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PRODUCT INFORMATION 1-800-522-6752

This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at www.te.com.

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

Foot pedal

Solenoid/trigger/timer

Air fitting (not supplied)

Valve

Power cord (to 110V or 240V supply)

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

Locator notch

Die orientation pin

Retainer

Locator installed

Locator orientation pin

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

Rear view of die and index pin hole

Die orientation pin

Retainer

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

400-26 cover nut

6230-11 O-ring

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