2425 West Vineyard Avenue, Escondido, California 92029-222 Phone: (800) 284-4460 Fax: (760) 746-4295 PORTABLE CABLE TERMINAL PULL TESTER AT520CT (Revised July 2003)
AT520CT Portable Cable Terminal Pull Tester Page of 3
2 3 4 5 0 9 6 7 8 Figure Cable Terminal Tester Assembly. Vise Screws 7. Vise 2. Terminal & Cable Assembly 8. Loading Head 3. Hook 9. Adjusting Screw 4. Tension Gauge 0. Handle 5. Tension Adjusting Screw. Cinch Block 6. Vise Jaws To operate this unit effectively, please follow this simple procedure:. Determine the size and type of cable and terminal to be tested. 2. Prepare the tester by turning the tension adjusting screw, vise screws and adjusting screw 9 counterclockwise as far as possible. 3. Select the proper pair of vise jaws 6 and terminal adapter. (See Figures 2 thru 6 on page 5 for types and sizes of adapters). 4. Insert terminal adapter into hook 3 as shown in on page 5, Figures 2 thru 6. If a threaded type terminal is to be tested, screw the terminal into the adapter before inserting into the adapter hook. 5. Insert either of the two vise jaws into the vise 7 opening with the flange to the left and the copper insert facing up. 6. Slip the cable through the opening in the vice and lay it into the groove in the lower vise jaw. 7. Place the upper jaw over the cable and the lower jaw. 8. Pull the cable through the vise jaw, remove the slack and center the cable in the groove of the vise jaws. 9. Push the jaws toward the loading head 8 until they shoulder against the vise. Page 2 of 3
0. Turn the vise screws clockwise to tighten the vise jaws on the cable. ----- CAUTION ----- The vise jaws must be tightened down securely to eliminate the possibility of the cable slippage during testing. Do not torque vise screws over 40 ft. lbs. MAX. If cable slippage occurs, use cinch block or replace the vise jaws.. If slippage occurs on larger size cables, the cinch block may be used. Loosen the cinch block and slide it toward the center of the tester. Wrap the cable around the cinch block once, before performing step 6. Allow the cinch block to align itself by pulling the cable tight before tightening the setscrews (see Figure, 3 page ). Continue with steps 6 thru 9. 2. Turn the adjusting screw 9 until some deflection is noted in the gauge. 3. Turn the tension adjusting crew clockwise until the desired load is attained as indicated on the tension gauge 4. After the cable and terminal assembly has been tested, remove as follows:. Turn the tension adjusting screw 5 counter-clockwise until it contacts the internal stop. 2. Turn the adjusting screw 9 counter-clockwise until it contacts the internal stop. 3. Turn the vise screws counter-clockwise to release clamp pressure. 4. Remove the terminal adapter from the hook. 5. Pull the cable and vise jaws out of the vise and remove the vise jaws from the cable. The tester is then ready to start another testing operation. Capacity MS20663-3 -4-5 -6 X X Double Shank Ball End Terminals MS20664-3 -4-5 -6-7 -8 Single Shank Ball End Terminals MS2259-3 -4-5 -6-7 -8 Threaded End Terminals Right Hand MS2259-3 -4-5 -6-7 -8 Threaded End Terminals Left Hand MS20667-3 -4-5 -6-7 -8 Fork End Terminals MS20668-3 -4-5 -6-7 -8 Eye End Terminals MS2260-3 -4-5 -6-7 -8 Turn Buckle Terminals Right Hand MS2260-3 -4-5 -6-7 -8 Turn Buckle Terminals Left Hand RA2478-3 -4 X X X X Single Ball Terminals Page 3 of 3
