400 Service Manual
Contents
1. lt 2 REST OR xX 22 ee Re ee L E EE WACO ROMO LETT Eeer GEOES EG LLL ome D NS LSA E NKM ELSA PILLAR ese TTD SAT LAS MS SEEKS VE 7 eo eee OLR ORIO Ee Dee SZ BES EECH O RE DERE Sis 400 27A ERR B Ee SSE CM KT LAS j 25 SL val A L poppe 1252 g gt gt 70 9 AOS LT KT TA ROBO SPAS KS AT RO 400 2A EE tee dy e X LRN DRAAK REE AE BEA ZZA Go ee KE 6230 11 O Ring e Ti IG MM S74 LTL L ILO 5 400 29 BE E Es AZII LSL m 1 SN f 22 Is ex R SRS A Ze 22 POR RL SNS KK 2 ejo Kalos tato 7 RSLS L LR 4 e SLRS PLL eg ODS fi S MOS LKKI gt LKI RI MIF OOO OIL RRL GE SL RRO RKS YI E mv Z lt Fei 2S 10 32 x 5 16 400 1 3000 354 Dog Point SSS 400 26 10 32 x 3 16 Cover 1 4 20 x 1 1 2 8 32 x 1 2 FHSCS 400 18 FHSCS 4 Pls 400 2A Cup Point SSS 4PLS 10 32 x 5 16 FHSCS 4PLS 400 31 Piston Rod Page 53 400 BHD Exploded View 6227 07 6227 02 00 0 0 400 29 6230 17 400 27A 1 4 20x 1 112 ADO 3D mai Rear Cover O Ring Cyc Assy FHSCS 4Pls Booster E 400 17A 400 17B o 6227 42 400 2A 400 31 6227 12 400 1H 6227 28 4002. Ore seen SE ZS lt TS LX T lt A se I X sch Wi D a A SS ELIAS BEE RAR ARSS SOS OS LK SEBO EE gt E A T LZ OSSE x o IIS RS AA ILLI EE ME SR d De AO LEEG RES ie es OOS PEEPS N CY awe ee 1 ER EE de R 2S e W Section Vie 00 Cross s Model 4 400 17A amp 17B 400 27A Assembly 400 TOG R e LK LO SEE SO CA SS RG j Ges VRE SOR EE Ee EIS ge in Y A SG PEEKED 573 ITIL 4 7 SC X GOS TTT S L I IELI ZIS TK El LEP LEKHKBS L LP VIA ee CVS gt SS O DROL XL varo Ee 25 TAS f TA z SS 7 ZZS S SES E LE ia af NS R ee ES 3 k po 2 S 00400 JE ZS See KX EIS SRL bg Y e gt 10 32 x 5 16 Dog Point SSS 10 32 x 3 16 Cup Point SSS 3000 354 400 26 Cover 400 1 8 32 x 1 2 FHSCS 10 32 x 5 16 FHSCS 4 PLS 4 PLS 400 18 Die Assembly 6230 11 O Ring Page 51 Model 400 Exploded View 6227 07 6227 02 1 4 20 x 1 1 2 00 N FHSCS
3. SSR Coe RO oot EE SS LLL IZA Y 2 r 2 ae ee S OES YOO EF Sl SE EST KS STE SI OLD ESSELEN LI ES ILLIA QI Ge RK F 400 5 Stop 2400 32 100 2B LKB CREEP X RE 400 27A D E de ZA EZRA RLR Sprin ds PA OL OLS 2 22 Ge KLE ZI is NN JOAN E SE CG lt 2 ZO M E K AAA Zel LL Sl ss 222 ZA oy ay SVL La gt pos ISIS AT LX LEKKI RHE LALLI LLII III LLI ZT 400 2A 400 1 3000 354 1 4 20 x 1 1 2 8 32 x 1 2 FHSCS 10 32 x 3 16 FHSCS 4 Pls 4 PLS Cup Point SSS be see Kos TTT RRA RR EE E Ee SKY Ne ee Fe SRK lt D Ze bes SZ WY Ka KEY LZ soras e Se 1e OSSE lt A LS 400 31 ing Piston Rod R 10 32 x 5 16 Dog Point SSS 400 TOG Toggle Assembly See Ce ee GES LT RTL KKK IX vag SSS NN a Ge REIL LIL LID OE Eg EG RENEE 52 ARE be sl Zl AN LAN ORE EE DORE A MW Y SEED CMS AK E A ZA E 2 E 8 p ZSS UL LEIS MRR SAA RSPR P Y ES BEER ASTA TL 7 NL UTI A A LSO ze D ZAS dae st x A 4 lt 2 BELEK 2S 400 18 lt 7 lt lt
4. Qty l l re PBR ra ra ZS SS A NR Lu ra FA EA FA ma
5. D 1 LK Ms SR ESOL L EITI XILLI LL Die Assembly TEISTER lt 2 LKT 2S RZ LSA Ed Ze T gt L RES d OO CeO See Se RAL ee 1 TO N es SCH d ZIR 6230 11 O Ring wl Y CH AE FA AN AT SVA K Es be a lt A 22 400 26 Cover 10 32 x 5 16 FHSCS 4 PLS Page 55 400 B 1 Exploded View 6227 07 6227 02 400 29 400 27A 400 29 1 6227 12 Cover Cyc Assy Cover 400 27A O Ring Cyc Assy 00 0 0 reer wll 6230 17 400 31 400 30 IM e O Ring Piston Rod Booster 6230 17 400 31 1 400 30 O Ring Piston Rod Booster 400 17A 400 17B ee as Ca SS si st oe AS al L gt 6227 42 400 2A 1 4 20x 1 2 ie 6227 42 400 2A 4 20 x 1 1 2 400 1H 6227 28 O Ring Piston FHSCS ing O Ring Piston FHSCS Handle O Ring 1 4 20 x3 8 400 27A 400 2B 400 32 8 32 x 1 2 10 32 Half Dog x 5 16 SSS SHCS Cyc Assy Piston Return Spring FHSCS FHSCS N l Hal e EI EF ofl Bao aim I O CA E 7 E 400 1 040 SS 6227 42 400 2A 400 5 3000 354 400 18 6230 11 400 26 400 TOG Body Washer O Ring Piston Stop Retaining Clip Housing O Ring Cover Nut
6. J PICO 400 SERIES SERVICE MANUAL PREFACE lt lt lt Copyright by Pico Corporation 2001 All rights reserved No part of this document may be reproduced copied transmitted stored in a retrieval system or translated into any language in any form by any means without the written permission of Pico Corporation Direct all inquires to Pico Corporation 444 Constitution Ave Camarillo California 93012 PH 805 388 5510 FAX 805 482 4038 www picotools com sales picotools com Ist EDITION e Dec 2001 REVISED e Feb 2003 ii Model 400 Operations Manual LIMITED 90 DAY WARRANTY All equipment sold by Pico Crimping Tools Co Inc Pico herein is warranted solely against defective parts materials and workmanship for a period of 90 days from the date of shipment This warranty does not cover parts becoming defective through abuse neglect or operation contrary to instructions Pico is not obligated for incidental expenses in fulfillment of the warranty provisions and its liability is limited to the replacement of defective parts returned to its factory at the cost of purchaser Except as specifically set forth above Pico expressly disclaims any and all warranties express or implied by law including any implied warranty of merchantable quality Pico further expressly disclaims liability to any person or entity for general special indirect or consequential damages occasioned by any neg
7. Page 56 400 TOG Toggle Assembly all models 400 9 114 x 3 4 ZX IER d 3 X 3 E pe 6 of 4 400 7 10 32 x 5 16 Dog Point SSS 400 10 H D y 4 Pls 10 32 x 3 16 Page 57 400 27A Cycling Valve Assembly Ge 400 27A Cycling Valve Assembly 400 2A Piston 400 2B Piston Rod 156C 7100 37 Inner Spring Retaining a di wn 1 400 275 400 28 400 27 Outter Spring Alignment Pin Page 58 Die Assembly 400 13 4Pls 400 375 4 Pls 3100 250 400 24 400 14 Specific Indentor Part Number is determined by the Die Application Page 59 Part 040 SS Washer 8 32 x 1 2 FHSCS 10 32 x 5 16 FHSCS 1 4 20 x 3 8 SHCS 1 4 20 x 1 1 2 FHSCS 400 1 400 1H 400 2A 400 2B 400 5 400 17A 400 17B 400 18 400 26 400 27A 156C 400 27 400 275 400 28 6227 08 7100 37 400 32 400 BM Page 60 PARTS LISTS MODEL 400 POWER UNIT Description Washer Flat Head Cap Screw Half Dog SSS Socket Head Screw 400 1H Screws Body Handle Front Piston Front Piston Rod Piston Stop Trigger Housing Trigger Slide Front Housing Cover Nut Cycling Valve Assembly Inner Spring Cycling Valve Body Outer Spring Alignment Pin O Ring Retaining Ring Return Spring Bench Mount Oty bech hd hd do hd hd do ht A a ES D mm p bech bech bech jel bech m Part 400 TOG 1 4 x 3 4 1 4 x 1 1 4 x 1 1 2 10 32 x 3 16 SSS 10 32
