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PICO 500 Series Service Manual

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PICO
500 SERIES
SERVICE MANUAL

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  • Page 1 PICO 500 SERIES SERVICE MANUAL...
  • Page 2 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.

  • Page 3: Limited 90-Day Warranty

    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.

  • Page 4: Table Of Contents

    PREFACE Table of Contents PREFACE Table of Contents ....................iii-viii Overview ......................vi-viii SETUP Overview ........................2 Air Setup ........................3-4 Installing Locator....................5-6 Installing Die ......................7-8 Installing Cover nut ....................9 Calibrating Die ....................10-11 EC Valve Adjustment....................12 Operation & Adjustment ..................13 Calibrating Tool.......................
  • Page 5 Main Unit Assembly 500-1H handle to 500-1 Body (model 500 only)............. 33 Booster Alignment ....................34-35 500-31 Piston ......................36 500-29 Booster Cap....................36 500-31-1 Piston....................... 37 500-29-1 Booster Cap ..................... 38 500-Toggle ......................38 500-2A Piston......................39 500-5 Stop....................... 39 500-18 Housing ....................40-41 Sleeve and Bench Mt....................

  • Page 6: Preface

    PREFACE Pico Model 500 Pneumatic Tool with Foot Pedal Preface...

  • Page 7: Overview

    Custom designs for unique applications 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 500 Operations Manual...
  • Page 8 PREFACE viii Preface...
  • Page 9 Setup...

  • Page 10: Overview

    SETUP 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 product, or contact the factory for assistance.

  • Page 11: Air 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.
  • Page 12 SETUP AIR SETUP Connecting Air - Foot Pedal For foot pedal use, the air hose must be connected to the port in the center of the cylinder. The port in the rear of the handle must be sealed with a 1/4" NPT pipe plug. The air hose connected to the tool cylinder is in turn connected to the outlet port of the foot pedal.

  • Page 13: Installing Locator

    LOCATOR INSTALLING LOCATOR Remove the open ended cover nut (P/N 500-26) on the front of the tool housing. Tool is not shipped with a die installed by the factory - if a die is installed, it Note must be removed before locator can be installed. Insert the locator into the retainer.
  • Page 14 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 particular contact being processed.

  • Page 15: Installing Die

    DIE ASSEMBLY INSTALLING DIE To 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.
  • Page 16 SETUP Retainer Mounting Die - side view Die must be mounted flush with retainer. Note SETUP...

  • Page 17: Installing Cover Nut

    COVER NUT 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 P/N 6230-20 O ring 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.
  • Page 18 SETUP 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.

  • Page 19: Calibrating Die

    CALIBRATING DIE • Go gage should enter, snug fit is acceptable. The No-Go gage should not enter. If the Go gage does not enter freely into the Die, check to see that you have the correct Go No-Go gage. If the No-Go gage enters freely into the Die, in most cases this is indication that wear has occurred to the indentors.

  • Page 20: Ec Valve Adjustment

    SETUP EC VALVE ADJUSTMENT For Model 500-EC, the valve permits adjustment for the time that the indentors remain in their fully closed position. Ideally, they should remain closed for a period of at least 1-2 seconds. If this is not the case, refer to the following procedure to adjust. CYCLE TOOL: Depress the foot pedal to cycle tool.

  • Page 21: Operation & Adjustment

    OPERATION OPERATION & 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 (or in the case for the EC and Foot Control equipped models, depress the foot pedal).

  • Page 22: Calibrating Tool

    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. To gage the tool remove the cover nut and die set. •...

  • Page 23: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING SYMPTOM: TOOL OPERATES SLUGGISHLY 1. Check the air supply to insure that there is a minimum of 80 P.S.I. 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: •...
  • Page 24 SETUP SETUP...

  • Page 25: Maintenance

    Maintenance...

