Rennsteig CM 25-3.4 User manual

Owner‘s Manual Crimping Machine CM 25-3.4
Rev.: 2020-06-24 1 / 20
Before starting any work, please read the operating instructions !
Owner‘s Manual
Crimping Machine CM 25-3.4

Owner‘s Manual Crimping Machine CM 25-3.4
Rev.: 2020-06-24 2 / 20
Table of Contents
1. Preface 3
2. Intended Use 3
3. Technical Data 3
3.1. General 3
3.2. Setup / Construction 4
3.2.1. Front 4
3.2.2. Back 5
3.2.3. Crimping Units 6
4. Transportation of Machine 7
5. Limitations of Liability 7
6. Requirements for Site Set-up 7
7. Set-up of the Crimping Machine 7
8. Start-up / Provisions 8
8.1. Operational Safety 8
8.2. Exchange of Crimping Units 8
8.2.1. Disassembly and Assembly 4/8 Indent Crimping Units 8
8.2.2. Disassembly and Assembly Ferrule Crimping Units 9
9. Set-up of Crimping Parameters / Ferrule Crimping Unit 10
9.1. General Information 10
9.2. Functional Operation 10
10. Set-up of Crimp Parameters / 4/8 Indent Crimping Uni 10
10.1. General Information 10
10.2. Functional Operation 11
10.3. Crimping Process 12
10.4. Exchange of Locator 12
10.5. Exchange of Batteries 12
10.6. Process Safety during Operation 13
10.7. Testing with Plug Gauge 13
10.8. Recalibration (REC) of Crimping Unit Wear Monitoring Function 14
10.9. Calibration (CAL) of Crimping Unit after Battery Replacement 15
10.10. Request E 1 after Calibration/Recalibration 15
10.11. Wear Monitoring – General Information 16
11. Maintenance and Repair 16
11.1. Maintenance of the Crimping Machine 16
11.2. Electronic Counter Mechanism 16
11.3. Maintenance of the 4/8 Indent Crimping Unit 17
11.4. Maintenance of the Ferrule Crimping Unit 17
12. Warranty 17
13. Troubleshooting 18
14. Technical Documentation 19
15. EU-Declaration of Conformity 20
Rennsteig Werkzeuge
An der Koppel 1
98587 Steinbach-Hallenberg, Germany
Telefon [phone] / 4 41-0
Fax [phone] / 4 41-14
E-Mail [email protected]
www.rennsteig.com

Owner‘s Manual Crimping Machine CM 25-3.4
Rev.: 2020-06-24 3 / 20
1. Preface
This owner’s manual is designed to get to know the crimping machine CM 25-3.4 and to properly operate the unit.
The owner’s manual contains important instructions to operate the crimping machine safely and efficiently. Follow
the instructions carefully to avoid risks and injuries, decrease repair costs, downtime and increase the life of the
machine. The pneumatic crimping machine CM 25-3.4 is manufactured by using the latest technology and the
generally accepted safety regulations. The machine may only be used in proper working condition, as well as with
safety and risk awareness. Unauthorized modifications to the machine, including the safety device, will exclude the
manufacturer from any liability.
Never process any connected electrical connections; they are subject to dangerous voltage!
Attention
2. Intended Use
The Crimping Machine CM 25-3.4 is used for crimping turned contacts with the specified cross sections in the
designated crimping units and are constructed in such a way. The machine is also used for the crimping of insulated
and non-insulated ferrules as well, with the proper crimping insert.
3. Technical Data
3.1. General
Type: CM 25-3.4
W x H x D: 230 x 480 x 340 mm
Weight: 30 kg
Crimp Force: 25 kN (2,5 t) at 5 - 6 bar
Crimp Time: < 1 s
Continues Sound Pressure Level: < 70 dB (A)
Pneumatic Pressure needed: 0,75 l / Work Stroke at 6 bar Operating Pressure
Operating Pressure: 5 - 6 bar (compressed dry air, oiled and filtered)
Working Temperature: -10 ... +55 °C, rel. humidity < 85 %, not condensed
Operating Temperature: -10 ... +60 °C
Storage Temperature: -20 ... +70 °C
Battery (Crimp Unit): CR 2025
Model Item No. Capacity
8.72-3 636 0723 3 01 0,08–2,5 mm²
8.72-6 (according to M22520 / 7-01) 636 0726 3 0 0,08–2,5 mm²
8.73-3 636 0733 3 01 0,03–0,5 mm²
8.73-6 (according to M22520 / 2-01) 636 0736 3 0 0,03–0,5 mm²
8.75-3 636 0753 3 01 0,14–6,0 mm²
8.75-6 (according to M22520 / 1-01) 636 0756 3 0 0,14–6,0 mm²
8.76-3 636 0763 3 01 1,50–10,0 mm²
Model Item No. Capacity
Ferrules (square) 636 084 3 0 0,08–10,0 mm²
Ferrules (hexagon-shaped) 636 086 3 0 0,08–6,0mm²