8. The tools can be operated with either the hand trigger or an optional Foot Pedal Assembly P N 104 The main advantage with the foot pedal assembly is operator convenience The tools operate on air pressure of 70 to 125 PSI 1 2 CFM Recommended air pressure is 80 PSI Use clean dry air with a guality filter and regulator installed within 25 feet of the tool Do not use an oiler Connecting Air Hand Trigger The air inlet port on the rear of the handle is tapped to accommodate 1 4 NPT fittings The air supply should be connected to the port at the rear of the handle Insure that the connection is tight enough to prevent leaks Use of pipe thread tape is suggested We recommend a 1 4 ID 3 8 OD air hose be used There is also a 1 4 NPT threaded hole in the center of the cylinder housing When operating the tool with the hand trigger this opening must be sealed with a pipe plug To Air Supply 1 4 NPT Pipe Plug Connecting Air to Hand Trigger Port Model 400 Operations Manual 3 SETUP lt lt lt Connecting Air Foot Pedal For foot pedal use the air hose must be connected to the port in the center of the cylinder The air hose connected to the tool cylinder is in turn connected to the outlet port of the foot pedal Connect the hose from the air supply to the inlet port of the foot pedal For foot pedal use the port in the rear of the handle must be sealed with a
9. 1 O Ring Piston Piston Rod O Ring Handle O Ring Body 1 4 20 x3 8 400 2A 400 27A 400 5 8 32x 1 2 FHSCS 10 32 Half Dog x 5 16 SSS Piston Cyc Valve Assy Stop 4 Pls FHSCS 4 PLS SHCS e OP al g 400 2B m Piston Rod 6230 11 400 26 040 SS 6227 42 400 32 3000 354 400 18 Washer O Ring Return Spring Retaining Clip Housing O Ring Cover Nut O 400 TOG Page 54 400 B 1 Cross section View 400 1H 400 17A amp 17 6227 42 f dm 6227 28 2552 49 6227 42 O Ring 6230 17 O Ring 400 30 400 29 1 400 29 400 27A OROS AE Se Gees D SE SMI ee DE R EE XI Li TE OAR a H Y SAS gt o Zeen 6230 17 O Ring O Ring 1 4 20 x 1 2 FHSCS 4 Pls 6227 12 400 30 ae Ka TTK TI Deeg EE eg a Va lt A O gt IO gt o Mee ss ZZ B ma KP LL gt Y eee ear Yan i ONO ee SRL lt NN ds ae ne sad lt A R LE A tine eee Z 4 ISS 6 oe pd RA LASEK RE OD BROERS Ee R Ring O Ring SITES Es ORES O Ring S se LKB S
10. Remove Nuts Remove Bench Sleeve Note it may be necessary to spread sleeve in order to remove Model 400 Operations Manual 19 MAINTENANCE 5 Remove Set Screw The toggle assembly is attached to the piston rod P N 400 2B with two set screws The innermost set screw is a dog point which locks into a groove on the piston rod The second set screw is a flat point and is installed behind the dog point and used to lock it in place A 3 32 Allen wrench will be required to remove the two screws Applying hard grease to the end of the allen wrench will assist in keeping the screw attached to the allen wrench so that it can be lifted out of the housing There are two methods for removing the screw and these are dependent upon the serial number for the unit being disassembled For each serial number sequence first locate the rectangular slot in the bottom side of the housing P N 400 18 see diagram on following page 400 7 Anchor Inner Set Screw S E 4 N l WN i 7 em 400 TOG Outer Set Screw 400 25 Toggle Assy Piston Rod Set Screw Side view showing location of setscrew in relation to piston assy and toggle 20 Maintenance REMOVING 400 18 HOUSING Slot in 400 18 for Access to set screws Set Screw Slot location looking upside down at 400 18 amp 400 1 housing 5A Serial Number Tools 6200 and newer The set screw will be visible and accessible when the tool is in
11. and trigger slide can now be pulled from the handle To Reassemble Locate the roll pin groove in the trigger housing part number 400 17A Insert the trigger slide 400 17B into the housing aligning the milled slot in the slide with the corresponding slot in the housing Insert the assembly into the tool handle To assist in aligning the roll pin slot with the opening in the handle it is suggested that a small diameter pin or paper clip be used to check that the openings are in line e Drive the roll pin into the handle It may be helpful to first insert a roll pin from the opposite side This will help to ensure that the trigger is properly aligned while inserting the roll pin Roll Pin used on opposite side used as aide in installation 6227 07 6227 02 Roll Pin 400 17A 400 17B Trigger Assembly Model 400 Operations Manual 43 MAINTENANCE Die Assembly The only reason to disassemble the Die is to replace worn indenters The indentors are manufactured using S 7 tool steel and are heat treated to Re 56 58 As a result they are should have a life span of many thousand cycles Indentors are available for purchase separately from a die assembly Contact the factory for details 1 Remove the 8 32 set screw holding the 400 24 die cap using an allen wrench 2 Remove the 3100 250 C Ring using C ring pliers 3 Once the C ring has been removed you can remove the indenters Assembly is simply reversin
12. must be aligned so that the piston rods are on the same centerline If there is misalignment the piston rod will bind and cause malfunction of the tool or will reduce the force available to complete the crimp Insert guide 400 1000 into the booster cylinder Position the booster cylinder such that the guide moves freely in the cylinder 400 1000 Guide Tool 400 1000 Guide Tool Booster Allen Wrench Using Alignment tool with booster assembly Model 400 Operations Manual 31 MAINTENANCE E Guide Tool continued Tighten the four flat head screws to a snug condition test the movement of the guide in the cylinder If the guide does not move freely reposition the booster cylinder until it does 4 Install 400 31 Piston Assembly Model 400 BHD 8 B 1 Install the complete 400 31 piston assembly consisting of 400 2A Piston 400 31 Piston rod 6227 42 O ring Install by inserting the assembly into the rear of the 400 30 booster until the unit is flush with the booster 6227 42 400 30 O Ring Booster 400 31 Piston Assy Installing 400 31 Piston in 400 30 Booster 5 Install Booster Cap 400 29 or 400 29 1 Model 400 BHD Screw on P N 400 29 Cap and proceed to step 9 on page 34 Model 400 B 1 Screw on P N 400 29 1 onto the 400 30 booster In both cases insure that the P N 6230 17 O ring is installed in the booster cap prior to installing P N 400 29 1 Install new 6227 12 O ring in Cap 400 29 1 Booste
