PICO TOOLS

Tooling Calibration
1. DIE CALIBRATION
Nominal Die Specifications

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.

Typical Go No-Go gages

Nominal Crimp Tolerance

Crimping die tolerance, unless otherwise specified:

GO minus .005 NO-GO plus .002 ( -.005 | +.002 )

NOTE: Calibration gages used should be ‘minus’ and Class Z or better.

Sample Die Calibration Specifications

Die P/N Nominal GO NO-GO

414DA-22N .032 .027 .034

Die P/N

‘Nominal’
Crimp Depth

Recommended Calibration Interval

Pico model 400 & 500 can achieve crimp cycles in the millions, to tens of million crimps before
maintenance is required.

Monthly duty cycle: up to 250,000 crimps/cycles

Yearly duty cycle: up to 3 million crimps/cycles

Pico recommends that both tool and die calibration at the start of the day, or before each crimp
project, which ever frequency is the shortest.
Die Calibration Procedure

General procedure for calibrating tool. Die must be installed in tool with cover nut. Air pressure
is supplied direct to the handle, pneumatic foot pedal, or EC valve. Tool must be cycled to full
closed position, and maintained while GO NO-GO gage is inserted. Depending on how air is
supplied to tool, engaging and maintaining crimp closure will vary.

Cycling tool to crimp closed position:

Hand Trigger

• If operating with the hand trigger, holding the trigger down will cause the tool to actuate and
remain in the closed position. Keep trigger button pressed while gaging the die.

Foot Pedal

• If operating with the foot pedal, holding the pedal down will cause the tool to actuate and
remain in the closed position. Keep foot pedal pressed while gaging the die.

EC Models

• If operating an EC equipped model, pressing the cycle button will cause tool to actuate and
remain in closed position. Keep button pressed while gaging the die.

EC Crimp
Cycle Button
General Procedure for Pin, Socket and Non-insulated Terminals

• Install Die set.

• Install Cover nut, hand tight.

• Select the proper go no-go gage for the die set being calibrated.

• Insert GO gage end into closed die opening. The gage should enter without obstruction. A snug
fit is acceptable.

• GO Gage fails

If GO gage end cannot be inserted into closed die - the die has failed calibration. Check to be
certain the proper gage is being used. Die cap will have nominal gage setting. If correct Gage has
failed, check tool calibration (starting on page).

• GO Gage successful

• Insert NO-GO gage end into closed die opening. Is it not possible to insert the NO-GO gage
end into a crimp die that is within tolerance specifications.

• NO-GO Gage clears

If NO-GO gage end can be inserted into closed die, the die has failed calibration. Check to be
certain the proper gage is being used. Die cap will have nominal gage setting. If correct Gage has
failed, check tool calibration (starting on page).

• NO-GO Gage insertion fails

Die is in proper tolerance specifications. Repeat calibration before each project, or once each day,
which ever period is the shortest.
 EXAMPLE: 414DA-22N.032 Die successfully Calibrated

The following photos demonstrate successful gaging for a 414DA-22N.032 Die.

Gage Used: GA-22N.032 GO .027 NO-GO .032

GO gage ‘end’ can be clearly seen to pass through crimp indentors. NO-GO gage end is unable to
penetrate the gap.

GO NO-GO gage prior to insertion GO gage end successfully inserted into die

GO NO-GO gage prior to insertion NO-GO gage end unable to clear die indentors
 Push Trigger & Hold

Keep Trigger Pressed

Insert Gage, "GO" end

 Die Calibration for Insulated Terminals

All IT crimping dies require different procedure for calibration. These dies contain one pair of
crimping indentors, and one pair to hold the insulation in place. The terminals cannot be crimped
with four symmetrical indentors, as material extrusion would cause too great of deformation.

One pair of indentors must be removed prior to gaging.

Vertical Indentors

Horizontal Indentors

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.

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. For 12-10 IT and smaller
die, in order to gage indentors, it is necessary to remove one pair, gage and repeat.

Assembly is simply reversing steps 1-3.

