TE Connectivity HDP-400 Reference guide

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Customer Manual
409-35018
17 FEB 21 Rev A
SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!......................................2
1. INTRODUCTION ..................................................................................................................3
2. SETUP..................................................................................................................................5
2.1. AIR SUPPLY SETUP ..................................................................................................6
2.2. INSTALLING THE LOCATOR.....................................................................................8
2.3. INSTALLING THE DIE ................................................................................................9
2.4. INSTALLING THE COVER NUT ...............................................................................10
2.5. CALIBRATING THE DIES.........................................................................................11
3. OPERATION AND ADJUSTMENT ....................................................................................14
4. CALIBRATING THE TOOL................................................................................................14
5. MAINTENANCE .................................................................................................................15
6. REPLACEMENT AND REPAIR .........................................................................................15
DEUTSCH Instructional Manual for
HDP-400 Power Crimper
(TE CONNECTIVITY PN 1606312-1)
ORIGINAL INSTRUCTIONS

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SAFETY PRECAUTIONS —AVOID INJURY —READ THIS FIRST!
Safeguards are designed into this application equipment to protect operators and maintenance personnel from
most hazards during equipment operation. However, certain safety precautions must be taken by the operator
and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application
equipment must be operated in a dry, dust-free environment. Do not operate equipment in a gaseous or
hazardous environment.
Carefully observe the following safety precautions before and during operation of the equipment:
Always wear approved eye protection while operating
equipment.
Always wear appropriate ear protection while using
equipment.
Moving parts can crush and cut. Always keep guard(s)
in place during normal operation.
Always insert power plug into a grounded receptacle to
avoid electrical shock.
Always turn off the main power switch and disconnect
the electrical cord from the power source when
performing repair or maintenance on the equipment.
Never insert hands into installed equipment.
Never wear loose clothing or jewelry that may catch in
moving parts of the equipment.
Never alter, modify, or misuse the equipment.
SUPPORT CENTER
CALL TOLL FREE 1-800-522-6752 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Support Center offers a means of providing technical assistance when required.
In addition, Field Service Specialists are available to provide assistance in the adjustment or repair of the
application equipment when problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE SUPPORT CENTER
When calling the Support Center regarding service to equipment, it is suggested that a person familiar with the
device be present with a copy of the manual (and drawings) to receive instructions. Many difficulties can be
avoided in this manner.
When calling the Support Center, be ready with the following information:
1. Customer name
2. Customer address
3. Person to contact (name, title, telephone number, and extension)
4. Person calling
5. Equipment number (and serial number if applicable)
6. Product part number (and serial number if applicable)
7. Urgency of request
8. Nature of problem
9. Description of inoperative component(s)
10. Additional information/comments that may be helpful

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Figure 1: HDP-400 power crimper
1
Foot pedal
4
Solenoid/trigger/timer
2
Air fitting (not supplied)
5
Valve
3
Power cord (to 110V or 240V supply)
6
Air exhaust
1. INTRODUCTION
When reading this manual, pay particular attention to DANGER, CAUTION, and NOTE statements.
DANGER
Denotes an imminent hazard that may result in moderate or severe injury.
CAUTION
Denotes a condition that may result in product or equipment damage.
NOTE
Highlights special or important information.

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Also, pay particular attention to the following safety precautions:
Always wear approved eye protection while operating equipment.
Always wear appropriate ear protection while using equipment.
Always disconnect the air and lockout the tool when not in use or when head or tool holder is detached.
Reasons for reissue of this document are provided in Section 10, REVISION SUMMARY.
NOTE
Dimensions in this customer manual are in metric units [with U.S. customary units in brackets]. Figures are not drawn to scale.
DANGER
This power unit should only be operated by trained personnel.
DANGER
If not using quick-disconnect fittings to connect the tool to the air supply, other means must be provided to easily disconnect
the tool from the air supply.
The HDP-400 Power Crimp Tool (TE PN 1606312-1) is a precision, pneumatic, full-cycling tool capable of
producing four-indent crimps on pin and socket type solid contacts, both HD and CE style, size 20 thru 4. This
is accomplished by changing out the die assembly and locators in accordance with factory specifications. The
HDP-400 is foot-controlled.
Power requirements:
Air supply: 620-827 kPa (90-120 PSI)
Electrical: 120V, 8 W

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2. SETUP
Each tool is shipped from the factory pre-assembled. The locator and die assembly are not pre-installed. These
must be purchased separately and installed by the user. For help in choosing the correct die and locator
solution, refer to instruction sheet 408-35142, or contact the factory for assistance.
The tool is operated with a foot control pedal (P/N 104), which is an optional purchase.
Setting the tool up for operation consists of the following:
1. Connect the air supply to the tool.
2. Install the locator.
3. Install the die.
4. Install the cover nut.
5. Check tool operation (without inserting a wire and contact, cycle the tool with air to check operation of
the indenters).
6. Gage the tool.
7. Proceed with normal operation.
Detailed setup and operating instructions follow.