13. the 400 series pneumatic tools Careful attention should be placed to the alignment of the piston assemblies including the piston assemblies that are contained in the booster units for models 400 BHD amp 400 B 1 An assembly guide tool 400 1000 is available for use in alignment of the cylinders It is strongly recommend that this guide be used Alignment problems can cause cycling problems and or damage to the tool Attach 400 1H Handle to 400 1 Body Model 400 Only Models 400 BHD amp 400 B 1 go to step 2 on page 31 Insert a new 6227 12 O ring into the 400 1H handle Mount the 400 1H handle to the 400 1 Body housing using the four 5 16 18 x 1 flat head cap screws Models 400 go to step 9 on page 34 1 4 20 x 1 1 2 Screws 6227 12 O Ring Installing 300 1H Handle to 400 1 body Model 400 Only 30 Maintenance NEE 2 Mount 400 30 Booster to 400 1H and 400 1 Model 400 BHD amp B 1 Install new 6227 12 amp 6227 28 O rings in the 400 1H handle Mount the 400 30 booster to the handle and the 400 1 body install the four 1 4 20 x1 1 2 flat head cap screws leaving them loose INSTALLING 400 30 BOOSTER 400 1H 6227 28 O Ring 400 30 Booster EE 1 4 20 x 1 1 2 Screws 4 pcs 6227 12 O Ring Attaching 400 30 Booster 400 1H amp 400 1 Body E Use Guide tool 400 1000 to align The alignment of the booster to the main cylinder is critical The cylinders
14. x 5 16 SSS 400 7 400 9 400 10 HD 400 11 3000 354 6227 02 6227 07 6227 28 6227 42 6230 11 Description Toggle Unit Dowel Dowel Dowel Cup Point Screw Dog Point Screw Rear Anchor Yoke Heavy Duty Arm Retainer Retaining Ring O Ring O Ring O Ring O Ring O Ring Qty re BBR Re a NO mm Part 040 SS Washer 8 32 x 1 2 FHSCS 10 32 x 5 16 FHSCS 1 4 20 x 3 8 SHCS 1 4 20 x 1 1 2 FHSCS 400 1 400 1H 400 2A 400 2B 400 5 400 17A 400 17B 400 18 400 26 400 27A 156C 400 27 400 275 400 28 6227 08 7100 37 400 29 400 30 400 31 400 32 400 BM PARTS LISTS 400 BHD POWER UNIT Description Washer Flat Head Cap Screw Half Dog SSS Socket Cap Screw Booster Body Cap Screw Body Handle Front Piston Front Piston Rod Piston Stop Trigger Housing Trigger Slide Front Housing Cover Nut Cycling Valve Assembly Inner Spring Cycling Valve Body Outer Spring Alignment Pin O Ring Retaining Ring Booster Cap Booster Body Piston Rod Return Spring Bench Mount Qty p bech Eech a a ma N ee bech Daa ha PD ra N hd hd do o Part 400 TOG 1 4 x 3 4 1 4 x 1 1 4 x 1 1 2 10 32 x 3 16 SSS 10 32 x 5 16 SSS 400 7 400 9 400 10 HD 400 11 3000 354 6227 02 6227 07 6227 12 6227 28 6227 42 6230 11 6230 17 Description Dowel Dowel Dowel Cup Point Screw Dog Point Screw Rear Anchor Yoke Heavy Duty Ar
15. 0 TOG from 400 18 Housing There are four 10 32 x 5 16 dog point set screws locking the toggle assembly into the main housing 400 18 Remove these set screws and the toggle assembly can be pulled from the front of the 400 18 When reassembling the set screw opening in the anchor P N 400 7 must be aligned with the rectangular opening in the 400 18 See figure on page 21 8 Remove 400 5 Stop from 400 1 housing Remove the C ring P N 3100 354 using suitable snap ring pliers This snap ring holds down the 400 5 stop in place The C ring is under considerable pressure Remove with caution 22 Maintenance REMOVING 400 5 STOP 400 TOG Mounting Screws 10 32 Dog x 5 16 Point 4 pcs 400 TOG Assy Removing 400 TOG from 400 18 3100 354 C Ring gt PS 400 5 Stop Removing 400 5 Stop Model 400 Operations Manual 23 MAINTENANCE 9 Remove Piston Assembly from 400 1 Body Model 400 Only Withdraw the piston assembly from the 400 1 If the piston will not remove easily with hand pressure it may be necessary to use a pipe 625 dia or smaller inserted in the rear to assist removal See diagram Use a soft rubber mallet and gently tap on the pipe to remove the piston For models 400 BHD amp 400 B 1 it will be necessary to first remove the booster units in order to insert the pipe Go to step 11 on page 26 400 2A Piston Assy 400 1 Body Removing 400 2A Piston from 400 1 Body 400 1 B
16. 00 B 1 There is a 1 4 20 thread in the center of the piston rod With the 400 29 1 booster cap removed screw a 1 4 20 bolt into the rear of the piston rod You will now be able to pull the piston from the housing It should move with minimal resistance 1 4 20 bolt used to aid in piston removal 400 30 400 31 Piston Booster Removing 400 31 Piston Assy 16 Remove 400 30 Booster Model 400 BHD amp 400 B 1 There are four 1 4 20 x 1 1 2 screws securring the 400 30 booster to the 400 1H handle Remove these screws and seperate the two units 400 30 Booster 1 4 20 x 1 1 2 Cap Screws Remove 400 30 Booster 28 Maintenance REMOVE 400 1H HANDLE 17 Remove 400 1 Body from 400 1H Handle Once the four 1 4 20 x 1 1 2 inch bolts are removed in step 16 you can separate the handle from the 400 1 body 400 1 Body Removing 400 1H Handle Disassembly of the unit is now complete For information on individual components and repair see pages 39 44 Assembly instructions begin on page 30 Model 400 Operations Manual 29 MAINTENANCE MAIN UNIT ASSEMBLY e It is suggested that all O rings amp springs be replaced prior to reassembly Refer to the parts list for your particular model included in the specification section of this manual Lubricate all O rings prior to assembly Dow Corning DC 55 O Ring lubricant is recommended e There are two critical steps in reassembly of
17. 1 4 NPT pipe plug and a plug must be installed in the exhaust port of the foot pedal Foot Pedal 1 4 Pipe Plug Foot Pedal Air Outlet Port Pipe Plug for Exhaust port From Foot Pedal Tool with Foot Pedal Connection 4 Setup LOCATOR INSTALLING LOCATOR Remove the open ended cover nut P N 400 26 on the front of the tool housing Tool is not shipped with die installed from factory if die is installed it must be removed before locator can be installed Insert the locator into the retainer The retainer is the component thru which the four drive arms protrude and which has an opening in the center which accepts the locator Observe the notch in the shoulder of the locator There is a corresponding pin in the face of the counterbore in the retainer Orient the notch in the locator shoulder to coincide with the pin in the retainer When properly installed the front of the locator shoulder will be flush with the retainer face Never crimp without the correct locator in the tool Contacts or terminals can fall into the tool causing the tool to jam and may cause damage to the unit Locator Notch Retainer Die Orient Pin Locator Notch Locator Orient Pin Retainer Locator Installed Drive Arm Installing Locator in Tool Model 400 Operations Manual 5 SETUP Locator Function The function of the locator is to orient the contact in the die housing su
