Customer Manual
Pneumatic Tools 68068 and 68068-1
409-2426
09 JAN 09 Rev A
SAFETY PRECAUTIONS
1. INTRODUCTION
READ THIS FIRST !
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2.
Air Line Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.
Air Pressure Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4.
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. DESCRIPTION
2.1.
Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. INSTALLING AND REMOVING JAW ASSEMBLY
3.1.
Installing Jaw Assembly
3.2.
Removing Jaw Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. OPERATING PROCEDURE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1.
Daily Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2.
Visual Inspection (Perform Monthly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. TROUBLESHOOTING
7. PARTS LIST
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8. REPLACEMENT AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.1.
Cam Replacement
8.2.
Piston and Piston Rod O" Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.3.
Air Valve Spool O" Ring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.4.
Air Valve Spool Adjustment
9. REVISION SUMMARY
E
2009 Tyco Electronics Corporation, Harrisburg, PA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TOOLING ASSISTANCE CENTER 1-800-722-1111
This controlled document is subject to change.
All International Rights Reserved
For latest revision and Regional Customer Service,
TE logo and Tyco Electronics are trademarks.
visit our website at www.tycoelectronics.com
*Trademark. Other products, logos, and company names used are the property of their respective owners.
1 of 17
LOC B
409-2426
Pneumatic Tools 68068 and 68068-1
DANGER
SAFETY PRECAUTIONS AVOID INJURY
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:
D ALWAYS wear appropriate ear protection.
D ALWAYS wear approved eye protection when operating powered equipment.
D ALWAYS keep guard(s) in place during normal operation.
D ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.
D ALWAYS turn off the main power switch and disconnect electrical cord from the power source when
performing maintenance on the equipment.
D NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.
D NEVER insert hands into installed application equipment.
D NEVER alter, modify, or misuse the application equipment.
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Tooling Assistance Center offers a means of providing technical assistance when required.
In addition, Field Service Engineers 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 TOOLING ASSISTANCE CENTER
When calling the Tooling Assistance 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 Tooling Assistance Center, be ready with the following information:
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
2 of 17
Customer name
Customer address
Person to contact (name, title, telephone number, and extension)
Person calling
Equipment number (and serial number if applicable)
Product part number (and serial number if applicable)
Urgency of request
Nature of problem
Description of inoperative component(s)
Additional information/comments that may be helpful
Tyco Electronics Corporation
Rev A
409-2426
Pneumatic Tools 68068 and 68068-1
Tool 68068
Tool 68068-1
Top Handle
Position
Jaw Assembly
(Not Included)
Side Handle
Position
Jaw Assembly
(Not Included)
Figure 1
1. INTRODUCTION
Pneumatic Tools 68068 and 68068–1 (shown in Figure 1) are light weight portable hand tools that accept an
interchangeable jaw assembly. The jaw assembly provides the tool with a versatility for crimping a wide variety
of types and sizes of terminals or splices. Tool 68068 has a top handle position, and Tool 68068–1 has a side
handle position.
When reading this manual, pay particular attention to DANGER, CAUTION, NOTE statements.
DANGER
Denotes an imminent hazard which may result in moderate or severe injury.
CAUTION
Denotes a condition which may result in product or equipment damage.
!
NOTE
Highlights special or important information.
i
Reasons for reissue of this customer manual are provided in Section 9, REVISION SUMMARY.
NOTE
All numerical values in this instruction sheet are in metric units [with U.S. customary units in brackets]. Dimensions are
in millimeters [and inches]. Figures are not drawn to scale.
i
1.1. Specifications
Specifications for the pneumatic tools are given in Figure 2.
Specifications
Air Pressure Range . . . . . .
552-689 kPa [80-100 psi]
Air Displacement . . . . . . . .
40 cu in. (Approx)
Weight . . . . . . . . . . . . . . .