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3.2. Set-up / Construction
3.2.1. Front
1.6 Square Counter
Bearing
1.7 Serial Plate
1.2 Intake of Mechani-
cal Transmission Ele-
ment for the Crimping
Units
1.8 Pneumatic Con-
nection with Pressure-
reducing Gauge and
shut-off Valve
1.3 Safety Fixture for
Impact and Transmission
Element
1.9 Crimping Unit
(exchangable, see „2.
Intended Use“)
1.4 Adapter to take in
Crimping Unit
1.10 Hand/Foot Pedal
1.5 Feet
1.1 Electronic
Counter Mechanism
Without Reset
With Reset through
Reset button
Fig. 1

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2.2 Shut-off Valve
2.3 Plug Nipple for Quick-connect
2.4 Pressure Gauge
2.5 Pressure Display/ Manometer
2.6 Lock Nuts
2.7 Foot
2.1 Square Counter Bearing
3.2.2. Back
Fig. 2 2.8 RESET button

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3.2.3. Crimping Units
3.1 Adjustment Screw
3.2 Battery Compartment
for CR 2025
3.3 ON / OFF Button
3.4 MODE - Button
3.5 Digital Display
3.7 Upper Adapter
3.8 Locking Pin
3.9 Shaft Cover
3.10 Crimp Opening
3.6 Stop Pin
3.12 Adapter Intake
3.7 Clamping Screw
3.11 Lower Adapter
Fig. 3
4.1 Positioning Dial
4.2 Ball Catch
4.3 Stop Pin
4.4 Clamping Screw
4.9 Lower Adapter
4.8 Clamping Screw
4.7 Safety Cover
4.6 Locking Pin
4.5 Upper Adapter
Fig. 4

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4. Transportation of Crimping Machine
Always avoid damages when loading and unloading the machine. All damages, which occur during transport,
are the responsibility of the carrier.
After carefully removing the packaging, the machine must be inspected for
possible damages. Any discovered damages must be reported to the manufacturer
RENNSTEIG WERKZEUGE GmbH. Please note that certain settings will be carried out
later at the job site.
Attention
5. Limitations of Liability
The manufacturer will not assue any responsibility for the following damages occuring because of:
• Failure to follow the operating instructions
• Improper Use
• Use by non-trained or non-skilled personnel
• Unauthorized modifications of the machine
• Technical modifications
• Usage of spare parts, which are not approved by the manufacturer
6. Requirements for Site Set-up
• Minimum load capacity of work bench: 45 kg
• Total space requirement for the machine (H x W x D): 500 x 500 x 400 mm
• Area for optimal operator performance: 1,5 m²
• Work bench height should be adjusted to the height of the operator.
• Sufficient lighting needs to be provided.
7. Set-up of the Crimping Machine
1. Place the machine at the final work location. The adjustable feet are used to place the machine firmly onto
the work surface and is secured in place with the lock nuts. A secure setup of the machine is of upmost
importance.
2. Connect the supply hose for the compressed air. The built-in pressure gauge is set at the factory and
limits the air pressure to a max. of 6 bar. Please ensure the proper connection of air supply hose. In order
to operate the machine safely, the air pressure needs to be between 5-6 bars.
3. After connecting the supply lines, the machine needs to be inspected for leaks and for the correct
operating pressure.