18. 16 Dog Point Screws 4 pcs 400 TOG Assy Installing 400 TOG into 400 18 Housing 34 Maintenance INSTALL 400 5 STOP 10 Install 400 2A Piston Assembly into 400 1 Install 400 2A Piston assembly directly into 400 1 body Insert until assembly is flush with the rear of the 400 1 body and the front of the 400 1H handle Installing 400 2A Piston Assy into 400 1 body Model 400 B 1 shown Install 400 5 Stop and C clip Install the 400 5 stop until it seats on the 400 2B piston rod Install the C ring P N 3100 354 C ring pliers are helpful in installing this item This ring holds the front stop P N 400 5 in place 3100 554 C Ring 400 5 Stop Installing 400 2A Piston Assy into 400 1 body Model 400 B 1 shown Model 400 Operations Manual 35 MAINTENANCE 12 Connect 400 18 Housing to 400 1 Body When mounting the front housing 400 18 containing the toggle assembly it is imperative that the anchor 400 7 be firmly seated against the shoulder of the piston rod 400 2B The suggested procedure Is e Place the 400 18 housing toggle assembly on the tool body 400 1 e Align the mounting holes and the rectangular slot in the body Do not install the flat head housing mounting screws View the position of the anchor and piston rod thru the rectangular slot There should be no gap between the base of the anchor and the shoulder of the piston rod Check to insure that the dog point set
19. 39 40 aeren KEE 41 GE E 42 PAT ORE EO ee ent EE pP AS MA Ee 44 SPECIFICATIONS ee ee 46 47 1799 0 LUTO O A O o A 48 49 ESO Buis E ere 50 62 Model 400 Operations Manual V PREFACE lt lt lt Pico Model 400 Pneumatic Tool with Foot Pedal vi Model 400 Operations Manual NEE OVERVIEW Congratulations on your purchase of a Pico Pneumatic Crimp tool This versatile crimping tool eliminates human effort in four eight indent crimping of pin and socket contacts as well as solderless terminals Nonadjustable die heads interchangeable between Models 400 400 BHD and 400 B 1 are available from stock to handle No 26 wire through 4 0 all using the same safety cycling Crimpmaster power unit Factory air pressure is now sufficient for even the largest sizes made possible by the addition of a power booster as standard equipment The Model 400 Crimpmaster is also supplied with a bench mount as standard equipment and can be used as a portable hand tool a bench mounted tool or an optional foot controlled unit Pico Crimp Tools are precision pneumatic full cycling tools capable of producing Four eight indent crimps on pin and socket type contacts size 22 thru 350 MCM Four or two indent crimps on terminals splices or pigtails insulated or non insulated size 26 thru 350 MCM Hexagonal crimps on coaxial contacts and connectors Custom designs for unique applications Human engineered to prev
20. 4 NIT Non Insulated Terminals Yes Yes Yes 414DA 12 10 NIT Non Insulated Terminals Yes Yes Yes 414DA 8NIT Non Insulated Terminals Yes Yes Yes 414DA 6NIT Non Insulated Terminals Yes Yes Yes 414DA 4NIT Non Insulated Terminals No Yes Yes 414DA 2NIT Non Insulated Terminals No Yes Yes 414DA 1 0 NIT Non Insulated Terminals No Yes Yes 414DA 2 0 NIT Non Insulated Terminals No Yes Yes OPTIONAL ACCESSORIES NOTE Foot Controls 1 Consult locator catalog or factory for proper Gages locators Fitted Storage Cases 2 Tools are warranted for 90 days against defects in material or workmanship but should be returned to the factory every year for servicing 3 Consult factory for special applications Model 400 Operations Manual 49 Page 50 400 1H di SO X SLZ gt gt BLK TS ITL ITS M S E E SH RY SOLE TTT QQS e Ro E E B Pis LTE x 00 LO RA LS Stop LS 00 l E GE o LS 6227 42 2 S Y O Ring SEES ORS TASS STT S SR LKT SA ROIG SLD SRS lt gt b lt gt SPSS ES 400 32 I Spring REL Zeie We Ka g 4 e d OK Ia LAA Z gt 22 RSG KOSS RISES bes DER ee RRS 1 4 20 x 1 1 2 FHSCS 4 Pls X 7 lt gt d GA 1284 6227 28 O Ring 400 2A Piston
21. 4 PIs i HO N JO 040 SS f f Washer 490 27A 400 32 Spring amt E qm 400 2B Piston Rod 400 1H 6227 28 400 1 6227 42 1 4 20 x3 8 400 2A 400 5 3000 354 Handle O Ring Body O Ring SHCS Piston Stop Retaining Ring 8 32 x 1 2 FHSCS 10 32 Half Dog x 5 16 SSS 2 D 4 Pls g ad ol r J 4 EP J i A L di _ gt lt Page 52 400 BHD Cross section View 400 1H 400 17A amp 17B 6227 28 6227 42 6227 42 O Ring O Ring O Ring 400 TOG KS RA ES EE fe ee Tee ITS 6227 12 Ge Toggle Assembly lt gt Y sesse SE E O Ri STR RNA CITC IG DEM WY hing KE gL 400 30 EAI ee ee AS E 400 32 Po ZSZ SOSEER XK KISS KL KY PSK ZRI m J 6230 17 dl EES RSA L Die Assembly O Ring P e A00 5 Stop Piston Rod
22. Assembly Install 6227 8 O Ring Reassemble the cycling valve starting first by installing a new 6227 8 O ring Pico recommends applying Dow Corning DC 55 O Ring lubricant prior to reassembly Install 400 275 outer spring Install alignment pin Insert the 400 28 alignment pin into the 400 27 valve Prior to insertion the 156C inner spring should be placed over the alignment pin rod There is a groove at the base of the 400 27 body that the first coil of the 156C spring snaps into Press the 400 28 156C assembly in until the snap is heard to insure that these are firmly seated Install Cycling Valve With O ring 6227 08 and outer spring 400 275 installed on the cycling valve body from the rear of the piston insert the cycling valve assembly into the 400 2A piston Install 3100 37 retaining ring Insert the 400 27A Assy into the 400 2A Piston from the rear Apply pressure to the head of the valve body and using c ring pliers insert the retaining ring onto the cycling valve from the front side of the 400 2A Piston Installation is now complete 42 Maintenance EE Trigger Assembly Malfunction of the trigger assembly is an extremely rare occurrence If it becomes necessary to remove the trigger components the procedure is as follows Locate the 093 diameter roll pin in the handle on the exploded view of the tool Using a drive punch with a diameter less than 093 inch punch out the roll pin The trigger housing