5 K [11 lb] (Approx) (Including Jaw Assembly)
Figure 2 (Cont’d)
Rev
A
Tyco Electronics Corporation
3 of 17
409-2426
Pneumatic Tools 68068 and 68068-1
Tool 68068
Handle and
Control Button
Air Hose
Jaw Assembly
Tool 68068-1
Handle and
Control Button
184.1
[7.25]
266.7 [10.5]
101.6 [4.0]
305 [12] Approx
Figure 2 (End)
1.2. Air Line Requirements
Use clean, dry, oil treated air, regulated between 552 kPa [80 psi] and 689 kPa [100 psi]. It is important that the
air pressure is maintained constantly within the required air pressure range. Pressure lower than stated will be
insufficient for the crimping operation. Pressure higher than stated may cause damage to the tool.
A filter and moisture separator, regulator, and lubricator (customer supplied) must be used with this tool to
ensure dependable performance and long life. It is strongly recommended that the units be installed at each
tool in the order shown in Figure 3. Mount the units as close as possible to the tool, preferably where the tool
hose is connected to the air system. Make sure that the units are checked regularly on an assigned schedule.
Suggested manufacturers and benefits realized by the use of this equipment is given in Figure 3.
1.3. Air Pressure Check List
Check the air pressure at the tool while the tool is operating.
A. If the Air Pressure is Below 552 kPa [80 psi]
1. Check the air compressor and air line pressure regulator for sufficient capacity, proper settings, and
mechanical condition.
2. Check for clogged or kinked air lines or hoses.
3. Check the air lines, hoses, and fittings or couplings for correct size (may be too small).
B. If the Air Pressure is Above 669 kPa [100 psi]
Check the air compressor and air line pressure regulator for proper settings and mechanical condition.
1.4. Safety Precautions
To avoid personal injury or damage to the tool, carefully observe the following safety precautions before and
during operation of the tool.
— ALWAYS disconnect the air supply before changing the jaw assembly or performing any maintenance
on the tool
— ALWAYS keep fingers clear of the jaws when operating the tool
— ALWAYS ensure that the correct type and size terminal or splice is used in the jaw assembly
— ALWAYS ensure that the pivot pins are fully inserted into the jaws
— NEVER operate the tool without the jaw assembly installed; otherwise, damage to the tool could occur
— NEVER allow air pressure to exceed 689 kPa [100 psi]
4 of 17
Tyco Electronics Corporation
Rev A
409-2426
Pneumatic Tools 68068 and 68068-1
Filter and
Lubricator
Moisture Separator
Airflow
To Tool
Regulator
DRAIN REGULARLY
CHECK AIR PRESSURE REGULARLY
CHECK OIL LEVEL REGULARLY
(552 kPa [80 psi] Min-689 kPa [100 psi] Max)
(Adjust to Very Fine Mist
Approximately 1 Drop per 15-20 Cycles)
D
Minimizes clogging and excessive
wear
D
Minimizes rust and corrosion
D
Prevents water from washing away
D
D
Promotes smooth, consistent performance
D
Protects hoses and components from
damage
D
Eliminates sluggish or sticking valves and
pistons
D
Provides protective film for highly
polished or close tolerance surfaces
lubricants
D
Provides seal in close tolerance areas
Prevents water emission from
D
Extends life of pistons, cylinders, and
exhaust ports
valves
SUGGESTED MANUFACTURERS
Lubricator Oil
Filter and Moisture Separator, Regulator, Lubricator
(Only Use Good Quality, Non-Synthetic Air Lubricant)
C.A. Norgen Co., Littleton, CO
(C.P. Airoilene SAE 10)
Chicago Pneumatic Tool Co., New York, NY
Chicago Pneumatic Tool Co., New York, NY
Airoilene is a trademark of Chicago Pneumatic Tool Co.
Figure 3
2. DESCRIPTION
2.1. Physical Description
The tool consists of a housing, handle, and air hose that connects to an air supply. The housing contains the
cylinder, piston, and cam. The front of the housing accepts an interchangeable jaw assembly that is secured to
the housing by two pivot pins. The back of the housing features an identification plate. The handle has a
control button that actuates the tool. Refer to Figure 4.