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8. Start-up/ Provisions
8.1. Safe Operation
Before starting to use the crimping machine, some important rules need to be followed:
• The machine may only be used by trained personnel to avoid injuries to persons and/or damages to the
machine.
• The operator needs to ensure that all safety devices are in proper working condition before starting any
job. Furthermore, all the relevant safety and accident prevention regulations must be observed.
• Only after a thorough inspection, the machine may be used.
8.2. Exchange of Crimping Units
8.2.1. Disassembly and Assembly 4/8 Indent Crimping Units
Due to the vast array of turned contacts on the market, a cross section- optimized assortment of crimping
units is necessary. The exchange of crimping units is done as follows:
Disassembly:
• The machine is in the starting position; the opening of the crimp unit (3.10) faces the operator.
• Close the shut-off valve (2.2), disconnect the air supply, and then open the shut-off valve (2.2)
(Note: When the shut-off valve is in the open position, the hand lever is in a horizontal position!).
• Push the RESET button (2.8) to release the remaining air.
• Loosen the shaft cover on both sides with an Allen wrench SW (size of wrench) 2,0 (3.9); the shaft
cover must be movable.
• Remove the locking pin (3.8) from the shaft with an appropriate tool, i.e. a pin punch.
• Loosen the lower adapter intake (3.12) with an Allen wrench SW 2,5 and swivel the 4/8-indent crimping
unit by 90° to the front (adjustment screw of the crimping unit (3.1) faces the operator).
• Loosen the clamping screws of the lower adapter (3.13) with an Allen wrench SW 2,5 and pull the
4/8-indent crimping unit out of the adapter intake in the direction of the arrow.
Assembly:
• Loosen the shaft cover on both sides with an Allen wrench SW (size of wrench) 2,0 (3.9); the shaft
cover must be movable.
• Push 4/8-indent crimping unit into the lower adapter up to the stop pin (3.6).
All adjustments, like settings, maintenance and exchanging of any units must be
conducted in an unpressurized state of the machine. Close the shutoff valve, disconnect
the air pressure; afterwards open the valve and release the remaining air by pressing
the RESET switch.
Attention

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• Place a wrench SW 12 onto the square counter bearing (2.1) to move the shaft of the machine down
till the holes of the upper adapter (3.7) line up with the connecting rod of the crimping unit.
• Connect the adapter intake and the connecting rod with the locking pin (3.8).
• Secure crimping unit with the clamping screw 2,5 mm (3.13) in the lower adapter.
• Fasten the shaft cover on both sides with an Allen wrench SW (size of wrench) 2,0 (3.9).
• Connect the air supply and open the shut-off valve (2.2). The machine is now ready to use.
8.2.2 Disassembly and Assembly Ferrule Crimping Units
The ferrule crimping unit will adjust automatically to the appropriate ferrule size. For an optimal crimping
result the ferrule must be matched with the correct cable cross section. The exchange of ferrule crimping
units is done as follows:
Disassembly:
• The machine is in the base position.
• Close the shut-off valve (2.2), disconnect the air supply, and then open the shut-off valve (2.2)
(Note: When the shut-off valve is in the open position, the hand lever is in a horizontal position!).
• Release the remaining air by pressing the RESET button (2.8).
• Loosen the clamping screws (4.8) of the shaft cover with an Allen wrench SW 3,0 and lift the shaft
cover (4.7) to the front to remove it.
• Remove the locking pin (4.6) from the shaft with an appropriate tool, i.e. a pin punch.
• Loosen the clamping screw (4.4) with an Allen wrench SW 2,5 and pull the ferrule crimping unit out of
the adapter intake in the direction of the arrow.
Assembly:
• Push the ferrule crimping unit into the lower adapter up to the stop pin (4.3).
• Place a wrench SW 12 onto the square counter bearing (2.1) to move the shaft of the machine down
till the holes of the upper adapter (4.5) line up with the connecting rod of the crimping unit.
• Connect the adapter intake and the connecting rod with the locking pin (4.6).
• Secure crimping unit with the clamping screw 2,5 mm (4.4) in the lower adapter
• Place a wrench SW 12 onto the square counter bearing (2.1) and move the wrench all the way up to
the stop.
• Place shaft cover (4.7) back onto the machine and fasten the clamping screw 3,0 mm (4.8) lightly.
• Move the wrench on the counter bearing (2.1) all the way down until the crimping dies of the crimp unit
are completely closed.
• Fasten the shaft cover (4.7) with clamping screw 3,0 mm (4.8).
• Reconnect the air supply and open the shut-off valve (2.2). The machine is now ready to use.
Before connecting the crimp machine CM 25-3.4 to the air supply line, be sure to remove
the wrench from the square counter bearing.
Attention

