Rennsteig PEW 12 User manual

Operating Manual Crimp system tool PEW 12
Rev.: 2011-07-22 1 / 6
Read this Operating Manual prior to beginning any work!
Operating Manual
Crimp system tool PEW 12

Operating Manual Crimp system tool PEW 12
Rev.: 2011-07-22 2 / 6
Table of contents
1. General 3
2. Intended use 3
3. Description 3
4. Changing die sets/crimping procedure 4
4.1. Changing the die set/installing the locator and wire stop 4
4.2. Crimping procedure 4
5. Emergency release of force lock 5
6. Setting the crimp height 5
7. Guarantee 6
8. Service and maintenance 6
Rennsteig Werkzeuge
An der Koppel 1
98547 Viernau/Thüringen, Germany
Tel- +49 3 68 47 / 4 41-0
Fax [phone] / 4 41-14
E-Mail [email protected]
www.rennsteig.com

Operating Manual Crimp system tool PEW 12
Rev.: 2011-07-22 3 / 6
1. General
Keep the Operating Instructions with the crimp system tool at all times. This crimp system
tool features state-of-the-art technology and complies with recognised safety regulations.
The Crimping tool may be used only in a technally fault-free condition, in a safety-conscious
manner with consideration given to potential hazards, and may be used only for the purpose
described in the Operating Instructions.
The manufacturer is not liable for any damages that occur as a result
of unauthorized modifications made to the hand crimping tool or its
improper use. Always isolate wires from the power supply!
Attention
2. Intended use
• Crimping of pin and socket contacts
• Use of different die sets enables a broad range of applications
3. Description
The crimp system tool consists of a set of pliers (1) with a setting dial (2) and emergency
release (3), a split crimping die (4), two fixing bolts (5) for the upper and lower die and (if
required) a positioning guide (6, locator). Positioning guides can be retrofitted to match the
connector type. The crimping force can be adjusted (see also section “Setting the crimping
height”). The crimp system tool utilises a ratchet mechanism. The crimper opens automatically
only after passing the last ratchet pawl (force operation to complete). In the event of a faulty
crimp, the emergency release can be used to open the crimper early, so as to avoid damaging
the crimping die or the connector.
1
3
2
5
4
6

Operating Manual Crimp system tool PEW 12
Rev.: 2011-07-22 4 / 6
4. Changing die sets/crimping procedure
4.1. Changing the die set/installing the locator and wire stop
• A die set consists of an upper (3) and lower (4) die
• Remove bolts 1and 2
• Remove the upper (3) and lower (4) die
• Insert new upper (3) and lower (4) die
• Close the tool until the upper (3) and lower (4) die can
centre themselves
• Tighten bolts 1and 2
• To install an optional locator, replace bolt 2on the lower
die with bolt M 4x15
• Screw the locator (5) onto the tool and, depending on
the locator type, secure using an Allen key or open-
ended wrench
4.2. Crimping procedure
1. Install the die set and any accessories
(see 4.1)
2. Strip the cable to a suitable length
(observe manufacturer‘s instructions)
3. Depending on cross-section, place the
connector in the die set or the appropriate
place in the locator and use the tool to
hold in place. Insert cable into connector.
4. Close the crimper and open after passing
the last ratchet pawl (force lock)
• To install an optional wire stop (7), replace bolt 1on the upper die with bolt M 4x25
• Holding the wire stop (7) against the tool, thread bolt 8through the upper die (4) and
secure using the nut supplied
1
2
3
4
M 4x11
6
5
7
8
M 4x25

Operating Manual Crimp system tool PEW 12
Rev.: 2011-07-22 5 / 6
5. Emergency release of force lock
The force lock opens automatically if the crimp procedure completes in full. In case the crimp
procedure needs to be interrupted, the force lock can be released by pressing the shanks
together slightly, then unlocking the emergency release by using the included allen key with
handle.
Emergency
release
6. Setting the crimp height
The crimping force applied by the tool is set at the factory. The manual force applied when
the tool is empty is 130–180 N. The crimping dies and hand tool are matched to one another
to ensure this force produces an optimum crimp. If the results of crimping do not meet the
specifications set by the connector manufacturer (crimp height, extraction force), this may
have the following causes:
Error Possible cause Solution
Crimping results do
not meet specifications
set by the connector
manufacturer
Wrong die set or
wrong crimp nest
Install the die set appropriate to
the application and ensure you
work with the correct crimp nest
Wrong cable Use cable as specified by the
connector manufacturer
Wear to the tool as a result of
normal use
Recalibrate the crimping force
Wear to the die set Replace die set to avoid damage

Operating Manual Crimp system tool PEW 12
Rev.: 2011-07-22 6 / 6
7. Guarantee
The crimp system tool is subjected to a thorough quality control process.
General warranty conditions apply.
8. Service and maintenance
Before starting work, ensure that the crimp system tool is clean and in proper working order.
Crimping residue must be removed. Joints should be regularly oiled with a light mineral oil
and protected against contamination. It must be ensured that all bolts are secured by means
of securing rings. Check that the setting dial is secured tightly by the slotted headless screw.
Maintenance of the crimper should be performed by the manufacturer.
1. Using a screwdriver, remove the slotted headless screw.
2. If the setting dial (2) is rotated counter-clockwise (+), this
configures a stronger crimp force and a smaller crimp height.
3. If the setting dial is rotated clockwise (-), this configures a weaker
crimp force and thus a greater crimp height. Regulation of the
hand force should not exceed 180 N.
4. If bolt aperture 3is used, it becomes possible to alter the
crimp force by only half a notch. This enables very fine-grained
adjustments to be made to the crimp force.
5. Replace the slotted headless screw
6. Prior to using the crimper, it must be ensured that the adjusting
disc is properly secured with the slotted headless screw.
1
2
The crimp height should be checked regularly by qualified personnel
from quality control and recalibrated as required using the method
described below.
Attention
3