2425 West Vineyard Avenue, Escondido, California 92029-1222 Phone: (800) 284-4460 Fax: (760) 746-4295

PORTABLE
CABLE TERMINAL

PULL TESTER
AT520CT

Operating and Maintenance Manual

(Revised July 2003)
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

AT520CT Portable Cable Terminal Pull Tester

Page 1 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

1 2 3 4 5
1 1 1 1 1
10
1
9
1

6 8
1 1
11
7
1
1
Figure 1 Cable Terminal Tester Assembly

1. Vise Screws 7. Vise

2. Terminal & Cable Assembly 8. Loading Head
3. Hook 9. Adjusting Screw
4. Tension Gauge 10. Handle
5. Tension Adjusting Screw 11. Cinch Block
6. Vise Jaws

To operate this unit effectively, please follow this simple procedure:

1. 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 counter-
clockwise as far as possible.

3. Select the proper pair of vise jaws6 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 vise7 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 head8 until they shoulder against the vise.

Page 2 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

10. 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.

11. If slippage occurs on larger size cables, the cinch block11 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 11, 3 page 11). Continue with steps 6 thru 9.

12. Turn the adjusting screw 9 until some deflection is noted in the gauge.

13. Turn the tension adjusting crew clockwise until the desired load is attained as indicated on the
tension gauge4.

After the cable and terminal assembly has been tested, remove as follows:

1. 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 screws1 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
MS21259 -3 -4 -5 -6 -7 -8 Threaded End Terminals Right Hand
MS21259 -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
MS21260 -3 -4 -5 -6 -7 -8 Turn Buckle Terminals Right Hand
MS21260 -3 -4 -5 -6 -7 -8 Turn Buckle Terminals Left Hand
RA2478 -3 -4 X X X X Single Ball Terminals

Page 3 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

AT520CTK Portable Cable Terminal Pull Tester Kit

The complete kit consists of:

AT520CT Cable Terminal Pull Tester

AT520CTA Handle
AT520CTB Carrying Case
AT520CTD-1 Block
AT520CTD-2 Pair of Jaws for 1/16 diameter cable
AT520CTD-3 Pair of Jaws for 3/32 diameter cable
AT520CTD-4 Pair of Jaws for 1/8 diameter cable
AT520CTD-5 Pair of Jaws for 5/32 diameter cable
AT520CTD-6 Pair of Jaws for 3/16 diameter cable
AT520CTD-7 Pair of Jaws for 7/32 diameter cable
AT520CTD-8 Pair of Jaws for 1/4 diameter cable

Page 4 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

Figure 3
AT520CTF -5 Adapter for 5/32 Terminals
AT520CTF -6 Adapter for 3/16 Terminals
AT520CTF -7 Adapter for 7/32 Terminals
AT520CTF -8 Adapter for 1/4 Terminals MS20667

Figure 6
AT520CTS-2 Adapter for 1/16 Terminals
AT520CTS-3 Adapter for 3/32 Terminals
AT520CTS-4 Adapter for 1/8 Terminals
AT520CTS-5 Adapter for 5/32 Terminals MS20663 & MS20664
AT520CTS-6 Adapter for 3/16 Terminals

Figure 5
AT520CTT-2 Adapter for 1/16 Terminals (R.H. Thread)
AT520CTT-3 Adapter for 3/32 Terminals (R.H. Thread)
AT520CTT-4 Adapter for 1/8 Terminals (R.H. Thread)
AT520CTT-4 Adapter for 5/32 Terminals (R.H. Thread)
AT520CTT-6 Adapter for 3/16 Terminals (R.H. Thread)
AT520CTT-7 Adapter for 7/32 Terminals (R.H. Thread)
AT520CTT-7 Adapter for 1/4 Terminals (R.H. Thread)
AT520CTT-20 Adapter for 1/16 Terminals (L.H. Thread) MS21259 & MS21260
AT520CTT-30 Adapter for 3/32 Terminals (L.H. Thread)
AT520CTT-40 Adapter for 1/8 Terminals (L.H. Thread)
AT520CTT-60 Adapter for 3/16 Terminals (L.H. Thread)
AT520CTT-70 Adapter for 4/32 Terminals (L.H. Thread)