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9. Set-up of Crimping Parameters / Operation with the Ferrule Crimping Unit
9.1. General Information
• Used for crimping ferrules with/ without PVC collar (insulated/uninsulated) according to DIN 46 228
part 1 and part 4
• Use for applications only as described in the owner’s manual
• The manufacturer will not assume any liability
- for any damages resulting from any use, which the tool was not intended for
- for any modifications performed to the crimping units.
9.2. Functional Operation
• selection of an appropriate ferrule and the matching cable cross section
• choose the correct cross section on the positioning disk
• insert the stripped cable into the ferrule
• place ferrule with inserted cable in between the crimping jaws of the crimping unit, positioning disk is
used as a stop
• activate the hand or foot switch to trigger the working stroke
• after the crimping process is completed, release the hand or foot switch in order for the machine to go
back to the starting position
• remove the crimped cable
• check if the connection of the ferrule has a tight fit
10. Set-up of Crimping Parameters/ Operation with the 4/8 Indent Crimping unit
10.1. General Information
The 4/8 Indent Crimping Unit may only be used in technically sound condition. The crimping unit is designed
to crimp turned male and female contacts in the respective cross section indicated and may only be used for
the purpose, which the crimping unit is intended for as described in the owner’s manual.
The user is able to check the crimping unit in certain testing intervals himself and to recalibrate the unit if
necessary.
In order to increase process liability, the crimping unit has an integrated wear and tear monitoring function.
The user is alerted when the tool wear and tear of a defined range is exceeded. In addition to that, the 4/8
indent crimping unit is equipped with a wear and tear forecast function. This function will prompt the user to
recalibrate the tool depending on the number of activations and the preset values of the crimping dimensions.
Any unauthorized modifications or a use, which is not specified in the owner’s manual, will exclude the
manufacturer from any liability claims for damages resulting from the misuse.

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10.2. Functional Operation
ON/OFF Switching
Push the “ON/OFF” button to turn the machine on or off.
Select Display
The crimping unit carries a wide range of display functions, which can be selected by pushing the recessed
“MODE” button. This enables the user to adjust the depth of the crimping indenters and to choose the value to
be shown in mm or inch, or alternatively the relevant selector positions from 1-8 according to the applicable
standard MIL22520 (does not apply to tool 8.76).
In order to change the display mode, take the gauge, which comes with the tool, and insert the gauge into
the recessed button „MODE“ and push it quickly until the desired display is shown. The display will show the
values in the following order:
Standard mm Inch MIL selector
positions
8.76
Adjusting to the appropriate Crimp parameter
1. Industrial Turned Contacts
• Select standard or mm on the display
• Obtain the crimp indenter setting for the particular contact from the setting matrix provided with the tool,
from the crimp processing guidelines of the contact manufacturer or directly from Rennsteig Werkzeuge
• Change the crimp indenter setting (depth of indenters) by turning the adjustment wheel until the display
shows the desired value (in mm or inches)
• Lock in settings by fastening the clamping screw on the back of the unit
• Position the locator by lifting and turning into the correct slot
Please ensure that the selected value needs to be set by always dialing down from a
larger value to the desired value, for example, to set the tool to crimp value 2,0 mm,
dial up to 2,05 mm first and then down to 2 mm.
Attention
2. MIL Contacts
• Select MIL Selector position mode on the display
• Obtain the crimp indenter setting for the particular contact from the crimp processing guidelines of the
contact manufacturer
• Change the crimp indenter setting (depth of indenters) by turning the adjustment wheel until the display
shows the desired selector position (F1 - F8)
• Crimping unit set-up can be locked in by tightening the clamping screw
• Position the MIL- Locator by lifting and turning into the correct slot

