tool.
           8  Crimp the other end of PVC copper wire in similar way.
           9  Connect the crimped wire to the terminals of electrical accessories like relay, contactor, MCB etc
           10 Practice the crimping with different size of wires and lugs.











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