p~ PICO 400 SERIES SERVICE MANUAL| PREFACE 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 * Dec, 2001 REVISED, * 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 day 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 1s 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 dlisclaims liability to any person or entity for general, special, indirect or consequential damages occasioned by any negligence of Pico in the manufacture, sale, use, repair, maintenance or any handling of such equipment. MODEL # SERIAL # DATE SOLD Important Precautions Air For optimal performance & tool lifetime, use clean, filtered dry air providing 70-120 PSL ‘Model 400 Operations Manual ittPREFACE Table of Contents PREFACE Table of Contents Overview... SETUP Overview Air Setup Installing Locator... Installing Die Installing Cover nut... Calibrating Die Operation & Adjustment. Calibrating Tool. Troubleshooting... MAINTENANCE General Maintenance General Overhaul ..... csi Remove Cover nut/Die/Locator/Bench Mt Set-Serew.. so Remove 400-18 Housing Remove Toggle Assy. Remove 400-5 Stop .a.nae Remove 400-2A Piston Remove 400-1H Handle (Model 400 Only) Booster REMOVAL ...-sscsesrseessesere 400-1H handle from 400-1 Body... iii-viii oo WEN 16 16-17 18-19 220-21 22 22-23 122-23 24 25 225-28 29 ‘Model 400 Operations ManualMain Unit Assembly 400-1H handle to 400-1 Body (Model 400 Only) 30 400-30 BOOStEE os serereren ese oc oe veces 31-32 400-31 Piston 32 400-29-1 Booster Cap .... oe sos fos sevcenteees 32 400-30 Booster (400-B-1) 33 400-311 PiStOM een 33 400-29 Booster Cap... oe sos fos seoctnneees 34 Toggle 34 400-2A Piston 35 400-5 StOP. ever soe 35 400-18 Housing... .csesneneneeen sos fo sevens 36-37 Sleeve and Bench Mt 38 Component Assembly / Disassembly Toggle Unit 30-40 Piston Assembly wl Cycling Valve...... sone so sos senses 42, Hand Trigger 43 Die Assembly. 44 SPECIFICATIONS Models..... sssnnenese fos fo evens 4-47 Applications 48-49 Series 400 Parts lists 50-62 ‘Model 400 Operations Manual vPREFACE Pico Model 400 Pneumatic Tool with Foot Pedal vi ‘Model 400 Operations Manual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 prevent 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 ‘Model 400 Operations ManualSetup| seruP 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 & locator solution, refer to the cross- reference guide included with your produet, 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 PSL : Use clean, filtered, dry air Do not use an oiler . Install Locator ° Install Die . Install Cover Nut ADJUST ¢ CHECK « 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: 2 SetupAIR SETUP AIR SETUP Air Supply Requirements 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 quali tool. filter and regulator installed within 25 feet of the 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 Hand Trigger Button 1/4" NPT Pipe Plug ‘Connecting Air to Hand Trigger Port ‘Model 400 Operations Manual 3| seruP Connecting Air (Foot Pedal) For foot pedal use, the air hose must be connected to the port in the center of the oylinder, 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 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 dic 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" aD Locator "Notch" Retainer Locator Orient Pin [Y— Retainer | Locator Installed ae 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, such that the contact barrel is directly in line with the die indentors. This will result in a crimp meeting specifications for the parti processed lar contact being The locator is matched to a specific contact & 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 6 locator solution, refer to the cross-reference guide included with your product, or contaet the factory for assistanc 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. SetupDIE ASSEMBLY Rear View of Die and 4 Index Pin Hole f Retainer Installing Die in Tool Retainer Die “Mounting Die - side view ‘Model 400 Operations Manual 7| seruP INSTALLING COVER NUT When you have insured that the die set is flush with the face of the retainer-the caver 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 and 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 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 from the factory. The tolerance, unless otherwise specified: is plus .002, minus .005. Die P/N Crimp Depth EXAMPLE Die P/N Crimp Depth | Go No-Go _— CALIBRATION : Select the proper go no-go gage for the die set which is in the tool : 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 dimension. : Go gage should enter, snug fit is acceptable. The No-Go gage should not enter. ‘Model 400 Operations Manual 9SETUP Calibrating Dies - continued : Foot Pedal: If operating, with a foot pedal, hold the pedal down, The indentors will then remain in the closed position for gaging. Ifthe Go gage does not enter freely into the Die, check to see that you have the correct Go No-Go gage Ifthe 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 Re 56-58. Asa 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 [Rie] 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 erimp > cycle \ Go No-Go Gauge Gaging Tool 10 SetupOPERATION OPERATION & ADJUSTMENT Adjust Regulator With the air supply connected, adjust the regulator to provide approximately 80 Ibs PSL 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 Operation 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 tured off while changing dies and locators. Ia 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 "| seruP CALIBRATING TOOL Ifa die set fails to calibrate within an acceptable range, calibrate the tool following the steps below to insure that the tool is within specification. : To gage the tool remove the cover nut and die set . 