GLW AC 100 User manual

AC 100
Operating instructions
Pneumatic Crimper AC 100
Date of issue: 05/2010
Keep for future use!

AC 100 SAFETY

AC 100 SAFETY
05/10 1
Basic information
The basic prerequisite for ensuring safe use and continuous operation of the AC 100 is knowledge of
and compliance with the safety instructions.
It is a question of your own safety!
All persons working with the AC 100 must observe the notes on safety.
In addition, rules and regulations which apply to the place of use, particularly regarding accident
prevention, must be observed.
Symbols
The following symbols will be used in these operating instructions:
indicates a possible
accident or injury hazard
and/or possible
damage
to the AC 100.
!indicates notes on application.
Dangerousness of the machine
The AC 100 has been constructed according to recognised technical safety regulations and has
undergone a safety examination and received official acceptance.
It is equipped with safety devices.
However, operating error and misuse could present a danger to
life and limb of the operator,
the machine.
The AC 100 should only be used
for the designated application and
in perfect condition with regard to technical safety.
All persons involved with commissioning, operating and maintaining the AC 100, must
be appropriately qualified and
follow these operating instructions precisely.

AC 100 SAFETY
05/10 2
Designated use
The AC 100 is to be used exclusively for crimping wire-end ferrules with cross sections between 4
and 10 mm². Under no circumstances should large metal parts or similar objects be introduced; the
die set will be ruined.
Unauthorised amendments to the AC 100 are prohibited for safety reasons!
!
Observation of all instructions and compliance with the prescribed operating
conditions are part of the designated use.
Sources of danger
The AC 100 must only be operated when the finger guard plate is screwed on.
Only filtered compressed air with a maximum pressure of 6 bar can be used.
Disconnect the machine from the compressed air before working on the AC 100, during breaks and
when the device is not in use. Do not pull on the compressed air tubing to disconnect.
Work places
The following should be avoided for operation and storage:
damp or dusty places,
places which are subject to high levels of heat, direct sunlight or low temperatures (operating
range: 15 °C to 35 °C).
Protect the compressed air tubing from heat, oil and sharp edges.
Safety devices
The AC 100 has a finger guard plate at the front as a contact safety device.
Under no circumstances should this be removed.
The AC 100 is stopped when disconnected from the compressed air supply.
Permitted operators
Only authorised and instructed operators can work on the AC 100.
The operator is responsible to third parties in the working area.
The owner must
make the operating instructions available to the operator and
make sure that the operator has read and understood them.

AC 100 SAFETY
05/10 3
Guarantee
In principle, our "General terms of purchase and delivery" apply. These are available to the owner
when the contract is concluded at the latest.
Guarantee and liability claims resulting from damage to personnel or property are inadmissible if the
following points have been violated:
Non-designated use of the AC 100.
Inappropriate working places.
Inappropriate use and use which goes beyond that described in the operating instructions.
Unauthorised structural amendments to the AC 100.
Continued use of the AC 100 when a malfunction has been established.
Repairs carried out inappropriately.
!Only use original spare parts.

AC 100 DESCRIPTION
05/10 4
Application
The AC 100 is a pneumatic crimping tool for wire-end ferrules with a cross-section of between 4 and
10 mm².
On account of its handy design it is ideally suited to wiring electrical cabinets.
Components
1 Compressed air tubing
2 Lever
3 Body
4 Head
5 Die set
6 Finger guard plate
Accessories
7 Magnetic holder
Fig. 1 Spare parts

AC 100 MAINTENANCE
05/10 5
Commissioning
Check whether finger guard plate (1) is present
and is sitting firm.
Check whether the die set (2) is free from foreign
matter.
Check whether the pneumatic tubing nuts (3)
have been tightened firmly.
Check the compressed-air supply:
min. 4 bar, max. 6 bar filtered air.
Connect the tubing plug-in connector (4) to the
compressed-air supply.
Operation
Introduce stripped wire, with wire-end ferrules
already fitted, at the side (1) in the hole
assigned to the cross-section.
Press the lever (2), the crimping process will be
triggered.
Release the lever (3), the crimped wire can be
removed again (4).
Fig. 2 Putting into operation
Fig. 3 Operation

AC 100 MAINTENANCE
05/10 6
The AC 100 must be opened.
Disconnect compressed air!
Cleaning
Unscrew hexagon socket screw (1).
Pull out die set (2).
Clean die set (3) and lightly oil pivot (4).
Push in die set (5).
Tighten hexagon socket screw (6).
Lubrication
Unscrew the head (1).
Remove the spring (2) and piston (3).
Lubricate the two arms of the die set (4)
(e. g. Gleitmo 746).
Insert piston and spring.
Insert head (5) and fasten fingertight.
Pay attention thatthe arms of the die set (4)
are correctly engaged in the piston (3).
Fig. 4 Cleaning
Fig. 5 Lubrication

AC 100 TECHNICAL DATA
05/10 7
The following spare parts can be ordered with the
appropriate Article No.
Address
GLW GmbH
Steinbeisstraße 2
D-88353 Kisslegg
Tel. [phone]
Fax [phone]
Fig. 6 Spare parts
No.
Part
Article No.
No.
Part
Article No.
1 Compressed air tubing 2516 8 Hexagon socket screw 2504
2 Body 2508 9 Pivot pin 2503
3 Sealing ring 2520 10 Die set 10001
4 Piston 2507 11 Finger spring 2502
5 Spring 2506 12 Finger guard plate 10000
6 Head, complete 10040 13 Magnetic holder DX
7 Head section 10005

AC 100 TECHNICAL DATA
05/10 8
Instrument...........................................................................................................Pneumatic Crimper
Crimping range.................................................................................................................4 -10 mm²
Compressed-air connection.............................................................................................. min. 4 bar
........................................................................................................................................ max. 6 bar
Air consumption............................................................................................. 0.2 l/Crimping at 5 bar
Dimensions (diameter x length).....................................................................................44 x 190 mm
Weight .........................................................................................................................approx. 450 g
Name plate
Type
Crimping range
Compressed air connection
Model year
Series number
Manufacture
EU Symbol

AC 100 EC Declaration of conformity
05/10 9
Manufacturer: GLW GmbH
Address: Steinbeisstraße 2
88353 Kisslegg
Germany
We hereby declare that the machine described in the following complies with the appropriate
fundamental health and safety requirements of the EC Directives regarding machinery with regard to
its design and construction as well as the equipment that we have introduced onto the market. This
declaration is rendered invalid in the case of amendments to the machine that have not been
authorised by our company.
Designation of the
equipment: Pneumatic Crimper
Machine type: AC 100
Appropriate
EC Directive: 2006/42/EG
Harmonisation DIN EN ISO 12100-1 und -2:2004
standard DIN EN ISO 13857:2008
used: DIN EN 349:2008
Place, Date Kisslegg, 10. December 2009
Legally binding signature:
Particulars regarding signatory: Bruno Weiland

GLW GmbH
Steinbeisstraße 2
88353 Kisslegg
Germany
Tel. [phone]
Fax [phone]
The company GLW retains the copyright to these
operating instructions.
It is not permitted to reprint, reproduce or
translate, even excerpts, without our consent.
2010 GLW GmbH