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2.1. AIR SUPPLY SETUP
The tools is operated with a foot pedal assembly (P/N 104).
Use a 1/4" ID, 3/8" OD line capable of 70 to 125 PSI (1-2 CFM).
Crimp tool operating pressure is 620 to 861 kPa [90 to 125 PSI] (1-2 CFM). Nominal pressure is
80 PSI.
Use clean, dry air with a quality filter and regulator within 7.62 m [25 ft.] of the tool.
CAUTION
Do not use an oiler. Do not turn on the air pressure before calibrating the dies (see Section 2.5).
The air inlet port in front of the handle (Figure 2) is tapped to accommodate 6.35 mm [¼-in.] NPT fittings.
Direct pipe threaded fitting or quick disconnect can be used with non-setting pipe thread compound. When
installing connections, avoid leakage or damaged threads. Ensure that the connection is tight enough to
prevent leaks. Recommended air hose: 6.35 mm [¼-in.] inside diameter. The 6.35 mm [¼-in.] NPT
threaded hole in the rear of the handle must remain sealed with a single pipe plug.
Figure 2: Location of air inlet

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The air hose must be connected to the port in the center of the cylinder (Figure 3).
Figure 3: Connecting the air hose

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2.2. INSTALLING THE LOCATOR
The function of the locator is to orient the contact in the die housing so that the contact barrel is directly in
line with the die indenters. This ensures that the crimp meets the specifications for the particular contact
being processed.
The locator is matched to a specific contact and die configuration. Use of non-factory specifications in this
regard can result in a poor crimp or damage to the tool and contact.
For help in choosing the correct die and locator solution, refer to the cross-reference guide included with
your product, or contact the factory for assistance.
NOTE
The tool is not shipped from the factory with the die installed. If the die is installed, it must be removed before the locator can
be installed.
To install the locator, complete the following steps.
1. Remove the open-ended cover on the front of the tool housing.
2. Insert the contact locator into the retainer (Figure 4). The retainer is the component through which the
four drive arms protrude, and has an opening in the center that accepts the locator.
Figure 4: Installing the locator
1
Locator notch
4
Die orientation pin
2
Retainer
5
Locator installed
3
Locator orientation pin
6
Drive arm
3. Find the notch on the locator flange, and the corresponding pin in the face of the counterbore in the
retainer.
4. Orient the notch on the locator flange so that it lines up with the pin in the retainer. When properly
installed, the front of the locator flange is flush with the retainer face. The locator part number should
be visible.
CAUTION
Never crimp without the correct locator in the tool. Contacts can fall into the tool causing the tool to jam and possibly damaging
the unit.

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2.3. INSTALLING THE DIE
To install the crimp die assembly, complete the following steps.
NOTE
The locator must be installed before you install the die assembly.
1. Find the index pin in the face of the retainer, and the drilled hole in the rear of the die assembly
(Figure 5).
2. Orient this hole to fit over the index pin in the retainer and press the die assembly in place. The die
assembly must sit flat on the retainer face.
NOTE
Expect to feel some resistance when the four drive arms come into contact with the indenters.
3. Replace the open-ended cover on the housing. Ensure that the open-ended cover O-ring is intact and
in place.
4. Tighten the open-ended cover onto the tool housing until the O-ring contacts the crimp die assembly,
then tighten approximately an additional 15°.
5. When the die set is flush with the face of the retainer, the cover nut can be installed (see Section 2.4).
Figure 5: Installing the die
1
Rear view of die and index pin hole
2
Die orientation pin
3
Retainer
4
Die

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2.4. INSTALLING THE COVER NUT
The O-ring (P/N 6230-11) is located on the inside face of the cover nut (Figure 6). During the process of
crimping, the contact or terminal grows in length with the displacement of material. The O-ring allows the
die set to move forward as the contact is crimped. This prevents excessive side load from being applied to
the side of the indenters, reduces wear, and prevents the contact from bending.
Install the cover nut with fingertip pressure only. Turn the nut until you feel the O-ring come in contact with
the die face, then tighten approximately an additional 15°.
NOTE
Do not overtighten the cover nut. Doing so prevents the O-ring from performing its intended purpose.
Figure 6: Installing the cover nut
1
400-26 cover nut
2
6230-11 O-ring