Figures 2 and 4
AT520CTP-1 3/16 Diameter Pin
AT520CTP-2 1/4 Diameter Pin
AT520CTP-3 5/16 Diameter Pin
AT520CTP-4 3/8 Diameter Pin MS20667

MS20668

Calibration of Dial is for 60% of the Rated Strength of the Cable

Rated Strength 60% of Rated Strength

Cable Size (Pounds) (Pounds)
1/16 - - 7 X 7 480 288
3/32 - - 7 X 7 920 522
1/8 - - 7 X 19 2000 1200
5/32 - - 7 X 19 2800 1680
3/16 - - 7 X 19 4200 2520
7/32 - - 7 X 19 5600 3360
1/4 - - 7 X 19 7000 4200

Page 5 of 13
 AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

MAINTENANCE

How to fill the Pull Tester Oil System

1 6

11 7 1. Piston Assembly 7. Seal

3 2. Gauge Opening 8. Hook
2 3. Sleeve 9. Loading Head Housing
4. Tension Adjusting Screw 10. Adjusting Screw
10 5. Lens 11. Bushing
8 6. Gauge

Figure 7 Filling the Oil System

1. Turn the tension adjusting screw 4 and adjusting screw 10 counter-clockwise as far as possible.

2. Loosen the seal7 securing the gauge6 with end wrench through the slotted opening in the loading
head housing11 . Remove the gauge and seal 9 from the housing.

3. Unscrew the bushing11 securing the tension adjusting screw 4 and piston assembly1. Removing the
bushing, screw and piston assembly from the sleeve3.

4. Add hydraulic oil, Mobile Aero H.F.A, per MIL-H-5606 to the sleeve until hydraulic oil reaches the
opening for the gauge2.

5. Install the new seal7 on the gauge6 and install the gauge in the loading head housing9. 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 sleeve3 to 1/8 from the top.

7. Replace quad rings on the piston1 (Figure 11, 34 on page 11) and install piston assembly1,
bushings 11 and the tension adjusting screw 4. Be careful installing the piston assembly in the
sleeve3 to prevent damage to the quad rings. Secure the piston and tension adjusting screws by
tightening the bushing11 firmly into the housing9.

8. Bleed the pull tester in accordance with the instructions contained in the following section.

Page 6 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

How to Bleed the Pull Tester Oil System

1. 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 11, 20
on page 11).

5. Remove the bleeder plug3. 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 nut1 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 nut1 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.

1. Nut
2. Tube Assembly
3. Bleeder Plug
2 4. Screw Holes

4
3

Figure 8 Bleeding Air from the Oil System

(Loading Head Housing with Cover Removed)

Page 7 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

How to Calibrate the Pull Tester Oil System

8
7 9
5

2 3 4 6
1
10

11

15 14 13 12

1. Washer 9. Gauge
2. Vise Screws 10. Tension Adjusting Screw
3. Vise Adapter 11. Adjusting Screw
4. Pin 12. Hook
5. Force Gauge 13. Pin
6. Pin 14. Hook Adapter
7. Cinch Block 15. Screw
8. Loading Head

Figure 9 Calibrating the Pull Tester

1. Remove the lens from gauge9 by rotating the lens counter-clockwise.

2. Turn the cinch block7 to the position shown here in Figure 9 and lock with the set screws (Figure 11,
3 on page 11).

3. Turn the tension adjusting screw 10 counter-clockwise until it engages the internal stop.

4. Place the hook adapter14 in position on the hook1 2. Secure with the pin13.

5. Turn the vise screws2 counter-clockwise and place the vise adapter3 with the washer1 and screw 15
in position in the vise block. Turn the vise screws 2 clockwise until the vise screw pads barely touch
the vise adapter3. Do not over tighten the vise screws.

6. Turn the adjusting screw 11 counter-clockwise until it engages the internal stop. Push the adjusting
screw toward the loading head8 to the bottom piston.

Page 8 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

7. Install the force gauge 5 as shown in Figure 9. Secure the force gauge to the vise adapter3 with the
pin4 and to the hook adapter14 with the pin6.

8. Remove any slack in the linkage by turning the screw 15 clockwise. Force gauge5 must read Zero.
Do not adjust pressure with the screw 15.