2.2. Functional Description
DANGER
To avoid personal injury, ALWAYS DISCONNECT the tool from the air supply when changing the jaw assembly.
Always keep fingers clear of jaws during the crimping operation.
When the tool is connected to the air supply, air pressure on the return side of the cylinder maintains the piston
and cam in a neutral position and allows the spring–loaded jaws to remain open. Refer to Figure 4, Detail A.
The operator can now position the wire–loaded terminal or splice in the jaws.
When the control button is depressed, full air line pressure is directed into the power side of the cylinder,
closing the jaws to the crimp position. Refer to Figure 4, Detail B.
Releasing the control button allows full air line pressure to enter the return side of the cylinder, returning the
piston and cam to neutral position. The spring–loaded jaws will open and the tool is ready for the next crimping
operation.
Rev A
Tyco Electronics Corporation
5 of 17
409-2426
Pneumatic Tools 68068 and 68068-1
Physical and Functional Description
ÒÒÒÒ
ÒÒÒÒ
ÛÛÛÛ
ÛÛÛÛ
Control Button
Air Pressure
Air Hose
Air Exhaust
ÒÒÒÒ
ÛÛ
ÒÒÒÒ
ÛÛ
ÒÒÒÒ
ÛÛ
ÒÒÒÒ
ÛÛ
ÒÒÒÒ
ÛÛ
Terminal or
Splice
Detail A
Jaws Open
Return Side
Piston
Cam in Neutral Position
ÛÛÒÒÒ
ÛÛÒÒÒ
ÛÛ
ÛÛÒÒÒ
ÛÛÒÒÒ
ÛÛÒÒÒ
Detail B
Jaws in Crimp
Position (Closed)
Cam Advanced
Power Side
Figure 4
3. INSTALLING AND REMOVING JAW ASSEMBLY
3.1. Installing Jaw Assembly
1. DISCONNECT the tool from the air supply.
DANGER
To prevent personal injury, ALWAYS DISCONNECT the tool from the air supply when installing the jaw assembly.
2. Refer to Figure 5, and select the applicable jaw assembly for the terminal or splice and wire size
being crimped. For detailed information about the jaw assembly, refer to the instruction sheet listed.
NOTE
The jaw assembly is coated with a preservative to prevent rust and corrosion. Wipe the preservative from the jaws,
particularly from the crimping area.
i
6 of 17
Tyco Electronics Corporation
Rev
A
409-2426
Pneumatic Tools 68068 and 68068-1
WIRE RANGE
TERMINAL OR SPLICE
SIZE
CMA
(AWG)
12-10
JAW ASSEMBLY
PART
INSTRUCTION
NUMBER
SHEET
5,180-13,100
68101 0
68101-0
COMPALUM* Insulation Piercing
g
Terminal and Splice
COMPALUM Bar Crimp Terminal and Splice
8
13,100-20,800
8
13,100-20,800
68192-1
6
20,800-33,100
68102-0
6
20,800-33,100
68106-0
8
13,100-20,800
68135-0
6
20,800-33,100
68136-0
6
20,800-33,100
68233-1
4
33,100-52,600
68254-1
12-6
19,500-42,700
68268-1
408 23930
408-23930
SOLISTRAND* Terminal and Splice
408 2395
408-2395
PLASTI GRIP* Terminal
PLASTI-GRIP*
Pre-Insulated Vinyl (ECV) Closed End Splice
408-2394
408 2532
408-2532
408-2564
Figure 5
3. Inspect the jaw closure surfaces, jaw bottoming surfaces, and jaw cam rollers for deposits of dirt or
other foreign particles. If necessary, wipe clean with a clean cloth. Re–lubricate the jaw cam rollers
according to Paragraph 5.3. Make sure the jaw cam rollers are not binding.