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2.5. CALIBRATING THE DIES
All die sets are marked with the nominal shut height setting (Figure 7). This is the fully closed diameter
when the tool is actuated. The dies can be easily checked with NO-GO and GO gages. The tolerance,
unless otherwise specified, is plus (+) 0.05 mm [.002 in.] (NO-GO), minus (-) 0.13 mm [.005 in.] (GO).
Example:
Die assembly 400-414DA 16N.048 has a nominal shut height of 1.22 mm [.048 in.].
The GO dimension for this die is 1.09 mm [.043 in.] (1.22 minus 0.13 mm [.048 minus .005 in.]).
The NO-GO is 1.27 mm [.050 in.] (1.22 plus 0.05 mm [.048 plus .002 in.]).
Refer to Information Drawing 0425-205-0000 (HD series) or 4025-003-0000 (CE series) for die assembly
calibration information on all contacts.
If a die set fails to calibrate within an acceptable range, calibrate the tool to ensure that the tool is within
specification (see Section 4).
Figure 7: Die markings
1
Die part number
2
Nominal shut height

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To calibrate the dies, complete the following steps.
1. Select the proper NO-GO and GO gage for the die assembly that is in the tool.
2. Depress and hold the gage button on the air inlet side of the tool (Figure 8), which causes the tool
to actuate and remain in the closed position.
Figure 8: Gage button

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3. Use the gage to check the opening between the indenters (Figure 9) to determine if the die
assembly is to the correct dimension.
The GO gage should enter freely. A snug fit is acceptable. If the go gage does not enter freely
into the die, check to see that you have the correct go/no-go gage.
The NO-GO gage should not enter. If the no-go gage enters freely into the die, this indicates
wear to the indenters, or (less probable) wear to the drive arms. Confirm that the tool is within
specification (see section 4).
NOTE
The indenters are manufactured using S-7 tool steel, and are heat treated to Rc 56-58. As a result, they have a life expectancy
of many thousand cycles. Indenters are available for purchase separately from a die assembly. Contact the factory for details.
CAUTION
Do not crimp against a gage. To do so damages the tool and voids the warranty.
Figure 9: Location of GO/NO-GO gage

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3. OPERATION AND ADJUSTMENT
1. Adjust Regulator: With the air supply connected, adjust the regulator to provide approximately 80 lbs
PSI.
2. Test Crimp Cycle: Without a contact and wire in place, operate the trigger. Observe the action of the
indenters to be sure they operate freely.
3. 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 turned off while
changing dies and locators.
Prior to crimping contacts, wire must be stripped per Information Drawing 0425-205-0000 for HD series
contacts or Information Drawing 4025-003-0000 for CE series contacts. Correctly stripped wire should show no
signs of insulation tearing or stretching or conductor strand damage. Conductor strands should be visible
through the contact inspection hole prior to crimping.
4. CALIBRATING THE TOOL
If a die set fails to calibrate within an acceptable range, calibrate the tool. Complete the following steps to
ensure that the tool is within specification.
1. To gage the tool, remove the cover nut and die set.
2. Press and hold the foot pedal. This actuates the tool and holds it in the closed position.
3. Measure the distance between the face of two opposing arms (Figure 10). It should be between 1.985
and 2.003. A value outside this range indicates that the arms are out of alignment or worn. Contact the
factory for replacement.
Figure 10: Calibrating the tool

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5. MAINTENANCE
The HDP-400 requires filtered, dry air. The tool is thoroughly lubricated at the factory and if clean, filtered, dry
air is provided, it should not require additional lubrication for the first year. The tool is assembled with the
highest quality O-ring lubrication, which 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.
6. REPLACEMENT AND REPAIR
To obtain replacement parts, refer to the applicable instruction sheet or customer manual and order parts
through your TE representative. You can also order parts by any of the following methods:
Go to TE.com and click the Shop TE link at the top of the page.
Call 800-522-6752.
Write to:
CUSTOMER SERVICE (038-035)
TE CONNECTIVITY CORPORATION
PO BOX 3608
HARRISBURG PA 17105-3608
For customer repair services, call 800-522-6752.