23. ant e Misalignment of the booster cylinder piston rod in the B or B 1 models To correct any of the above the tool must be disassembled To disassemble refer to specific model instructions in the Maintenance chapter or contact the factory SYMPTOM TOOL CYCLES FORWARD DOES NOT RETURN e The usual problem is the cycling valve P N 400 27A This unit is mounted in the face of the piston and the tool must be disassembled to replace it Follow the disassembly specified in the maintenance section When the piston is removed check the valve to determine if the spring and o ring are functioning properly Replace if necessary Check the alignment of the booster cylinder rod Remove the booster cap P N 400 29 by screwing the cap counterclockwise The piston rod will now be exposed Follow the directions on page to check alignment SYMPTOM TOOL CRIMPS TOO LOOSE e If terminations are failing tensile or electrical tests Calibrate the die set per section Calibrating Die pages 9 Calibrate the tool instructions found on the page 12 SYMPTOM TOOL CRIMPS TOO LOOSE If the tool and die set calibrate properly contact the factory to determine if the correct die set is being used for the application Model 400 Operations Manual 13 SETUP 14 Setup Maintenance MAINTENANCE E GENERAL MAINTENANCE The Pico model 400 series tools should be supplied with filtered dry air The tools are thoroughly lubricat
24. ce MODELS 400 BHD BOOSTER UNITS 400 B 1 SERIES 400 MODEL TYPES Models 400 BHD amp 400 B 1 have additional booster units not present on models 400 o Remove Booster Units Note Only Models 400 BHD amp 400 B 1 have Booster Units Remove 400 30 2 units on 400 B 1 400 31 Piston Assemblies o Remove 400 5 Stop o Remove 400 2A Piston Assembly from 400 1 Body e Disassemble as needed internal components Cycling Valve Piston Assemblies Model 400 Operations Manual 17 MAINTENANCE MAIN UNIT DISASSEMBLY General overhaul for the unit is accomplished by first disassembling the main unit and then depending on need disassembly of the toggle unit and piston assemblies Models 400 BHD and 400 B 1 have additional booster unit s 1 Remove Cover Nut Remove by turning counterclockwise Die will now be exposed V V d Fi Remove Die Die Locating Pin Remove die pulling with hand E pressure directly away from the retainer in a straight line 18 Maintenance REMOVING BENCH MOUNT 3 Remove Locator Remove by pulling directly from retainer Locator notch Locator slot 4 Remove Bench Mount amp Sleeve Remove by first unscrewing the bench mount nuts When removing the sleeve it may be necessary to spread it partway to remove
25. ch that the contact barrel is directly in line with the die indentors This will result in a crimp meeting specifications for the particular contact being processed The locator is matched to a specific contact amp die configuration Use of non factory specifications in this regard can result in a poor crimp and or damage to the tool and contact For help in choosing the correct die amp locator solution refer to the cross reference guide included with your product or contact the factory for assistance Locator Contact Indentor Cutaway view of locator and Die Assembly INSTALLING DIE Install the die set There is an index pin in the face of the retainer Observe the drilled hole in the rear of the die housing Orient this hole to fit over the index pin in the retainer and press the die set into place There will be some resistance when the four drive arms come into contact with the indentors The die set must sit flat on the retainer face Locator should be installed prior to installing die 6 Setup DIE ASSEMBLY Rear View of Die and Index Pin Hole Die Orient Pin Y AA Y e Mounting Die side view Model 400 Operations Manual 7 SETUP EE INSTALLING COVER NUT When you have insured that the die set is flush with the face of the retainer the cover nut can then be installed Please note the O ring P N 6230 11 on the inside face of the cover nut During the process of crimping contacts a
26. ed at the factory and if clean filtered dry air is provided they should not require additional lubrication for the first year The tools are assembled with the highest quality O ring lubrication and should provide adequate lubrication under normal conditions for the lifetime of the tool If it becomes necessary to lubricate the tool Dow Corning DC 55 O Ring lubricant is recommended Factory personnel are available to advise on additional repair questions which may occur Additional information including video files are available at our web site www picotools com GENERAL OVERHAUL 16 General overhaul for the unit can be accomplished by disassembling the tool into its component parts and after inspection replacing parts as needed Pico recommends replacing all springs amp O rings when performing any general overhaul to the tool For other problems such as a broken arm or a broken link in the Toggle assembly it is suggested that the tool be sent to the factory for repair To produce a symmetrical crimp the face of the drive arms must be equidistant from the theoretical centerline When a new arm is replaced it may not match the other three due to wear which has occurred DISASSEMBLY SEQUENCE o Remove Cover nut Die amp Locator Bench Mount if installed o Detach 400 18 Housing from 400 1 Body Remove set screw prior to 400 18 removal o Remove 400 TOG from 400 18 o Separate 400 1H 400 1 Model 400 Only Maintenan
27. ent accidents This can be accomplished simply by changing dies and locators in accordance with factory directions For further information on this product and other Pico products please visit us on the web at www picotools com Model 400 Operations Manual vii PREFACE lt lt lt viii Model 400 Operations Manual Setup SETUP ao SETUP OVERVIEW Each tool is shipped from the factory pre assembled However the tool will not have a locator and die assembly pre installed These are purchased separately and are installed by the user For help in choosing the correct die amp locator solution refer to the cross reference guide included with your product or contact the factory for assistance The tool can be operated manually through the use of the hand trigger or through a foot control pedal P N 104 which is an optional purchase Setting the tool up for operation consist of the following SETUP Connect Air supply to tool Use a 1 4 ID 3 8 OD line capable of 70 to 125 PSI 1 2 CFM Nominal pressure is 80 PSI Use clean filtered dry air Do not use an oiler Install Locator Install Die Install Cover Nut ADJUST e CHECK e RUN Check Tool Operation cycle tool with air without inserting a wire and contact to check operation of indentors Gage Tool Proceed with normal operation Detailed setup and operating instructions follow Setup AIR SETUP i AIR SETUP Air Supply Reguirements