9. The force gauge5, 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 1. Record each
setting.

10. Turn the adjusting screw 11 clockwise until the reading on the force gauge5 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 gauge9 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.

11. Proceed to set the remaining gauge markers in the gauge 9 by turning the tension adjusting screw 10
clockwise to obtain the applicable readings on the force gauge5 as recorded in step 9. Set the
gauge markers accordingly.

12. After all of the markers have been set, turn the tension adjusting screw 10 and adjusting screw 11
counter-clockwise until it is against the internal stop. The force gauge must read Zero.

13. Install the lens onto the gauge.

14. Holding the force gauge carefully remove the pins. Now remove the force gauge.

15. Remove the pin securing the hook adapter to the hook and remove the hook adapter.

16. Turn the vise screws counter-clockwise and remove the vise adapter, washer and screw.

17. The pull tester is now ready for operation.

Page 9 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

Table 1
Gauge Settings

Pull Tester Gauge Reading (Pounds)

Cable Size (Inches) (60% of rated strength of the cable)
1/16 288
3/32 552
1/8 1200
5/32 1680
3/16 2520
7/32 3360
1/4 4200

Figure 10 AT520CGC Pull Tester Calibration Kit

Page 10 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

Figure 11 AT520CT - Portable Cable Terminal Pull Tester Exploded View

Page 11 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

Parts List
(Index numbers refer to Figure 11)

Index # Part # Part Name # Required

1 AT520CTA Handle Assembly 1
2 AT259RG-8 Screw 4
3 AT520CT-41 Screw 2
4 AT520CT-40 Bushing 2
5 AT520CT-39 Cinch Block 1
6 AT520CT-9 Rod 2
7 AT520CT-14 Screw 2
8 AT520CT-1 Pad 2
9 AT520CT-35 Screw 3
10 AT520CT-10 Insert 1
11 AT520CT-34 Screw 4
12 AT520CT-33 Plate 2
13 AT493HA-3 Screw 4
14 AT520CT-29 Pad 1
15 AT520CT-22 Cover 1
16 AT520CT-8 Vise Block 1
17 AT336CW-2 Drive Pins 4
18 AT520CT-7 Nameplate 1
19 AT493HA-3 Screw 4
20 AT520CT-30 Pad 1
21 AT520CT-25 Cover 1
22 AT520CT-32 Tube 1
23 AT226B -35 Elbow 1
24 AT520CT-37 Seal 1
25 AT226B -38 Fitting 1
26 AT520CT-28 Bleeder 1
AT520CTG Gauge Assembly 1
27 AT520CTG -3 Lens 1
28 1/16 PIN STRIPE TAPE Gauge Marker Tape 7
29 AT520CTG -2A Dial Contact Cover 1
30 AT520CTG -1 Gauge 1
31 AT520CT-36 Seal 1
32 AT520CT-3 Tension Adjusting Screw 1
33 AT520CT-5 Bushing 1
34 AT520CT-16 Quad Ring 2
35 AT520CT-38 Ring 1
36 AT520CT-13 Piston 1
37 AT520CT-4 Sleeve 1
38 AT520CT-19 Bolt 1
39 AT520CT-6 Adjusting Screw 1
40 AT451KA-13 Dowel 1
41 AT520CT-15 Hook and Screw 1
42 AT520CT-20 Quad Ring 1
43 AT493HA-3 Screw 4
44 AT520CT-31 Cylinder Cap 1
45 AT520CT-18 Oil Seal 1
46 AT520CT-21 Washer 1
47 AT520CT-2 Piston 1
48 AT520CT-17 Quad Ring 2
49 AT520CT-16 Quad Ring 2
50 AT520TC Cylinder Assembly 1
51 AT520CT-1 Loading Head Housing 1

Page 12 of 13
AT520CT Portable Cable Terminal Pull Tester Operating and Maintenance Manual

Parts List
(Index numbers refer to Figure 10)

Index # Part # Part Name # Required

1 AT520CGC-4 Pin 2
2 AT520CGC-8 Hook Adapter 1
3 AT520CGC-5 Pin 1
4 AT520CGC-1 Screw 1
5 AT520CGC-2 Washer 1
6 AT520CGC-3 Vise Adaptor 1
7 AT520CGC-6 Force Gauge 1
8 Calibration Reference Sheet AR

Page 13 of 13