  • Page 26: General Maintenance

    GENERAL MAINTENANCE GENERAL MAINTENANCE The Pico model 500 series tools should be supplied with oil-free, filtered, dry air. The The Pico model 500 series tools should be supplied with oil-free, filtered, dry air. The tools are thoroughly lubricated at the factory and if clean, filtered, dry air is provided, 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.

  • Page 27: Model Types

    MODEL TYPES Model 500-EC Model 500-D Booster Units Model 500-D-1 Series 500 Model Types Remove 500-1H Handle (Models 500-EC Only) • Models 500-D & 500-D-1 have additional booster units not present on models Note 500-EC. Remove Booster Units • Models 500-D & 500-D-1 only •...

  • Page 28: Main Unit Disassembly

    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 500-D and 500-D-1 have additional booster unit(s). Note Remove Cover Nut Remove by turning counterclockwise.
  • Page 29 REMOVING DIE & LOCATOR Remove Locator Remove by pulling directly from retainer. Locator notch Locator slot Remove Bench Mount & Sleeve Remove Nuts - Remove Bench Mount Bench Mount Sleeve - Note, it may be necessary to spread sleeve in order to remove Model 500 Operations Manual...
  • Page 30 MAINTENANCE Remove Set-Screw The toggle assembly is attached to the piston rod (P/N 500-2B) 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.
  • Page 31 REMOVING 500-18 HOUSING 500-1 Cycling Valve Bleeder - 500-D & 500-D-1 only 500-18 Slot in 500-18 for Access to 500-1H set screws Set-Screw Slot location - looking upside down at 500-18 & 500-1 housing Set screw not visible : If the tool is an older model, the set screw may not be visible when the tool is in the retracted position.
  • Page 32 MAINTENANCE 500-18 Housing Screws 10/32 x 5/8" - 4 pcs 500-1 500-18 Removing 500-18 Housing Remove 500-18 from 500-1 Housing There are four 10/32 x 5/8" screws locking the 500-18 assembly into the main housing 500-1. Remove these screws and the 500-18 assembly can be pulled from the front of the 500-1.
  • Page 33 REMOVING 500-5 STOP 500-TOG Mounting Screws 10-32 Dog x 5/16" Point - 4 pcs 500-18 500-TOG Assy Removing 500-TOG from 500-18 3000-550 C Ring 500-5 Stop 500-5 Stop Removing 500-5 Stop Model 500 Operations Manual...

  • Page 34: Remove 500-2A Piston

    MAINTENANCE Remove Piston Assembly from 500-1 Body - Model 500 EC only Withdraw the piston assembly from the 500-1. 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.

  • Page 35: Booster Removal

    BOOSTER REMOVAL Remove 500-1 Body from 500-1H Handle - Models 500 EC only Remove the four 5/16-18 x 1 inch bolts from the 500-1H handle. Once these are removed, separate the units. 500-1 Body 500-1H screws 5/16-18 x 1" 500-1H Removing 500-1H Handle At this stage, the model 500 tool has been disassembled into its' component parts: Toggle assembly, body housings and piston assembly.

  • Page 36: Remove 500-31-1 Piston

    MAINTENANCE Remove Outer Booster Cap - Model 500-D-1 Turn the 500-29 booster cap counterclockwise to remove. If the cap cannot be removed by hand, use a strap wrench to gain additional leverage. Remove 500-29 Booster Cap by turning Counter-Clockwise 500-1 Removing 500-29 Booster Cap (Model 500-D-1) Remove 500-31-1 Piston from 500-30 Booster - Model 500-D-1 There is a 1/4-20 thread in the center of the piston rod.
  • Page 37 BOOSTER REMOVAL Remove 500-30 Booster from 500-29-1 Booster Cap - Model 500-D-1 You will see four screws which mount the booster cylinder (500-30) to the 500-29-1 booster cap. Loosen these screws and remove the booster from the rear of the booster cap.

  • Page 38: Remove 500-31 Piston

    MAINTENANCE Remove 500-31 Piston - Model 500-D & 500-D-1 There is a 1/4-20 thread in the center of the piston rod. With the 500-29-1 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.