The complete kit consists of: AT520CTK Portable Cable Terminal Pull Tester Kit AT520CT AT520CTA AT520CTB AT520CTD- AT520CTD-2 AT520CTD-3 AT520CTD-4 AT520CTD-5 AT520CTD-6 AT520CTD-7 AT520CTD-8 Cable Terminal Pull Tester Handle Carrying Case Block Pair of Jaws for /6 diameter cable Pair of Jaws for 3/32 diameter cable Pair of Jaws for /8 diameter cable Pair of Jaws for 5/32 diameter cable Pair of Jaws for 3/6 diameter cable Pair of Jaws for 7/32 diameter cable Pair of Jaws for /4 diameter cable Page 4 of 3
Figure 3 AT520CTF -5 Adapter for 5/32 Terminals AT520CTF -6 Adapter for 3/6 Terminals AT520CTF -7 Adapter for 7/32 Terminals AT520CTF -8 Adapter for /4 Terminals MS20667 AT520CTS-2 AT520CTS-3 AT520CTS-4 AT520CTS-5 AT520CTS-6 Adapter for /6 Terminals Adapter for 3/32 Terminals Adapter for /8 Terminals Adapter for 5/32 Terminals Adapter for 3/6 Terminals Figure 6 MS20663 & MS20664 AT520CTT-2 AT520CTT-3 AT520CTT-4 AT520CTT-4 AT520CTT-6 AT520CTT-7 AT520CTT-7 AT520CTT-20 AT520CTT-30 AT520CTT-40 AT520CTT-60 AT520CTT-70 Figure 5 Adapter for /6 Terminals (R.H. Thread) Adapter for 3/32 Terminals (R.H. Thread) Adapter for /8 Terminals (R.H. Thread) Adapter for 5/32 Terminals (R.H. Thread) Adapter for 3/6 Terminals (R.H. Thread) Adapter for 7/32 Terminals (R.H. Thread) Adapter for /4 Terminals (R.H. Thread) Adapter for /6 Terminals (L.H. Thread) Adapter for 3/32 Terminals (L.H. Thread) Adapter for /8 Terminals (L.H. Thread) Adapter for 3/6 Terminals (L.H. Thread) Adapter for 4/32 Terminals (L.H. Thread) MS2259 & MS2260 AT520CTP- AT520CTP-2 AT520CTP-3 AT520CTP-4 3/6 Diameter Pin /4 Diameter Pin 5/6 Diameter Pin 3/8 Diameter Pin Figures 2 and 4 MS20667 MS20668 Calibration of Dial is for 60% of the Rated Strength of the Cable Cable Size Rated Strength (Pounds) 60% of Rated Strength (Pounds) /6 - - 7 X 7 480 288 3/32 - - 7 X 7 920 522 /8 - - 7 X 9 2000 200 5/32 - - 7 X 9 2800 680 3/6 - - 7 X 9 4200 2520 7/32 - - 7 X 9 5600 3360 /4 - - 7 X 9 7000 4200 Page 5 of 3
MAINTENANCE How to fill the Pull Tester Oil System 5 4 6 8 2 3 0 7. Piston Assembly 7. Seal 2. Gauge Opening 8. Hook 3. Sleeve 9. Loading Head Housing 4. Tension Adjusting Screw 0. Adjusting Screw 5. Lens. Bushing 6. Gauge 9 Figure 7 Filling the Oil System. Turn the tension adjusting screw 4 and adjusting screw 0 counter-clockwise as far as possible. 2. Loosen the seal 7 securing the gauge 6 with end wrench through the slotted opening in the loading head housing. Remove the gauge and seal 9 from the housing. 3. Unscrew the bushing securing the tension adjusting screw 4 and piston assembly. Removing the bushing, screw and piston assembly from the sleeve 3. 4. Add hydraulic oil, Mobile Aero H.F.A, per MIL-H-5606 to the sleeve until hydraulic oil reaches the opening for the gauge 2. 5. Install the new seal 7 on the gauge 6 and install the gauge in the loading head housing 9. DO NOT use a wrench to tighten the gauge, tighten the gauge by hand. Hold the gauge in alignment and use a wrench to tighten the seal securely. 6. Fill the oil level in the sleeve 3 to /8 from the top. 7. Replace quad rings on the piston (Figure, 34 on page ) and install piston assembly, bushings and the tension adjusting screw 4. Be careful installing the piston assembly in the sleeve 3 to prevent damage to the quad rings. Secure the piston and tension adjusting screws by tightening the bushing firmly into the housing 9. 8. Bleed the pull tester in accordance with the instructions contained in the following section. Page 6 of 3