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10.3. Crimping Process
• Adjust 4/8 indent crimping unit to the work requirements; loosen the adapter with an Allen wrench SW 3,
turn the crimping unit to the desired position and then tighten the adapter again.
• Open shut-off valve (2. 2)
• 4/8 indent crimping unit moves to the starting position; the machine is now ready to be used.
• Place stripped cable into the contact
• Place the contact with the inserted cable into the crimp area to the stop (the locator will position the
contact perfectly)
• Push the hand/foot pedal (1.10) to activate the working stroke.
• After the crimping process is completed, release the hand/foot pedal in order to have the machine move
into the starting position.
• Remove the crimped contact.
NEVER crimp onto the gauge or any similar objects to avoid damage to the crimping
unit! NEVER crimp onto the gauge or any similar objects to avoid damage to the
crimping unit! Avoid crimping solid materials, such as steel with a hardness of more
than 35 HRC!
Attention
10.4. Exchanging the locator
• Loosen the center screw of the locator with an Allen wrench (SW 2,5), possibly use a second Allen wrench
on the opposite side for better stability.
• Remove the locator.
• Place optional locator onto the unit by following the steps in reverse order.
10.5. Exchange of Batteries
The life span of the battery (Type CR 2025) for the digital display averages at about one year depending on
usage. After such time has passed, the battery must be exchanged. Flip the battery compartment upwards
in the direction of the arrow in order to remove the battery with ease.

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Before placing the new battery into the crimping unit turn the adjustment knob to the
lowest reference value. A battery exchange will prompt the user to conduct a calibration
of the crimping unit (CAL).
Information
Any further steps are described in chapter 10.9 “Calibration of the Crimping Unit after Battery Exchange”.
Used batteries are to be disposed off only at authorized recycling locations.
10.6. Process Safety during Operation
All crimping units are subject to mechanical wear and tear, depending upon the load that the crimping unit
needs to handle (cable cross sections, material usage, …), which also effects the life time of the crimping
unit. The wear and tear can be compensated for through recalibrating of the unit within certain limits. The
wear limit is reached at about 50,000 to 200,000 cycles depending upon the intensity of use.
The prompt to calibrate or recalibrate will be visible on the digital display as follows:
• After the battery exchange (CAL) a calibration is inevitable to restore the original function of the crimping
unit.
• Crimping unit will prompt the user after a certain number of crimps indicated by the crimping unit on the
display (REC)
If after several recalibrations are conducted according to the steps in the owner‘s manual, and a message/
code E1 appears in the display of the crimping unit, the wear and tear maximum is reached and the crimping
unit needs to be repaired.
10.7. Testing with Plug Gauge
The following plug gauges are to be used:
Model Item No. Plug Gauge
Size
8.72-3 636 0723 3 01 1 mm
8.72-6 (according to M22520 / 7-01) 636 0726 3 0 1 mm
8.73-3 636 0733 3 01 1 mm
8.73-6 (according to M22520 / 2-01) 636 0736 3 0 1 mm
8.75-3 636 0753 3 01 2 mm
8.75-6 (according to M22520 / 1-01) 636 0756 3 0 2 mm
8.76-3 636 0763 3 01 2 mm

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Before starting any job, the base setting of the crimping unit (crimping dimensions) needs to be tested.
• Turn crimping unit on by using the “ON/OFF” switch
• Turn the adjustment wheel to the basic setting of the crimping unit (1 or 2 mm depending on the model).
Please ensure that the selected value needs to be set by always dialing down from a larger value to the
desired value, for example, to set the tool to crimp value 2,0 mm, dial up to 2,05 mm first and then down
to 2 mm.
• Push the hand or foot switch to engage the trigger mechanism for the working stroke, keep foot pedal
pushed down (crimping indenters will stop at base setting) now insert the plug gauge between the
indenters. Please note the following:
• The plug gauge is movable in between the indenters without any play – conclusion: There is no
measurement deviation; the crimping unit can be used right away.
• The plug gauge has too much play between the indenters or cannot even be inserted in between the
indenters - There is a measurement deviation; the crimping unit needs to be recalibrated.
10.8. Recalibration of Crimping Unit / Wear and Tear Forecasting Function
The wear and tear forecast function serves the purpose to have the crimping unit, depending upon the
quantity of crimps and the preset crimping measurement, prompting the user to recalibrate the unit (REC in
display).
The recalibration should only be executed by authorized personnel, because an
improper calibration can lead to faulty crimping results.
Attention
• Push the “MODE” button and select mm shown in the d isply ( see chapter 1. 2 “Operational Functionality”)
• Turn the adjustment wheel until the crimping indenters have a value of 2 mm (or 1 mm depending on
crimping unit) and then use the plug gauge to test for the proper fit (plug gauge must fit tight without any
play)
• Start the machine by pressing the hand or foot pedal and keep the button or pedal pushed down (Crimping
indenters will stay in the base position until the proper fit is determined)
• Repeat procedure until the plug gauge value is reached
• Please note that the selected value needs to be set by always dialing down from a larger value to the
desired value, for example, to set the tool to crimp value 2,0 mm, dial up to 2,05 mm first and then down
to 2 mm.
• Keep “ON/OFF” button pressed and at the same time use the plug gauge to push the recessed “MODE”
button for at least 5 seconds
• After 5 seconds release the “MODE” button and afterwards the “ON/OFF” button
• The digital display will jump automatically to the plug gauge measurement of 2 mm (or 1 mm depending
on the crimping unit)
• The crimping unit is now recalibrated and ready for the entering of crimping parameters