  • Page 39: Remove 500-2A Piston

    BOOSTER REMOVAL 6227-28 O Ring 500-1 500-1H 6227-14 500 - 30 Booster 500 - 33 Cycling Valve 500 - 33 Cycling 5/16-18 x 1-3/4" 500-1H Valve Cap Screws - 4 pcs Removing 500-30 booster & 500-1H handle Remove 500-2A Piston - Model 500-D & 500-D-1 Withdraw the piston assembly from the 500-1.

  • Page 40: Remove 500-33 Cycling Valve

    MAINTENANCE Remove 500-33 Cycling Valve Once the 500-2A piston assembly has been removed, it is now possible to withdraw the cycling valve from the front of the 500-1 body. Disassembly of the unit is now complete. For information on individual components and repair, see pages 43-48 Front 500 - 1...
  • Page 41 Note lubricant is recommended. • There are two critical steps in reassembly of the 500 series pneumatic tools. Note 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 500-D &...
  • Page 42 MAINTENANCE Models 500-D & 500-D-1: Booster Piston Alignment Note 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.
  • Page 43 INSTALLING 500-30 BOOSTER 500-1H 500-1000 500-1000 Guide Tool Guide Tool 500-30 Booster Allen Wrench Using Alignment tool with booster assembly Once the valve is seated, install the 6227-33 washer, followed by the 4100-100 C-ring, from the rear of the 500-30 booster. Reinsert the guide tool When you are satisfied that the guide moves freely in the booster cylinder, tighten the four 5/16-18 x 1-3/4”...
  • Page 44 MAINTENANCE Install 500-31 Piston Assembly - Model 500-D & 500-D-1 Install the complete 500-31 piston assembly - consisting of 500-2A Piston, 500-31 Piston rod, 568-353 O-ring. Install by inserting the assembly into the rear of the 500- 30 booster until the unit is flush with the booster. 568-353 500-30 O-Ring...
  • Page 45 INSTALL 500-31-1 PISTON Install second 500-30 Booster - Model 500-D-1 Mounting the booster to the 500-29-1 booster cap. Insert the four 5/16-18 x 5/8” flat head cap screws, leaving them loose. Insert guide 500-1000 into the booster cylinder. Position the booster cylinder such that the guide moves freely in the cylinder.
  • Page 46 MAINTENANCE Install Booster Cap 500-29-1 Install booster cap P/N 500-29. The cap mounts onto the 500-30 booster, and is tightened by turning clockwise. Booster installation for 500-D-1 now complete. 500-29 Booster Cap Installing 500-29 Booster Cap The remaining steps apply to all models, 500-EC, 500-D & 500-D-1 Install 500-TOG into 500-18 Housing Mount the 500-TOG assembly into the 500-18 housing using four 10-32 x 5/16”...
  • Page 47 INSTALL 500-5 STOP Install 500-2A Piston Install 500-2A piston assembly directly into 500-1 body. Insert until assembly is flush wtih rear of the 500-1 body and the front of the 500-1H handle. 500-2A Pisotn 500-1 Installing 500-2A Piston Assy into 500-1 body - Model 500-D-1 shown Install 500-5 Stop and C-clip Install the 500-5 stop until it seats on the 500-2B piston rod.
  • Page 48 MAINTENANCE Connect 500-18 Housing to 500-1 Body When mounting the front housing, 500-18, containing the toggle assembly, it is imperative that the anchor, 500-7 be firmly seated against the shoulder of the piston rod 500-2B. The suggested procedure is: • Place the 500-18 housing-toggle assembly on the tool body 500-1.

  • Page 49: 500-31 Piston

    INSTALL 500-18 HOUSING • Install the locking set screw against the dog point screw. • Air can now be removed from the tool. • Check the alignment of the 500-18 clearance holes to the threaded holes in the 500-1 body. Reposition if necessary and install the four 10-32 x 5/8”...
  • Page 50 MAINTENANCE 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 Installing Sleeve and Bench Mount Main Unit Disassembly...