How to Bleed the Pull Tester Oil System. If air is suspected to be in the system, fill the system with hydraulic oil. (See How to Fill the Pull Tester Oil System.) 2. Install a small cable and terminal for testing. (Refer to the instructions on pages 2 and 3.) DO NOT apply pressure to test the cable. 3. Turn the entire unit upside down on the edge of a padded workbench, with the tension adjusting screw (Figure 7, 4 on page 6) of the tester overhanging the edge of the workbench. Tester will remain approximately level. 4. Remove the four screws 4 securing the cover. Remove the cover and attached pad (Figure, 20 on page ). 5. Remove the bleeder plug 3. Turn the tension adjusting screw (Figure 7, 4 on page 6) clockwise until hydraulic oil reaches the opening of the bleeder. Install the bleeder plug and tighten securely. 6. Loosen the nut securing tube 2 to elbow. Turn the tension adjusting screw (Figure 7, 4 on page 6) clockwise until hydraulic oil emerges from the tube assembly around the nut. Discontinue turning the tension adjust screw and tighten the nut on the tube assembly. 7. Remove the test cable and terminal, installed in step 2 above. Recalibrate the pull tester in accordance with instructions contained in the following section. 2. Nut 2. Tube Assembly 3. Bleeder Plug 4. Screw Holes 4 3 Figure 8 Bleeding Air from the Oil System (Loading Head Housing with Cover Removed) Page 7 of 3
How to Calibrate the Pull Tester Oil System 5 7 8 9 2 3 4 6 0 5 4 3 2. Washer 9. Gauge 2. Vise Screws 0. Tension Adjusting Screw 3. Vise Adapter. Adjusting Screw 4. Pin 2. Hook 5. Force Gauge 3. Pin 6. Pin 4. Hook Adapter 7. Cinch Block 5. Screw 8. Loading Head Figure 9 Calibrating the Pull Tester. Remove the lens from gauge 9 by rotating the lens counter-clockwise. 2. Turn the cinch block 7 to the position shown here in Figure 9 and lock with the set screws (Figure, 3 on page ). 3. Turn the tension adjusting screw 0 counter-clockwise until it engages the internal stop. 4. Place the hook adapter 4 in position on the hook 2. Secure with the pin 3. 5. Turn the vise screws 2 counter-clockwise and place the vise adapter 3 with the washer and screw 5 in position in the vise block. Turn the vise screws 2 clockwise until the vise screw pads barely touch the vise adapter 3. Do not over tighten the vise screws. 6. Turn the adjusting screw counter-clockwise until it engages the internal stop. Push the adjusting screw toward the loading head 8 to the bottom piston. Page 8 of 3