4. Pull one cowling pin and remove the retaining pin from the lower housing cover. The cover will swing
open. See Figure 6.
5. Remove the pivot pins.
6. Orient the jaws as described in the instruction sheet packaged with the jaw assembly (refer to Figure
5). Position the jaws in the tool housing ensuring that the jaw cam rollers are properly mated with the
tool cam and the pivot pin holes of the jaws and the tool housing are aligned. See Figure 6.
7. Insert the pivot pins.
CAUTION
To avoid damage to the tool or pivot pins, make sure that the pivot pins are fully inserted.
!
8. Pivot the lower housing cover into the closed position, and re–install the retaining pin and cowling pin.
3.2. Removing Jaw Assembly
1. DISCONNECT the tool from the air supply.
DANGER
To prevent personal injury, ALWAYS DISCONNECT the tool from the air supply when removing the jaw assembly.
2. Pull one cowling pin and remove the retaining pin from the lower housing cover. The cover will swing
open.
3. Remove the pivot pins, then remove the jaws.
Rev A
Tyco Electronics Corporation
7 of 17
409-2426
Pneumatic Tools 68068 and 68068-1
Installing Jaw Assembly
Tool 68068 Shown
Pivot Pin
Holes
Cam
Pivot Pins
Jaw Assembly
(Ref)
Lower Housing Cover
Locator (Ref)
Cowling
Jaw Cam Rollers
Pin
Retaining
Pin
Figure 6
4. OPERATING PROCEDURE
Make sure to follow safety precautions (refer to Paragraph 1.4) before and during operation of the tool. Refer to
the instructions included with the jaw assembly for specific wire preparation and crimp inspection requirements.
DANGER
To avoid personal injury, ALWAYS keep fingers clear of the jaw closure during crimping cycles.
1. Connect the tool to the air supply according to Paragraph 1.2, and check the air pressure according to
Paragraph 1.3.
2. Insert the wire into the wire barrel of the terminal or splice.
3. Place the terminal or splice in the lower jaw (refer to the instructions included with the jaw assembly
for specific location in the jaw).
4. FULLY depress the tool control button (the jaws will close).
5. Release the tool control button to open the jaws, then remove the crimped terminal or splice.
8 of 17
Tyco Electronics Corporation
Rev
A
409-2426
Pneumatic Tools 68068 and 68068-1
5. PREVENTIVE MAINTENANCE
It is important that a preventive maintenance program be performed at regular intervals to ensure efficient
dependable performance of the tool.
DANGER
To avoid personal injury or damage to the tool, ALWAYS DISCONNECT the tool from the air supply before performing
any preventive maintenance on the tool.
5.1. Daily Cleaning
1. Clean the jaw closure surfaces. DO NOT allow deposits of dirt or other foreign matter to build up on
the bottoming surfaces of the jaws.
2. Wipe clean the surfaces of the jaw cam, jaw cam rollers, and housing of the tool with a solvent and a
clean cloth. Re–lubricate the tool and jaws as instructed in Paragraph 5.3.
5.2. Visual Inspection (Perform Monthly)
1. Inspect the jaw housing for worn or bent pins or worn bushings.
2. Inspect the cam for lubrication, excessive wear, or damage. If necessary, replace the cam.
3. Check the jaw return plunger for binding.
4. Make sure that all screws are tight.
5. Cycle the tool to ensure that the jaws function satisfactorily.
6. With the air supply connected, inspect the air fitting, exhaust ports, and the area around the piston
rod for air leaks. If necessary, replace the main piston or piston rod “O” ring.
7. Inspect the jaw housing for metal particles. The presence of metal particles indicates that the jaws
should be lubricated or parts are misaligned or worn.
8. Check the jaw cam rollers for binding and proper lubrication.
5.3. Lubrication
Refer to Figure 7 for areas of the tool that should be lubricated and the type of lubricant to use.