  • Page 51: Component Assembly / Disassembly

    TOGGLE UNIT COMPONENT DISASSEMBLY Toggle Unit Disassembly of the toggle unit consists of removing the links connecting the arm to the yoke (500-7), and the front retainer. Using the proper diameter drive punch will aid in removal. Remove Pins from 500-11 Retainer Using a suitable punch, use light pressure to tap the pins out from the retainer.
  • Page 52 MAINTENANCE Punch 500-7 Yoke 500-10 Arm 500-9 Link 3/8 x 1-1/2" Link Removing 500-10 Arms Remove Pins from 500-9 Link & 500-7 Yoke Using a suitable punch, use light pressure to tap the pins out from each 500-9 link. Note, each link is connected to the 500-7 yoke. There are 4 pins, each is 3/8” x 1-1/4” long.

  • Page 53: Piston Assembly

    PISTON ASSEMBLY Remove O Ring Remove the 568-353 O ring from the piston. Pico recommends applying Dow Corning DC-55 “O” Ring lubricant prior to reassembly. For booster piston assemblies, all use the same O-ring and piston - however the piston rod P/N is different.

  • Page 54: Cycling Valve

    MAINTENANCE CYCLING VALVE MAINTENANCE Note The 500-33 cycling valve assembly is used only with models 500-D & 500-D-1. 4100-100 500-33 Valve Body Retaining Ring 6227-33 Washer 500-33 Cycling Valve Assembly Typically, the only maintenance that needs to be performed is to replace the washer and retaining ring prior to reinstalling the assembly.

  • Page 55: Trigger Assembly

    TRIGGER ASSEMBLY 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.

  • Page 56: Die Assembly

    MAINTENANCE DIE ASSEMBLY The only reason to disassemble the Die is to replace worn indenters. Note 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.

  • Page 57: Specifications

    Specifications...

  • Page 58: Booster Cylinder

    SPECIFICATIONS MODEL 500-EC MODEL 500-D BOOSTER CYLINDER MODEL 500-D-1 Specifications...

  • Page 59: Models

    MODELS There are 3 basic models available in the 500 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.