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10.9. Calibration (CAL) of the crimping unit after battery replacement
The mechanical stop at the lowest point of the adjustment wheel serves as a reference
value of the actual wear and tear values. This value is stored permanently in the tools
memory and cannot be changed. Every time a battery is replaced, it will be compared
to the reference value. The following process must be adhered to.
Information
• Open battery compartment upwards
• Remove used battery
• Turn adjusting wheel all the way down (in the direction of minus) and leave there
• Place in new battery; the display will show “CAL” as a request to calibrate
• Adjust the crimping indenters to the plug gauge value by turning the adjustment wheel until the plug
gauge fits tightly, without play, in between the indenters as described in chapter 10.7
• Press the hand or foot pedal and keep the button/pedal pressed down (crimping indenters will stay in
this position until the plug gauge value is reached)
• If necessary repeat the procedure until plug gauge value is reached
• Please note that the selected value needs to be set by always dialing down from a larger value to the
desired value, for example, to set the tool to crimp value 2,0 mm, dial up to 2,05 mm first and then
down to 2 mm; that means when finding the proper value, the plug gauge may have more play in the
beginning in order to come down to a lower value
• Keep “ON/OFF” button pressed and use the plug gauge to push the “MODE” button for 5 seconds, after
the 5 seconds release the “MODE” button and then the “ON/OFF” button
• The display will jump automatically to the plug gauge value
• The crimping unit is now calibrated and ready for the entering of crimping parameters.
If the display shows an error code of E1 instead of the plug gauge value, then the
lowest reference value was not correctly adjusted. The process of calibration must be
repeated.
Attention
10.10. Request E 1 after Calibration/Recalibration
If the error message E1 appears after several attempts to calibrate or recalibrate (the error code will
appear cyclical first and then switch to permanent), the indenters of the crimping unit are so worn out that a
recalibration is not possible anymore. The crimping unit needs to be repaired and send to the manufacturer
or an authorized repair center.

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11. Maintenance and Repair
11.1. Maintenance of crimping machine
• The Crimping Machine CM 25-3.4 is maintenance-free.
• Any necessary repairs may only be performed by qualified personnel or certified technicians at the
manufacturer; only original equipment parts from the manufacturer may be used.
• The electronic counter mechanism has an estimated life of about 8 years. A replacement of the battery
is not possible. After such time has passed, the entire counter mechanism needs to be exchanged
(ATTENTION: Loss of data for the permanent counter, number of cycles will not be stored).
11.2. Electronic Counter Mechanism
The Crimping machine CM 25-3.4 has two electronic counting mechanisms. The upper counter mechanism
is a permanent counter, which cannot be set back by the operator. The lower counter can be reset.
The counter should not be used in explosion-proof areas and/ or areas, which are
excluded in standard EN 61010 part 1.
Attention
10.11. Wear monitoring – General information
Every tool, even if used for the purpose intended for, will show signs of wear and tear. When pushing and
holding down the “MODE” button for 8-15 seconds, the information about the current state and numeric
figures of the tool are displayed.
The information is displayed in the following order:
• Serial number (8 consecutive numbers)
• Remaining life in % (remaining utilization capacity)
• Reference value – lowest adjustment value as defined by the manufacturer
• Quantity of crimps performed

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11.3. Maintenance of the 4/8 Indent Crimping Unit
The 4/8 indent crimping units are maintenance –free. If necessary (certain environmental conditions) the
crimping units can be lubricated with grease. Please use the following grease:
Sumidera 76-3 (Item number: 636 025 0 08)
The grease can be ordered from the manufacturer of the crimping units.
11.4. Maintenance of the ferrule crimping unit
The ferrule crimping unit is maintenance – free. Before starting any job, dirt and debris needs to be cleaned
off the crimping unit.
12. Warranty
The delivered product is subject to the statutory warranty period. The warranty does not cover any wear or
spare parts, especially possible 4/8 indent crimping units and locators (positioners), which may have been
ordered. Spare or wear parts are those, which are all movable parts, like bearings, bearing pins/bolts and
gasket (seals) kits in all pneumatic components.