NOTE
Apply lubricant sparingly; thereby avoiding build-up of lubricant and dirt and possible tool malfunction.
i
The air system of the tool must receive lubrication via an air line lubricator. Refer to Paragraph 1.2.
Frequency of lubrication should be as follows:
Tools used daily — lubricate daily
Tools used occasional — lubricate weekly
Tools used weekly — lubricate monthly
Rev A
Tyco Electronics Corporation
9
of 17
409-2426
Pneumatic Tools 68068 and 68068-1
Visual Inspection and Lubrication
Chicago Mfg and Distributing
SAE 20 Non-Detergent
Anti-Scouring Extreme
Motor Oil
Pressure Lubricant No. 3
Inspect Jaw Housing
for Metal Particles
Check Pivot Pin Holes for Wear
Check for Worn or Bent
Pins or Worn Bushings
Check Jaw Return Plunger
for Binding
Check Jaw Cam Rollers for
Inspect Exhaust Port
Lubrication and Binding Ċ
for Air Leak
Lubricate Dowel Pins
Inspect Air Fitting
for Air Leaks
Inspect Exhaust Port
for Air Leak
Inspect Cam for
Inspect Area Around
Lubrication, Wear
Piston Rod for Air Leaks
or Damage
Figure 7
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Tyco Electronics Corporation
Rev
A
409-2426
Pneumatic Tools 68068 and 68068-1
6. TROUBLESHOOTING
In the event of tool malfunction, perform the following five–point visual inspection of the tool before attempting
a detailed troubleshooting procedure.
1. Ensure that the air pressure is regulated at 552 kPa [80 psi] minimum to 689 kpa [100 psi] maximum.
2. Ensure that the pivot pins are fully inserted.
3. Ensure that the jaws are properly mated with the cam.
4. Ensure that the jaw cam rollers are not binding and are properly lubricated.
5. Ensure that the cam is properly lubricated.
If the five–point visual inspection does not eliminate the malfunction, refer to Paragraph 2.2, Functional
Description; Figure 8 (troubleshooting table); and Section 7, Parts List (which contains an exploded view of the
tool). If the malfunction cannot be remedied with these aids, contact TOOLING ASSISTANCE CENTER at the
number at the bottom of page 1.
DANGER
To avoid personal injury or damage to the tool, ALWAYS DISCONNECT the tool from the air supply before attempting
to disassemble the tool for parts inspection or replacement.
MALFUNCTION
Jaws close too slowly or will not
PROBABLE CAUSE
Insufficient air pressure.
REMEDY
Ensure that the air pressure is at least 552 kPa
[80 psi].
bottom and complete the crimp.
Piston O" ring is deteriorated allowing too much
Replace piston O" ring. Refer to Paragraph 8.2.
blow-by."
Air valve spool O" rings are deteriorated
Replace air valve spool O" rings. Refer to
allowing too much blow-by."
Paragraph 8.3.
Air valve spool needs to be adjusted.
Adjust air valve spool. Refer to Paragraph 8.4.
Jaw cam rollers are binding or need to be
Clean, inspect, and lubricate the jaw cam rollers.
lubricated.
Refer to Section 5.
Cam is damaged or needs to be lubricated.
Replace the cam (refer to Paragraph 8.1) or
lubricate the cam (refer to Paragraph 5.3).
Piston cam will not retract to open
Piston rod O" ring is deteriorated (air leaks into
Replace piston rod O" ring. Refer to Paragraph
jaws or retracts too slowly.
jaw housing from behind the main piston cam).
8.2.
Air valve spool O" rings are deteriorated
Replace air valve spool O" rings. Refer to
allowing too much blow-by."
Paragraph 8.3.
Air valve spool needs to be adjusted.
Adjust air valve spool. Refer to Paragraph 8.4.
There is insufficient air pressure.
Ensure that the air pressure is at least
552 kPa [80 psi].