 Typical Insulated Terminal Die Specifications (Model 400)

Die P/N Notes Nominal Go No Go Nominal Go No Go

Vertical Horizontal
414DA-26-24IT 0.052 0.047 0.054 0.166 0.161 0.168
414DA-22-18IT 0.070 0.065 0.072 0.234 0.229 0.236
414DA-16-14IT 0.080 0.075 0.082 0.270 0.265 0.272
414DA-12-10IT 0.100 0.095 0.102 0.296 0.291 0.298
414DA-8IT 0.186 0.181 0.188 0.376 0.371 0.378
414DA-6IT 0.228 0.223 0.23 0.412 0.407 0.414
414DA-4IT 0.275 0.27 0.277 0.476 0.471 0.478
414DA-2IT Holly 0.350 0.345 0.352 0.371 0.366 0.373
414DA-2IT 0.350 0.345 0.352 0.560 0.555 0.562
414DA-1IT 0.384 0.379 0.386 0.662 0.657 0.664
414DA-0IT 0.386 0.381 0.388 0.438 0.433 0.44

400-24 (400 Series )

400-13 (400 Series ) 500-24 (500 Series )
500-13 (500 Series )
4 plcs 3100-250 (400 Series )
3100-375 (500 Series )

400-14 (400 Series )

500-14 (500 Series )

400-375 (400 Series )

500-625 (500 Series )
4 plcs

Typical Die components - Model 400 & 500

1. TOOL CALIBRATION
Nominal Tool Specification

Calibration of both Model 400 & 500 consists of measuring distance between parallel faces for
toggle drive arms.

Model Drive arm tolerance (in) Drive arm tolerance (cm)

400 1.885” to 2.003” 4.788 to 5.087
500 2.990” to 3.010” 7.594 to 7.645

Measure distance between Arms

Measure distance
between parallel
Arms

Calibrate the tool following the steps below to insure that the tool is within specification.
Calibration consists of measuring distance between faces of parallel drive arms faces. Make
measurement for both sets of parallel arms. Tool must be in full forward/closed position. This
requires that hand trigger, foot pedal or EC cycle button be pressed.

Cycling tool to crimp closed position:

Hand Trigger

• If operating with the hand trigger, holding the trigger down will cause the tool to actuate and
remain in the closed position. Keep trigger button pressed while gaging the die.
 Foot Pedal

• If operating with the foot pedal, holding the pedal down will cause the tool to actuate and
remain in the closed position. Keep foot pedal pressed while gaging the die.

EC Models

• If operating an EC equipped model, pressing the cycle button will cause tool to actuate and
remain in closed position. Keep button pressed while gaging the die.

Measuring distance between arms

• Remove the cover nut and die set.

• Cause the tool to be actuated and held in the closed position.

• Measure the distance between the face of two opposing/parallel arms.

Model 400 1.885” to 2.033”

Model 500 2.990” to 3.010”

Measurement outside the specified range indicates possible worn drive arms, anchor, yoke or
dowel pins. Dis-assembly of toggle unit will be required to determine exact cause of problem.

Press Trigger & Hold

Keep Trigger De-pressed

Open caliper and measure distance

from each parallel arm
 Keep Trigger De-pressed

Measuring end play in drive arms

If arm calibration meets specifications, it is also important to check up/down/side movement of

the drive arms.

Side to Side tolerance

• There should be no side movement of arm inside the retainer - see illustration.

• For up & down play, 0.000 to 0.015” is acceptable.

Tools out of specification

Toggle units can be repaired by user or sent to factory for refurbishment. Contact Pico or consult
the service manual, available at www.picotools.com
 .000-.015”
up/down
play

No side to side
play allowed

400-9(400 Series )
1/4”x 3/4” (400 Series ) 500-9 (500 Series ) 1/4”x1” (400 Series )
3/8”x 1-1/2” (500 Series ) 4 plcs 3/8”x1-1/2” (500 Series )
4 plcs 4 plcs

1/4”x1-1/2” (400 Series )

3/8”x 2” (500 Series )
400-7 (400 Series )
4 plcs
500-7 (500 Series )

10/32 x 5/16 Dog pt

10/32x3/16 Cup pt

400-10 (400 Series )

500-10 (500 Series )
4 plcs 400-11 (400 Series )
500-11 (500 Series )

Typical Toggle components - Model 400 & 500