28. g steps 1 3 400 24 Die Cap 3100 250 C ring Indentors 400 14 Die 400 13 XXX Body 4 Pcs Cn The XXX refers to a specific crimp depth which is application specific 8 32 Allen Point Screw Die Assembly 44 Maintenance Specifications SPECIFICATIONS 400 Booster Cylinder 400 BHD Booster Cylinders 400 B 1 46 Model 400 Operations Manual _A4 _ _ AA MODELS There are 3 basic models available in the 400 Series The applications chart on the following pages help to differentiate the models and their capabilities The basic difference between each model is determined by the addition of one or more boosters The 400 model does not come with a booster the 400 BHD has one booster unit and the 400 B 1 has two booster units The booster unit s facilitate crimping larger diameter contacts An optional Foot pedal assembly for engaging the crimp cycle P N 104 is available for purchase for all models AIR For optimal performance amp tool lifetime use clean filtered dry air providing 70 120 PSI WEIGHT 400 400 BHD 400 B 1 14 lbs 17 lbs 21 lbs Model 400 Operations Manual 47 SPECIFICATIONS APPLICATIONS APPLICATIONS CONTACTS PINS AA 22 thru 2 22 thru 4 0 SOCKETS Gam SOLDERLESS TERMINALS sur 26 24 thu 26 24 thru 2 UNINSULATED ken 26 24 thru 6 26 24 thru 2 COAXIAL APPLICATIONS MAX DIA MAX DIA CONTACTS CONNECTORS e Consult Factory on Spec
29. ific Applications 400 BHD 22 thru 4 0 26 24 thru 1 0 22 18 thru 2 0 MAX DIA NOTE Applications listed above represent a small sample of connector applications serviced by PICO Pneumatic crimping tools If your particular application is not listed on page 48 49 contact the factory By providing connector specifications Pico can often produce a Die and locator solution that will meet your needs 48 Model 400 Operations Manual NEE 400 Series STANDARD DIES 400 400 BHD 400B 1 414DA 22N Pins amp Sockets Yes Yes Yes 414DA 20N Pins amp Sockets Yes Yes Yes 414DA 16N Pins amp Sockets Yes Yes Yes 414DA 12N Pins amp Sockets Yes Yes Yes 414DA 8N Pins amp Sockets Yes Yes Yes 414DA 6N Pins amp Sockets Yes Yes Yes 414DA 4N Pins amp Sockets Yes Yes Yes 414DA 2N Pins amp Sockets Yes Yes Yes 414DA 0N Pins amp Sockets No Yes Yes 414DA 2 0N Pins amp Sockets No Yes Yes 414DA 4 0N 1 Pins amp Sockets No Yes Yes 414DA 26 24 T Insulated Terminals Yes Yes Yes 414DA 22 18 1T Insulated Terminals Yes Yes Yes 414DA 16 14 IT Insulated Terminals Yes Yes Yes 414DA 12 10 1T Insulated Terminals Yes Yes Yes 414DA 8IT Insulated Terminals Yes Yes Yes 414DA 61T Insulated Terminals Yes Yes Yes 414DA 4T Insulated Terminals No Yes Yes 414DA 21T Insulated Terminals No Yes Yes 414DA 1 0 IT Insulated Terminals No No Yes 414DA 26 24 NIT Non Insulated Terminals Yes Yes Yes 414DA 22 18 NIT Non Insulated Terminals Yes Yes Yes 414DA 16 1
30. iston however the piston rod P N is different Refer to the parts list for specific part numbers 2 Remove Piston Rod Generally there is no reason to remove the rod unless it needs to be replaced Unscrew the socket cap screw located at the rear of the piston rod Next unscrew 400 2B piston rod from the 400 2A piston by turning counterclockwise Locktite is used during initial assembly it may be necessary to heat up the assembly if difficulty unscrewing the piston rod from the piston is encountered To reassemble Reverse steps 1 2 It is recommended that the O ring be replaced Pico recommends applying Dow Corning DC 55 O Ring lubricant prior to reassembly Cycling Valve Assembly removal instructions in next section 6227 42 O Ring h Piston 400 27A Cycling Valve Assy 400 27A Cycling Valve Assy Socket Cap Screw 400 2B Piston Rod Piston Assembly Model 400 Operations Manual 41 MAINTENANCE Cycling Valve Disassembly Remove 3100 37 retaining ring Remove 400 27A Cycling Valve Assy from the rear of the 400 2A Piston Extract the 400 28 alignment pin by pulling it out from the 400 27 valve Typically the 156C spring will come when withdrawing the alignment pin The remaining components can now be removed 400 27 400 275 400 28 Valve Outer Spring Alignment Pin CDQ WW we 6227 08 156C 3100 37 O Ring Inner Spring Retaining Ring Cycling Valve Assembly Cycling Valve
31. ligence of Pico in the manutacture sale use repair maintenance or any handling of such equipment MODEL SERIAL DATE SOLD Important Precautions Air For optimal performance amp tool lifetime use clean filtered dry air providing 70 120 PSI Model 400 Operations Manual iii PREFACE OO Table of Contents PREFACE loc AA EE EE i EE 11i viii Ss e UA III vi viii SETUP o i aa B aso a i i i cue 2 E oe a tas io ai a o EE o E EE EE 3 4 et TIS E es E GE EE Ee FF 5 6 ee KE PI An 7 A ep E OE EE a ere eee eT 8 PU DI N OE EE EN N 9 10 BEE e Ad US LC E erai o ti Ee a OD BR DR ai DA OR 11 L hle eed e e 12 Tea les atejo IE ie ee e S 13 MAINTENANGE Sarai m N N OR OE AE N 16 Sato O A E S EEE EE E E 16 17 Remove Cover mat Dic Locator DERE oe ee EE sa RA 18 19 Eed RE OE RE EE EE EN 20 21 FI ee E 22 Remove LOIS EO EE N 22 23 Remove AUU e 22 23 Remove EE ZA Remove 400 124 Handle Model 400 Eege 25 o e o o 25 28 Os Ll handie Fom OO eege 29 Iv Model 400 Operations Manual NEE ___________ Main Unit Assembly 400 1F Pandile to 00 Body Model 400 OO RA panama GER ER EE 30 ei OJ IB e EE 31 32 si Id Se AO EE N OE EE N N EO ON N OE 22 IA AA a A i o a 32 400 30 Booster KOOL EE ins ini a i d i 33 OE eN ie 33 e MP 34 A e E EEE E SEN IA EE 22 0 6 2 O Di a a EE EE ey ee 35 DLE EMO EE pass EE EE r E i 30 37 i Bem n MIE ane ee ee eo ee Ge Ee ee nafs ie 38 Component Assembly Disassembly Toe UN eebe
32. m Retainer Retaining Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring Qty re PBR ra ra HB A me N mm mm N NO mm Page 61 PARTS LISTS 400 B 1 POWER UNIT Part 040 SS Washer 8 32 x 1 2 FHSCS 10 32 x 5 16 FHSCS 1 4 20 x 1 2 FHSCS 1 4 20 x 3 8 FHSCS 1 4 20 x 1 1 2 FHSCS 400 1 400 1H 400 2A 400 2B 400 5 400 17A 400 17B 400 18 400 26 400 27A 156C 400 27 400 275 400 28 6227 08 7100 37 400 29 400 29 1 400 30 400 31 400 31 1 Page 62 Description Washer Flat Head Cap Screw Half Dog SSS Booster Body Cap Screw Socket Head Cap Screw Booster Body Cap Screw Body Handle Front Piston Front Piston Rod Piston Stop Trigger Housing Trigger Slide Front Housing Cover Nut Cycling Valve Assembly Inner Spring Cycling Valve Body Outer Spring Alignment Pin O Ring Retaining Ring Booster Cap Booster Cap Booster Body Piston Rod Piston Rod Qty ce pd pd a a bech Se mm Ll hm hd hm Fei lR N mm Part 400 32 400 BM 400 TOG 1 4 x 3 4 1 4 x 1 1 4 x 1 1 2 10 32 x 3 16 SSS 10 32 x 5 16 SSS 400 7 400 9 400 10 HD 400 11 3000 354 6227 02 6227 07 6227 12 6227 28 6227 42 6230 11 6230 17 Description Return Spring Bench Mount Dowel Dowel Dowel Cup Point Screw Dog Point Screw Rear Anchor Yoke Heavy Duty Arm Retainer Retaining Ring O Ring O Ring O Ring O Ring O Ring O Ring O Ring