Figure 8
Rev
A
Tyco Electronics Corporation
11 of 17
409-2426
Pneumatic Tools 68068 and 68068-1
7. PARTS LIST
Figure 9 is a complete list of all parts contained in the tools. The exploded view should be used to identify
location and assembly of parts.
Detail A
12
14
8
9
13
11
6
1
4
3
2
3
5
16
15
8
7
38
Detail A Ċ Tool 68068
37
36
17
18
22
19
18
23
20
10
19
34
33
20
32 21
27
31
30
29
27
28
24 25
27
26
20
10
18
35
Detail A Ċ Tool 68068-1
17
18
36
19
19
37
38
Figure 9 (Cont’d)
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Tyco Electronics Corporation
Rev A
409-2426
Pneumatic Tools 68068 and 68068-1
PARTS LIST
ITEM
PART NUMBER
DESCRIPTION
QTY PER TOOL
1
237130-0
GRIP, Handle
1
2
237116-0
BUTTON
1
3
4-21086-5
O" RING, Air Valve Spool
2
4
237134-0
SPOOL, Air Valve
1
5
22284-7
SPRING, Compression
1
6
237118-0
HANDLE
1
7
237111-0
STRAP
1
8
21055-7
WASHER, Flat, No. 10
3
9
5-21000-3
SCREW, Socket Head Cap, 10-24
10
2-21002-0
SCREW, Button Head, 8-32
11
300093-0
HOSE, Coupling
1
12
302222-0
CAP, Plastic
1
13
300094-0
HOSE, Air, 10 ft
1
14
21030-7
15
4-21086-3
O" RING
16
6-21002-5
SCREW, Button Head, 10-24
17
308391-1
18
23138-2
19
237133-0
20
2-21002-3
21
237114-0
22
PIN, Dowel, .125 in. Dia.
.500 in. Long
.250 in. Long
4
1
1.125 in. Long
2
2
.750 in. Long
1
COVER, Housing
2
PIN, Cowling
8
PIN, Retaining
4
SCREW, Button Head Socket Cap, 8-32
.630 in. Long
8
PLUG, Front
1
2-21106-6
RING, Back-Up
2
23
3-21107-5
RING, Back-Up
2
24
3-21000-6
SCREW, Socket Head Cap, 10-32
25
237113-0
26
25625-2
27
1-21976-4
28
.625 in. Long
1
PLUG, Rear
1
PLATE, Identification
1
O" RING, Piston
3
237101-0
PISTON
1
29
237099-0
ROD, Piston
1
30
5-21084-0
O" RING, Piston Rod
1
31
237106-0
INSERT, Front Plug
1
32
5-21028-7
33
237131-0
CAM
1
34
237156-0
HOUSING
1
35
306209-7
PIN, Pivot
2
36
308389-1
PLUNGER
2
37
3-22280-7
SPRING, Compression
2
38
308390-1
RETAINER, Spring
2
PIN, Slotted Spring, .125 in. Dia
.880 in. Long, Cam Retaining
1
Figure 9 (End)
Rev
A
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409-2426
Pneumatic Tools 68068 and 68068-1
8. REPLACEMENT AND REPAIR
Customer–replaceable parts are listed in Figure 9. A complete inventory should be stocked and controlled to
prevent lost time when replacement of parts is necessary. Parts other than those listed should be replaced by
Tyco Electronics Corporation to ensure quality and reliability. Order replacement parts through your
representative, or call 1–800–526–5142, or send a facsimile of your purchase order to 717–986–7605, or write
to:
CUSTOMER SERVICE (038–035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105–3608
For customer repair service, call 1–800–526–5136.
8.1. Cam Replacement
1. DISCONNECT the tool from the air supply.
DANGER
To prevent personal injury, ALWAYS DISCONNECT the tool from the air supply when making replacements.
2. Remove the two screws (Item 9), washers (Item 8), and strap (Item 7) from the handle.
3. Remove screw (Item 16) and washer (Item 8) from the handle, then remove the handle from the tool
housing.