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. : 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 2 Setup| TROUBLESHOOTING | TROUBLESHOOTING SYMPTOM: TOOL OPERATES SLUGGISHLY 1. Check the air supply to insure that there is a minimum of 80 P.S.L. 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 rings. + A build up of debris and congealed Inbricant. + 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 + 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 GRIMPS TOO LOOSE + Ifterminations 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 Ifthe tool and die set calibrate properly, contact the factory to de die set is being used for the application ermine if the correct ‘Model 400 Operations Manual 13SETUP SetupMaintenance| MAINTENANCE GENERAL MAINTENANCE The Pico model 400 series tools should be supplied with filtered, dry air. The tools are thoroughly lubricated 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 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 & 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 . Remove Cover-nut, Die & Locator, Bench Mount (if installed) . Detach 400-18 Housing from 400-1 Body Remove set-screw prior to 400-18 removal : Remove 400-T0G from 400-18 : Separate 400-1H, 400-1 (Model 400 Only) 16 MaintenanceMODELS 400-BHD BOOSTER UNITS 400-B-1 SERIES 400 MODEL TYPES Models 400-BHD & 400- 1 have additional booster units not present on models 400. : Remove Booster Units (Note: Only Models 400-BHD & 400-B-1 have Booster Units) Remove 400-30 (2 units on 400-B-1), 400-31 Piston Assemblies : Remove 400-5 Stop : Remove 400-2A Piston Assembly from 400-1 Body + Disassemble (as needed) internal components (Cycling Valve), Piston Assemblies ‘Model 400 Operations Manual 7| 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. Nie] Models 400-BHD and 400-B-1 have additional booster unit(s). BI] Remove Cover Nut Remove by turning counte Die will now be exposed. 400-26 Cover Ey Pemove die Remove die pulling (with hand pressure) directly away from the retainer, in a straight line. OU, Die Locating Pin 18 Maintenance| REMOVING BENCH MOUNT BH Remove Locator Remove by pulling directly from retainer Locator notch Locator slot o Remove Bench Mount & Sleeve Remove by first unscrewing the bench mount nuts. When removing the sleeve, it may be necessary to spread it partway to remove. Remove Nuts - Remove Bench Mount Bench Mount Sleeve - Note, it may be necessary to spread sleeve in order to remove Model 400 Operations Manual 19| MAINTENANCE Remove Set-Screw The toggle assembly is attached to the piston rod (P/N 400-28) 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 ~ Dog Point \ re 400-TOG Outer Set Screw Toggle Assy 400-28 Piston Rod Set Screw Side view showing location of setscrew in relation to piston assy and toggle MaintenanceREMOVING 400-18 HOUSING Slot in 400-18 for Access to set screws Set-Screw Slot location - looking upside down at 400-18 & 400-1 housing Serial Number Tools 6200 and newer: The set screw will be visible and accessible when the tool is in 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. Serial Number Tools 6199 and olde: Ifthe 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: Ifusing 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: Lfusing 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 24MAINTENANCE Ray 400-18 Housing Screws 8/32 x 1/72"- 4 pes Removing 400-18 Housing 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, Remove 400-T0G 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 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. MaintenanceREMOVING 400-5 STOP >< 400-TOG Mounting Screws ? 10-32 Dog x 5/16" Point - 4 pes 400-TOG Assy ‘Removing 400-TOG from 400-18) 3100-354 C Ring Removing 400-5 Stop Model 400 Operations Manual 23| MAINTENANCE oO 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 e necessary to use a pipe (.625 dia or smaller) inserted in diagram. Use a soft rubber mallet and gently tap on the with hand pressure, it may the rear to assist removal. pipe to remove the piston. For models 400-BHD & 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 Body Piston Assy 625" Pipe used to help remove piston \ i \ Removing 400-2A Piston from 400-1 Body using .625" pipe 24 Maintenance400-BHD & B-1 BOOSTER REMOVAL Remove 400-1 Body from 400-1H Handle - Models 400 only Remove the four 1/4-20 x 1-1/2" inch bolts from the 400-1H handle, Once these are removed, separate the units 400-1H screws 1/4-20 x 1-1/2" 400-1H, Removing 400-1H Handle At this stage, the model 400 tool has been disassembled into its component parts: Toggle assembly, Piston & 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 & 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 400-1 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 a Remove 400-29 Booster