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General InformationFerrules4/8 Indent
13. Troubleshooting
Error Possible Cause Solution
Crimp process is not completed Pressure in the pneumatic system is not
functioning
Pull out pressure regulator and adjust by
turning. Check pressure in the system (set-up
to be 6 bar).
Foreign object in the 4/8 indent crimping unit Close shut-off valve, pull off air supply hose.
Press RESET; if necessary, remove 4/8
indent crimping unit and clean it and check
crimp parameters.
Use of the wrong contact, which is not appro-
ved to be crimped an 4/8 indent crimping
unit
Close shut-off valve, pull off air supply
hose. Press RESET, remove contact, select
approved contact, check crimp parameters.
Pull-out Force values according to DIN
are not achieved
Cable cross section and size of ferrule do not
match
Check cross section. Find the correct match-
up. Proceed to crimp again.
Ferrule and cable are not conforming to DIN
requirements. Only crimp conform components.
Crimping profile is dirty or displaced. A Ferrule was crimped without the cable
inserted, pieces of the crimped contact can be
found between the crimp indenters.
Remove debris of the contact from the unit with
an appropriate tool. Proceed to crimp again.
The crimp profile of the crimp jaws is
damaged. . Send crimp unit to the manufacturer for repair.
Crimp parameter deviates from inspec-
tion with gauge
Wear of indenters, for example, wrong 4/8
indent crimping unit was used
Readjustment of the basic setting
Send 4/8 indent crimping unit to the manu-
facturer for inspection
Display shows „E1 When the battery was changed, the crimp
unit’s adjustment wheel was not set back to
the lowest reference value.
Review chapter „10.9 Calibration (CAL) of
crimping unit after battery exchange“
Wear-and-tear limit of the tool is reached Contact manufacturer
Display shows „E2“ Calibration was performed at a higher value,
than the base value set at the manufacturer
at initial delivery
Repeat calibration with the appropriate
gauge.

Owner‘s Manual Crimping Machine CM 25-3.4
Rev.: 2020-06-24 19 / 20
14. Technical Documentation

Owner‘s Manual Crimping Machine CM 25-3.4
Rev.: 2020-06-24 20 / 20
15. EU- Declaration of Conformity according to EU Guidelines for Machines
2006/42/EG, Appendix II
The construction of the Crimping Machine
Type: CM 25-3.4
No.:
Year of Construction:
Was developed, constructed and manufactured in compliance with the EU- Guidelines for Machines 2006/42/
EG with sole responsibility:
Company: Rennsteig Werkzeuge GmbH
An der Koppel 1
98587 Steinbach-Hallenberg
Responsible person in charge of documentation: Klaus Bamberger
The following EU-Guidelines and harmonized standards were used:
• Machine Guideline 2006/42/EG
• RoHS-Guideline 2011/65/EU
• DIN EN 12100:2010 Safety of Machines – General Principles of Design– Risk Assessment
and Risk Reduction
• DIN EN ISO 13857:2008 Safety of Machines – Safety distances to prevent upper and lower
extremities from entering hazardous zones
• EN ISO 13849-1:2008/AC: 2009 Safety of Machines – Safety-related Parts of the Control
System- Part 1: General Principles of Design
• EN ISO 13849-2:2012 Safety of Machines – Safety-related Parts of the Control System - Part
2: Validation
• DIN EN ISO 4414:2011-04 Fluid Technology - General Rules and Safety-related Regulations
concerning Pneumatic Systems and Parts thereof (ISO 4414:2010); German Version EN ISO
4414:2010
Hereby we declare that this delivery includes the entire above described machine.
Steinbach-Hallenberg, the ________________________________
CEO Mr. Sascha Zmiskol