33. mension Go gage should enter snug fit is acceptable The No Go gage should not enter Model 400 Operations Manual 9 SETUP lt lt lt Calibrating Dies continued e Foot Pedal If operating with a foot pedal hold the pedal down The indentors will then remain in the closed position for gaging It the Go gage does not enter freely into the Die check to see that you have the correct Go No Go gage It the No Go gage enters freely into the Die in most cases this is indication that wear has occurred to the indentors Less probable is wear to the drive arms Confirm that the tool is within spec by calibration specified on page 12 The indentors are manufactured using S 7 tool steel and are heat treated to Rc 56 58 As a result they are should have a life span of many thousand cycles Indentors are available for purchase separately from a die assembly Contact the factory for details CAUTION Do not crimp against a gage To do so will damage the tool and void the warranty Prior to inserting Go No Go gage Hold down trigger to actuate crimp cycle Go No Go Gauge Gaging Tool 10 Setup OPERATION EE OPERATION amp ADJUSTMENT Adjust Regulator With the air supply connected adjust the regulator to provide approximately 80 lbs PSI Test Crimp Cycle Without a contact and wire in place operate the trigger Observe the action of the indentors to be sure they operate freely Normal O
34. nd terminals the contact or terminal will grow in length with the displacement of material The function of the O ring is to allow the die set to move forward 040 as the contact is being crimped This prevents excessive side load being applied to the side of the indentors Reduces wear and prevents the contact from bending When installing the cover nut it should be installed with finger tip pressure only Turn the nut on until you feel the O ring come in contact with the die face Tightening the cover nut down excessively will prevent the O ring from performing it s intended purpose 6230 11 O Ring 400 26 Cover Installing 400 26 Cover Nut 8 Setup CALIBRATING DIE CALIBRATING DIES All die sets are marked at the factory with the nominal crimp depth setting This is the fully closed diameter when the tool is actuated The dies can be easily checked with Go No Go gages A complete line of gages are available trom the factory The tolerance unless otherwise specified is plus 002 minus 005 Die P N Crimp Depth EXAMPLE Die P N Crimp Depth 414DA 4N CALIBRATION Select the proper go no go gage for the die set which is in the tool e Hand Trigger If operating with the hand trigger holding the trigger down will cause the tool to actuate and remain in the closed position The gage can then be used to check the opening between the indentors to determine if the die set is to the correct di
35. nstalling Sleeve and Bench Mount Maintenance NEE COMPONENT DISASSEMBLY Toggle Unit Disassembly of the toggle unit consists of removing the links connecting the arm to the yoke 400 7 and the front retainer 400 11 Using the proper diameter drive punch will aid in removal 1 Remove Pins from 400 11 Retainer Using a suitable punch use light pressure to tap the pins out from the retainer There are 4 pins 1 4 x 1 1 2 long 2 Remove Pins from 400 10 Arm Using a suitable punch or cylinder rod use light pressure to tap the pins out from each 400 10 arm Note each arm is connected to a 400 9 Link There are 4 dowel pins each is 1 4 x 1 long 4 Pls ee 114 x 1 1 2 OM x 1 eg 1 4 x 3 4 10 32 x 5 16 Dog Point SSS 10 32 x 3 16 Cup Point SSS 400 10 H D 4 Pls Exploded Toggle Model 400 Operations Manual 39 MAINTENANCE 400 7 Yoke 400 9 Link Removing 400 10 Arms 3 Remove Pins from 400 9 Link amp 400 7 Yoke Using a suitable punch use light pressure to tap the pins out from each 400 9 link Note each link is connected to the 400 7 yoke There are 4 pins each is 1 4 x 3 4 long To reassemble Reverse steps 1 3 from previous section 400 7 Yoke Removing 400 19 Link from Yoke 40 Maintenance NEE Piston Assembly H Remove O Ring Remove the 6227 42 O ring from the piston For booster piston assemblies all use the same O ring and p
36. ockwise Removing 400 29 Booster Cap Model 400 B 1 shown Remove 400 31 1 Piston from 400 30 Booster Model 400 B 1 There is a 1 4 20 thread in the center of the piston rod With the 400 29 booster cap removed screw a 1 4 20 bolt into the rear of the piston rod You will now be able to pull the piston from the housing It should move with minimal resistance 400 31 1 Piston Assy Model 400 B 1 1 4 20 bolt inserted to aide in piston removal 400 30 Booster Removing 400 31 1 Piston Assy 26 Maintenance REMOVE 400 29 1 BOOSTER CAP 13 Remove 400 30 Booster from 400 29 1 Booster Cap Model 400 B 1 You will see four screws 1 4 20 x 1 2 which mount the booster cylinder 400 30 to the 400 29 1 booster cap Loosen these screws and remove the booster from the rear of the booster cap 400 30 Booster 1 4 20 x 1 2 Cap Screws 400 30 Booster 400 29 1 Booster Cap Removing 400 30 booster Model 400 B 1 shown 14 Remove 400 29 1 Booster Cap Model 400 B 1 Turn the 400 29 1 booster cap counterclockwise to remove Model 400 BHD Turn the 400 29 booster cap counterclockwise to remove It the cap cannot be removed by hand use a strap wrench to gain additional leverage Model 400 B 1 Model 400 BHD 400 29 Turn Counter Clockwise Booster Cap to remove Removing 400 29 1 or 400 29 Booster Cap Model 400 Operations Manual 27 MAINTENANCE Remove 400 31 Piston Model 400 BHD amp 4