  • Page 60: Applications

    • Consult Factory on Specific Applications 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 52 or 53, contact the factory. By providing connector specifications, Pico can produce a Die and locator solution that will meet your needs.
  • Page 61 500 Series STANDARD DIES 500-EC 500-D 500-D-1 514DA-20N Pins & Sockets 514DA-16N Pins & Sockets 514DA-12N Pins & Sockets 514DA-8N Pins & Sockets 514DA-6N Pins & Sockets 514DA-4N Pins & Sockets 514DA-2N Pins & Sockets 514DA-1/0N Pins & Sockets 514DA-2/ON Pins &...
  • Page 62 Specifications...
  • Page 63 Model 500 Operations Manual...
  • Page 64 Specifications...
  • Page 65 Model 500 Operations Manual...
  • Page 66 Specifications...
  • Page 67 Model 500 Operations Manual...
  • Page 68 Specifications...
  • Page 69 Model 500 Operations Manual...
  • Page 70 Specifications...
  • Page 71 Model 500 Operations Manual...
  • Page 72 Specifications...
  • Page 73 Model 500 Operations Manual...
  • Page 74 Specifications...
  • Page 75 PICO CORPORATION 500 Series Die & Locator Cross Reference Catalog...
  • Page 76 Table of Contents ...................... 2 500 Series Tech Sheet ....................3 500 Series Std. Die Applications ................4 500 Series Terminals Data ..................6 Insulated Terminals ....................7 Non-Insulated Terminals ..................8-9 Pin & Socket Contacts..................10-11 Pico Corp - 500 Series Die & Locator Cross-reference...
  • Page 77 PICO CORPORATION ���������� ������������������������������������������������� ��������������������������������������������������������������� ������������������������������������������������������������� ��������������������������� ���� ������ ���� ���� ���� ����� ������� �������� �������� ����� ��� ������ ����� ���� ��� ���� ����� ����� ��� �������� ������� ��� ������ ��������� ����� �� ������ ������ ��� ��������� ����������� �������� ���� ��������� ��� ���� ������� ���� ���� ������� ����� �����...
  • Page 78 Consult locator catalog or factory for proper locators. Fitted Storage Cases Tools are warranted for 90 days against defects in material or workmanship but should be returned to the factory every year for servicing. Pico Corp - 500 Series Die & Locator Cross-reference...
  • Page 79 PICO CORPORATION LOCATOR and DIE ASSEMBLY CATALOG for use with PICO MODEL 500 SERIES POWER UNITS Order by Locator No. and /or Die assembly No. Effective March 1st, 2002 Version 1.0 NOTE: Contacts or terminals which may not be listed in the current catalog can usu- ally be satisfactorily crimped with stock dies.
  • Page 80 “ -B “ suffix. 3) Terminals made from SOLID STOCK AND COLD HEADED: Contact Pico Corporation for proper die assemblies and locators for these terminal styles.. In most cases the same locator will perform satisfactorily for "IT" INSULATED and "NIT" NON- INSULATED TERMINALS, but a locator for a tube stock terminal will not work with a flat stock terminal.
  • Page 81 INSULATED TERMINALS-MS25036 GROUP 1 T & B BURNDY MS25036 Dash SIZE 514DA- 514DA- 514DA- -115 5502 5502-1 5502-3 -116 5502 5502-1 5502-3 -117 5502 5502-1 5502-3 -118 5502 5502-1 5502-3 -119 5503 5503-1 5503-3 -120 5503 5503-1 5503-3 -121 5503 5503-1 5503-3 -122...
  • Page 82 5510-1 0NIT 5510-3 -135 ONIT 5510-2 ONIT 5510-1 ONIT 5510-3 -151 ONIT 5510-2 ONIT 5510-1 ONIT 5510-3 -152 ONIT 5510-2 ONIT 5510-1 ONIT 5510-3 -153 2/0NIT 5520-2 2/0NIT 5520-1 2/0NIT 5520-3 Pico Corp - 500 Series Die & Locator Cross-reference...
  • Page 83 NON-INSULATED TERMINALS-MS20659 GROUP 1 T & B BURNDY MS20659 Dash SIZE 514DA- 514DA- 514DA- -119 2/0NIT 5520-2 2/0NIT 5520-1 2/0NIT 5520-3 -120 2/ONIT 5520-2 2/ONIT 5520-1 2/ONIT 5520-3 -154 2/ONIT 5520-2 2/ONIT 5520-1 2/ONIT 5520-3 -136 2/ONIT 5520-2 2/ONIT 5520-1 2/ONIT 5520-3 -155...
  • Page 84 BAN 7027-501 P) Tri-Star 514DA-2/-D 5402 MS90453-0-0 Mil. Std 514DA-1/0N 5440 MS90453-4-4 Mil. Std 514DA-4N 5420 MS90453-8-8 Mil. Std 514DA-8N 5400 MS90454-0-0 Mil. Std 514DA-1/0N 5440 MS90454-4-4 Mil. Std 514DA-4N 5420 Pico Corp - 500 Series Die & Locator Cross-reference...
  • Page 85 PIN & SOCKET CONTACTS CONTACT SIZE MANF'R DIE ASSY LOCATOR MS90454-8-8 Mil. Std 514DA-8N 5400 MS90559-1 Mil. Std 514DA-4/0N 5470 MS90559-10 Mil. Std 514DA-4N 5420-1 MS90559-11 Mil. Std 514DA-6N 5410 MS90559-12 Mil. Std 514DA-6N 5410 MS90559-13 Mil. Std 514DA-4N 5420-1 MS90559-14 Mil.

This manual is also suitable for:

500-ec500-d500-d-1

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