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Crimp System Tool
PEW 12
Operating Instructions
Rev.: 2022-02-01
(Images and descriptions might slightly vary between this manual and the
actual product you have)
This crimp system tool features state-of-the-art technology and complies
with recognized safety regulations. The crimping tool may be used only in a
technically sound 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.
ATTENTION!
Unauthorized changes or improper use of the crimp
system tool excludes the manufacturer from liability for
any resulting damage. Never work on live wires!
• for crimping of a vast variety of different contacts, i.e. turned contacts, stamped
and formed contacts, ferrules, data plugs a.s.o.
• use of different die sets offers a broad range of applications
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 fi xing bolts (5) for the upper
and lower die and (if required) a positioning guide (6), locator). Positioning
guides can be retrofi tted to match the connector type. The crimping force can
be adjusted (see also section "Setting the crimping height") and should only
be carried out by trained personnel. The crimp system tool utilizes a ratchet
mechanism. The crimp tool 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 crimp tool early, so as to avoid
damaging the crimping die or the connector.
1
5
2
3
EN
Changing the die set/
installing the locator and wire stop
• A die set consists of an upper (3) and lower (4) die
• Remove bolts (1) and (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 center themselves
•Tighten bolts (1) and (2)
1
• To install an optional locator, replace
bolt (2) on the lower die with bolt
3
M 4x15
• Screw the locator (5) onto
the tool and, depending on the
locator type, secure using an
2
Allen wrench or open-end wrench
4
General
M 4x11
1
3
2
4
• To install an optional wire stop (7), replace bolt (1) on the upper die with
bolt M 4x25
Intended Use
• Holding the wire stop (7) against the tool, thread bolt (8) through the upper
die (4) and secure by using the nut supplied
Description
5
1.
Install the die set and any
accessories (see 4.1)
2.
Strip the cable to a suitable
length (check 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
4
hold in place. Insert cable into
connector
6
4.
Close the crimp tool and open
after passing the last ratchet
pawl (force lock)
Emergency release of forced locking mechanism
The forced locking mechanism opens automatically if the crimp procedure
completes in full. In case the crimp procedure needs to be interrupted, the
forced locking mechanism can be released by pressing the handles slightly
together, then unlocking the emergency release by using the included Allen
wrench.
M 4x11
Emergency
release
The crimping force applied by the tool is set at the factory. The manual
7
force applied when the tool is empty is 130–180 N. The crimping dies and
the hand tool are matched to one another to ensure this force produces an
M 4x25
optimal crimp. If the results of crimping do not meet the specifi cations set
8
by the connector manufacturer (crimp height, pull-out force), this may have
the following causes:
Error
Crimping results
do not meet
specifi cations set
by the connector
manufacturer
6
ATTENTION!
The crimp height should be checked regularly by qualifi ed
personnel from quality control and recalibrated as required
using the method described below.
1. Using a screwdriver, remove the screw (1).
(Circlip (4) remains on the screw and is not
removed).
Crimping procedure
2. If the setting dial (2) is rotated counter-
clockwise (+), this confi gures a stronger crimp
force and a smaller crimp height.
3. If the setting dial is rotated clockwise (-), this
confi gures a weaker crimp force and thus a
greater crimp height. Regulation of the hand
force should not exceed 180 N.
4. If bolt aperture (3) is used, it becomes possible
to alter the crimp force by only half a notch. This
enables very fi ne adjustment to the crimp force.
5. Fasten the screw.
6. Prior to using the crimper, it must be ensured
that the adjusting disc is properly secured
with the screw.
The crimp system tool is subjected to a thorough quality control process.
General warranty conditions apply. The guarantee does not apply to wear
and tear.
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 oil and protected against contamination. It must
be ensured that all bolts are secured by means of retaining rings. Check if
the setting dial is secured tightly by the screw. Maintenance of the crimping
tool should be performed by the manufacturer.
Setting the crimp height
Possible Cause
Solution
Wrong crimping die or
Use the appropriate crimping
wrong crimping cavity
die or place contact in the
correct crimping cavity
Wrong cable
Use the cable as specifi ed by
the connector manufacturer
Application-related wear
Readjust the crimp force
of tool
Worn out crimping die
Exchange and repalce with new
crimping die in order to avoid
damages
1
3
2
4
Warranty
Service and Maintenance
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