CAUTION
Observe the following precautions while removing the handle:
Ċ Protect exposed tubes from damage.
!
Ċ DO NOT allow foreign matter to enter the tubes or holes of the handle.
4. Remove the screws (Item 20) from the rear of the cylinder housing.
5. Remove the rear plug (Item 25) being careful not to damage the piston “O” ring (Item 27).
6. Open both tool housing covers (Item 17) as far as they will open.
7. Push the piston (Item 28) toward the front of the tool until access to the cam retaining pin (Item 32) is
permitted through the slot in the tool housing.
8. While observing the cam (Item 33), use a hex wrench to turn the screw (Item 24) CLOCKWISE until
the cam retaining pin (Item 32) is parallel with the large slot in the jaw housing.
NOTE
DO NOT turn the screw COUNTER-CLOCKWISE; otherwise, the piston may loosen on the piston rod (Item 29).
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9. Brace and support the cam from one side, and drive the cam retaining pin (Item 32) out of the piston
rod and cam from the opposite side.
CAUTION
Make sure that the cam is properly braced and supported before driving the cam retaining pin out of the piston;
otherwise, the piston rod could bend or damage could occur to the piston rod O" ring, back-up rings, or insert.
!
10. Replace the cam. Align the hole of the new cam with the hole of the piston rod, and re–install the
cam retaining pin (Item 32).
11. Using a hex wrench, turn the screw (Item 24) CLOCKWISE until the cam retaining pin is
perpendicular to the large slot of the tool housing.
NOTE
DO NOT turn the screw COUNTER-CLOCKWISE; otherwise, the piston may loosen on the piston rod (Item 29).
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Tyco Electronics Corporation
Rev A
409-2426
Pneumatic Tools 68068 and 68068-1
12. Examine the piston “O” ring (Item 27) for wear and damage. If necessary, replace it. Apply a small
amount of “O” ring lubricant to the “O” ring.
13. Align the holes of the rear plug with the holes of the cylinder housing, and insert the rear plug. Install
and tighten the screws (Item 20).
14. Carefully position the handle over the tubes and secure with the screw (Item 16) and washer (Item
8).
15. Re–install the strap (Item 7) using the two screws (Item 9) and washers (Item 8).
8.2. Piston and Piston Rod O" Ring Replacement
1. DISCONNECT the tool from the air supply.
DANGER
To prevent personal injury, ALWAYS DISCONNECT the tool from the air supply when making replacements.
2. Remove the two screws (Item 9), washers (Item 8), and strap (Item 7) from the handle.
3. Remove the screws (Item 20) from the rear of the cylinder housing.
4. Remove the rear plug (Item 25), being careful not to damage the piston “O” ring (Item 27).
5. Remove the screws (Item 20) that mount the front plug (Item 21) to the front of the cylinder.
6. Remove the cam (Item 33), front plug (Item 21), and piston (Item 28) as a unit from the cylinder.
7. Remove the screw (Item 24), and remove the piston from the piston rod (Item 29).
8. Slide the front plug off of the piston rod.
9. Remove the piston rod “O” ring (Item 30) from the front plug insert (Item 31), and inspect the back–up
rings (Item 22) for wear and damage. If necessary, replace the back–up rings.
NOTE
Stagger the slits in the back-up rings before installing the O" ring.
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10. Install the new piston rod “O” ring, and apply “O” ring lubricant.
11. Slide the front plug onto the piston rod.
12. Remove the piston “O” ring (Item 27) from the piston, and inspect the back–up rings (Item 23) for
wear and damage. If necessary, replace the back–up rings.
NOTE
Stagger the slits in the back-up rings before installing the O" ring.
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13. Mount the piston on the piston rod. Apply a heavy–duty anti–seize lubricant to the threads of the
screw (Item 24), and install and tighten the screw to lock the piston onto the piston rod.
14. Inspect the piston “O” ring (Item 27) on the front plug for wear and damage. If necessary, replace
the “O” ring. Apply “O” ring lubricant.