37. ody Ben Assy 625 Pipe used to X remove piston ME Removing 400 2A Piston from 400 1 Body using 625 pipe 24 Maintenance 400 BHD amp B 1 BOOSTER REMOVAL Remove 400 1 Body from 400 1H Handle Models 400 only 10 Remove the four 1 4 20 x 1 1 2 inch bolts from the 400 1H handle Once these are removed separate the units 400 1 Body 400 1H screws 1 4 20 x 1 1 2 Removing 400 1H Handle At this stage the model 400 tool has been disassembled into its component parts Toggle assembly Piston amp Cycling valve body housings For information concerning components parts see pages 39 44 Models 400 BHD and 400 B 1 will still have booster assemblies attached Refer to the instructions below to remove Models 400 BHD amp 400 B 1 Booster Assembly Removal The procedure for removing the booster assemblies for each model is essentially identical except that model 400 BHD has only one booster unit while model 400 B 1 has two We will describe the procedure for removing the two booster units for model 400 B 1 For model 400 BHD the basic procedure is the same with the exception that this model has only one booster unit Model 400 Operations Manual 25 MAINTENANCE 11 Remove 400 29 Booster Cap Model 400 B 1 Turn the 400 29 booster cap counterclockwise to remove If the cap cannot be removed by hand use a strap wrench to gain additional leverage Remove 400 29 Booster Cap by turning Counter Cl
38. peration Insert the contact or terminal and wire assembly and proceed to crimp After operating personnel have become accustomed to using the tool the air need not be turned off while changing dies and locators If a die set fails to calibrate within an acceptable range calibrate the tool following the steps below to insure that the tool is within specification Contact inserted for crimp Model 400 Operations Manual 11 SETUP CALIBRATING TOOL If a die set fails to calibrate within an acceptable range calibrate the tool following the steps below to insure that the tool is within specification e To gage the tool remove the cover nut and die set e Cause the tool to be actuated and held in the closed position If using a foot pedal hold it down If using the thumb button hold it down e Measure the distance between the face of two opposing arms This dimension should be 1 985 to 2 003 If this is not the case the arms are out of alignment or worn Contact the factory for replacement Measure from face to face Dim 1 985 to 2 003 Calibrating Tool 12 Setup TROUBLESHOOTING or TROUBLESHOOTING SYMPTOM TOOL OPERATES SLUGGISHLY 1 Check the air supply to insure that there is a minimum of 80 P S 1 provided to the tool 2 Check the air line size It should be a 1 4 ID 3 8 OD line If this does not correct the condition the usual causes are e Worn O rings e A build up of debris and congealed lubric
39. r Cap 6227 12 Booster Cap Difference between 400 29 1 amp 400 29 Booster Caps 32 Maintenance INSTALLING 2nd 400 30 BOOSTER 6 Install second 400 30 Booster Model 400 B 1 only Mount the booster to the 400 29 1 booster cap Insert the four 1 4 20 x 1 2 flat head cap screws leaving them loose Insert the 400 1000 guide tool and tighten the cap screws Allen Wrench 1 4 20 x 1 2 Screws 4 pcs 400 1000 Guide Tool Tightening Second Booster Screws 7 Install 400 31 1 Piston Assembly Model 400 B 1 Install the complete 400 31 1 piston assembly consisting of 400 2A Piston 400 31 1 Piston rod 6227 42 O ring and 400 27 Cycling valve Install by inserting the assembly into the rear of the 400 30 booster until the unit is flush with the booster 6227 42 O ring 400 31 1 Piston Assy Installing 400 31 1 Piston in Model 400 B 1 Model 400 Operations Manual 33 MAINTENANCE 8 Install Booster Cap 400 29 Model 400 B 1 Install booster cap P N 400 29 and P N 6230 17 O ring The cap mounts onto the 400 30 booster and is tightened by turning clockwise Booster installation for 400 B 1 now complete 400 29 Booster Cap Installing 400 29 Booster Cap EN install 400 T0G into 400 18 Housing All Models The following proceedures apply to all models 400 400 BHD amp 400 B 1 Mount the 400 TOG assembly into the 400 18 housing using four 10 32 x 5 32 half dog screws 10 32 x 5
40. screw is in the anchor 400 7 e Apply air to the tool causing the piston to come forward and remain in that position e Use a rod of about 3 4 inch diameter insert it thru the retainer 400 11 and tap the anchor 400 7 to insure that it is firmly against the shoulder of the piston rod While still maintaining air to the tool and the piston in the forward position tighten the dog point set screw e Install the locking set screw against the dog point screw e Air can now be removed from the tool Check the alignment of the 400 18 clearance holes to the threaded holes in the 400 1 body Reposition if necessary and install the four 8 32 X 1 2 housing screws Slot in 400 18 for Access to set screws Set Screw Slot location looking upside down at 400 18 amp 400 1 housing 36 Maintenance INSTALLING 400 18 HOUSING 400 18 Housing Screws 8 32 x 1 2 4 pcs 400 2B Piston Rod e SS Set Screw NE gt We 400 7 Anchor 400 7 Anchor 3 4 Rod Side View Mounting 400 18 Housing to 400 1 Body Model 400 Operations Manual 37 MAINTENANCE 38 Install Sleeve and Bench Mount Install the sleeve and bench mount At this stage assembly is complete Refer to the setup guide for operating instructions For information on components refer to the next section Sleeve Bench Mount Nuts Bench Mount I
41. the retracted position If the set screw is visible remove the locking set screw completely Applying hard grease to the end of the allen wrench will assist in keeping the screw attached to the allen wrench so that it can be lifted out of the housing Next back out the dog point screw approx 4 complete turns until you are sure that it is no longer engaged into the piston rod 5B Serial Number Tools 6199 and older If the tool is an older model the set screw may not be visible when the tool is in the retracted position With this condition the tool must be caused to move to the closed position Using Hand Trigger If using the push button to operate the tool hold the button down keeping the toggle in its forward position The set screw will now be visible through the 400 18 slot Remove set set screw as described in previous section Using Foot Pedal If using the foot pedal to operate the tool depress the pedal down keeping the toggle in its forward position The set screw will now be visible through the 400 18 slot Remove set set screw as described in previous section 5A Model 400 Operations Manual 21 MAINTENANCE 400 18 Housing Screws 8 32 x 1 2 4 pcs Removing 400 18 Housing 6 Remove 400 18 from 400 1 Housing There are four 8 32 x 1 2 screws locking the 400 18 assembly into the main housing 400 1 Remove these screws and the 400 18 assembly can be pulled from the front of the 400 1 7 Remove 40
Download Pdf Manuals
Related Search