Cap - Model 400-B-1 Turn the 400-29 booster cap counterclockwise to remove, Ifthe cap cannot be removed by hand, use a strap wrench to gain additional leverage: Remove 400-29 Booster Cap by turning Counter-Clockwise Removing 400-29 Booster Cap (Model 400-B-1 shown) FE] Aemove 400-31-1 Piston from 400-30 Booster - Mode! 400-B-1 ‘There is a 1/4-20 thread in the cemter 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 y 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 | B 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, Z Remove 400-29-1 Booster Cap Model 400-B-1: Turn the 400-29-1 booster cap counterclockwise to remove Model 400-BHD: Tum the 400-29 booster cap counterclockwise to remove. If the cap cannot bi moved by hand, use a strap wrench to gain additional leverage Model 400-B-1 ( - Model 400-BHD gy 400-29-1 Booster Cap x 400-29 T tom Counter-Clockwise Booster Cap to remove Removing 400-29-1 (or 400-29) Booster Cap Model 400 Operations Manual 27| MAINTENANCE B Remove 400-31 Piston - Model 400-BHD & 400-B-1 a 1/4-20 thread in the center of the piston rod. With the 400-29-1 booster cap d, 'w 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 Booster 400-31 Piston Assy Removing 400-31 Piston Assy FE Remove 400-30 Booster - Model 400-BHD & 400-B-1 There are four 1/4-20 x 1-1/2" screws securting the 400-30 booster to the 400-1H. handle. Remove these screws and seperate the two units 400-30 Booster 14.20" x L122” Cap Screws Remove 400-30 Booster 28 Maintenance| REMOVE 400-1 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 (FMe]_—-+ “This suggested that all 40" rings & 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 "0" Ring lubricant is recommended. B Re] + There are two critical steps in reassembly of 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 & 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 & 400-B-1 go to step 2 on page 31. Bo 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| INSTALLING 400-30 BOOSTER B Mount 400-30 Booster to 400-1H and 400-1 - Model 400-BHD & B-1 Install new 6227-12 & 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. 400-1H. 6227-28 O-Ring 400-30 Booster ~N, 6227-12 O-Ring 400-1H Side View 1/420 x 1-12" Screws - + pes Attaching 400-30 Booster, 400-1H & 400-1 Body EX Use Guide toot 400-1000 to align The alignment of the booster to the main cylinder is critical. The cylinders 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 400-30 Booster Allen Wrench Using Alignment tool with booster assembly Model 400 Operations Manual I| MAINTENANCE H Guide Tool - continued Tighten the four fat 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 a Install 400-31 Piston Assembly - Model 400-BHD & 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 GB 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. Nie} 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 Booster Cap . / Booster Cap _ Model 400-B-1 Difference between 400-29-1 & 400-29 Booster Caps 32 Maintenance| INSTALLING 2nd 400-30 BOOSTER a 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. 1/4-20 x 172" ) | Allen Wrench Screws - 4 pes 400-1000 Guide Tool Tightening Second Booster Screws 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 Installing 400-31-1 Piston in Model 400-B-1 Model 400 Operations Manual 33| MAINTENANCE is | 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 EX instal 400-106 into 400-18 Housing - All Models The following proceedures apply to all models, 400, 400-BHD & 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 5/16" Dog Point Screws - 4 pes 400-TOG Assy Installing 400-T0G into 400-18 Housing 34 Maintenance| INSTALL 400-5 STOP w Install 400-2A Piston Assembly into 400-1 Install 400-2A Piston assembly directly into 400-1 body. Insert until assembly is lush, 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 LE) nstait 400-5 Stop and C-clip Install the 400-5 stop until it seats on the 400-28 piston rod Install the “C” ring, P/N 3100-354. (Rie) ving pliers are helpfil in installing this item. This ring holds the front stop. P/N 400-5 in place 400-5 Stop Model 400-B-1 shown, Installing 400-2A Piston Assy into 400-1 body Model 400 Operations Manual 35| MAINTENANCE FE Connect 400-18 Housing to 400-1 Body When mounting the front housing, 400-18, containing the toggle assembly, itis imperative that the anchor, 400-7 be firmly seated against the shoulder of the piston rod 400-28. The suggested procedure is: : Place the 400-18 housing-toggle assembly on the tool body 400-1 : 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 screw is in the anchor 400-7 : Apply air to the tool, causing the piston to come forward and remain in that position. : 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 itis 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. : Install the locking set screw against the dog point screw. : 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. 400-18 Slot in 400-18 for Access to set screws Set-Screw Slot location - looking upside down at 400-18 & 400-1 housing 36 MaintenanceINSTALLING 400-18 HOUSING 400-18 Housing Screws - 8-32 x 1/2" “4 pes ‘Mounting 400-18 to 400-1 Body 400-28 Piston Rod |_— Set-Screw 400-7 Anchor 400-7 Anchor, Z\ senna a Side View - Mounting 400-18 Housing to 400-1 Body Model 400 Operations Manual 37