7. Install the force gauge 5 as shown in Figure 9. Secure the force gauge to the vise adapter 3 with the pin 4 and to the hook adapter 4 with the pin 6. 8. Remove any slack in the linkage by turning the screw 5 clockwise. Force gauge 5 must read Zero. Do not adjust pressure with the screw 5. 9. The force gauge 5, used in calibrating the pull tester, should be recalibrated in a certified laboratory testing machine once a year. Consult the current calibration reference sheet for the force gauge reading (in degrees) applicable to the pull tester gauge settings shown in Table. Record each setting. 0. Turn the adjusting screw clockwise until the reading on the force gauge 5 is equal of the degrees indicated by the calibration reference sheet, supplied with the calibration kit, as being applicable for 288 pounds of pull. The pointer on the pull tester gauge 9 shall point to gauge marker at 288 pounds. If the gauge marker is out of position, removed the marker and replace it in line with the pointer gauge.. Proceed to set the remaining gauge markers in the gauge 9 by turning the tension adjusting screw 0 clockwise to obtain the applicable readings on the force gauge 5 as recorded in step 9. Set the gauge markers accordingly. 2. After all of the markers have been set, turn the tension adjusting screw 0 and adjusting screw counter-clockwise until it is against the internal stop. The force gauge must read Zero. 3. Install the lens onto the gauge. 4. Holding the force gauge carefully remove the pins. Now remove the force gauge. 5. Remove the pin securing the hook adapter to the hook and remove the hook adapter. 6. Turn the vise screws counter-clockwise and remove the vise adapter, washer and screw. 7. The pull tester is now ready for operation. Page 9 of 3
Table Gauge Settings Pull Tester Gauge Reading (Pounds) Cable Size (Inches) (60% of rated strength of the cable) /6 288 3/32 552 /8 200 5/32 680 3/6 2520 7/32 3360 /4 4200 Figure 0 AT520CGC Pull Tester Calibration Kit Page 0 of 3
Figure AT520CT - Portable Cable Terminal Pull Tester Exploded View Page of 3
Parts List (Index numbers refer to Figure ) Index # Part # Part Name # Required AT520CTA Handle Assembly 2 AT259RG-8 Screw 4 3 AT520CT-4 Screw 2 4 AT520CT-40 Bushing 2 5 AT520CT-39 Cinch Block 6 AT520CT-9 Rod 2 7 AT520CT-4 Screw 2 8 AT520CT- Pad 2 9 AT520CT-35 Screw 3 0 AT520CT-0 Insert AT520CT-34 Screw 4 2 AT520CT-33 Plate 2 3 AT493HA-3 Screw 4 4 AT520CT-29 Pad 5 AT520CT-22 Cover 6 AT520CT-8 Vise Block 7 AT336CW-2 Drive Pins 4 8 AT520CT-7 Nameplate 9 AT493HA-3 Screw 4 20 AT520CT-30 Pad 2 AT520CT-25 Cover 22 AT520CT-32 Tube 23 AT226B -35 Elbow 24 AT520CT-37 Seal 25 AT226B -38 Fitting 26 AT520CT-28 Bleeder AT520CTG Gauge Assembly 27 AT520CTG -3 Lens 28 /6 PIN STRIPE TAPE Gauge Marker Tape 7 29 AT520CTG -2A Dial Contact Cover 30 AT520CTG - Gauge 3 AT520CT-36 Seal 32 AT520CT-3 Tension Adjusting Screw 33 AT520CT-5 Bushing 34 AT520CT-6 Quad Ring 2 35 AT520CT-38 Ring 36 AT520CT-3 Piston 37 AT520CT-4 Sleeve 38 AT520CT-9 Bolt 39 AT520CT-6 Adjusting Screw 40 AT45KA-3 Dowel 4 AT520CT-5 Hook and Screw 42 AT520CT-20 Quad Ring 43 AT493HA-3 Screw 4 44 AT520CT-3 Cylinder Cap 45 AT520CT-8 Oil Seal 46 AT520CT-2 Washer 47 AT520CT-2 Piston 48 AT520CT-7 Quad Ring 2 49 AT520CT-6 Quad Ring 2 50 AT520TC Cylinder Assembly 5 AT520CT- Loading Head Housing Page 2 of 3
Parts List (Index numbers refer to Figure 0) Index # Part # Part Name # Required AT520CGC-4 Pin 2 2 AT520CGC-8 Hook Adapter 3 AT520CGC-5 Pin 4 AT520CGC- Screw 5 AT520CGC-2 Washer 6 AT520CGC-3 Vise Adaptor 7 AT520CGC-6 Force Gauge 8 Calibration Reference Sheet AR Page 3 of 3