15. Align the screw holes of the front plug with the mounting holes at the rear of the cylinder.
16. Slide the front plug, cam, and piston as a unit into the cylinder until the front plug screw holes are
aligned with the mounting holes at the front of the cylinder.
17. Install and tighten the screws (Item 20) to lock the front plug into position.
18. Examine the piston “O” ring (Item 27) for wear and damage. If necessary, replace the “O” ring, and
apply “O” ring lubricant to the “O” ring.
Rev A
Tyco Electronics Corporation
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409-2426
Pneumatic Tools 68068 and 68068-1
19. Align the holes of the rear plug with the holes of the cylinder housing, and insert the rear plug. Install
the screws (Item 20), and tighten.
20. Re–install the strap (Item 7) using the two screws (Item 9) and washers (Item 8).
8.3. Air Valve Spool O" Ring Replacement
1. DISCONNECT the tool from the air supply.
DANGER
To prevent personal injury, ALWAYS DISCONNECT the tool from the air supply when making replacements.
2. Remove the handle grip (Item 1).
3. Remove the dowel pin (Item 14) from the valve housing.
4. Slide the button (Item 2) and attached air valve spool (Item 4) out of the valve housing.
5. Remove the compression spring (Item 5) from inside of the valve housing, and inspect it for excessive
wear or breakage. If necessary, replace the compression spring.
NOTE
DO NOT disturb the air valve spool adjustment within the button. If the spool adjustment is disturbed, refer to
Paragraph 8.4 to re-adjust it.
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6. Replace both air valve spool “O” rings (Item 3), then apply “O” ring lubricant to the new “O” rings.
7. Re–install the compression spring (Item 5).
8. Slide the air valve spool and button into the valve housing until the slot of the button is aligned with
the dowel pin hole of the valve housing. See Figure 10.
9. Insert the dowel pin (Item 14) all of the way into the valve housing. The ends of the dowel pin must be
flush with the sides of the valve housing.
10. Re–install the handle grip.
Air Valve Spool O" Ring Replacement
Slot of Button Aligned with
Dowel Pin Hole of Valve Housing
Air Valve Spool Adjustment
Tip of Screw Driver in
Slot at Rear of Spool
Figure 10
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Tyco Electronics Corporation
Rev A
409-2426
Pneumatic Tools 68068 and 68068-1
8.4. Air Valve Spool Adjustment
A. Crimp Function
If the jaws close too slowly or not at all the control button is fully depressed, perform the following:
1. Make sure that the air pressure is regulated at 552 kPa [80 psi] minimum to 689 kpa [100 psi]
maximum.
2. With the control button fully depressed, insert the tip of a screw driver through the rear exhaust port
and into the slot at the rear of the air valve spool. See Figure 10.
3. Turn the screw driver COUNTER–CLOCKWISE until the jaws are fully closed. Stop turning the screw
driver as soon as the jaws are closed and when there is no evidence of air escaping through the exhaust
ports.
4. Cycle the tool a few times to ensure that the tool is functioning properly.
B. Cam Return Function
If jaws open too slowly or not at all when the control button is released, perform the following:
1. Make sure that the air pressure is regulated at 552 kPa [80 psi] minimum to 689 kpa [100 psi]
maximum.
2. With the control button fully depressed, insert the tip of a screw driver through the rear exhaust port
and into the slot at the rear of the air valve spool. See Figure 10.
3. Turn the screw driver CLOCKWISE until the jaws are fully open. Stop turning the screw driver as
soon as the jaws are open and when there is no evidence of air escaping through the exhaust ports.
4. Cycle the tool a few times to ensure that the tool is functioning properly.
9. REVISION SUMMARY
Revisions to this customer manual include:
S
S
S
S
S
S
S
S
S
Rev A
Updated document to corporate requirements
Removed obsolete Tool 68068–4
Removed obsolete jaw assemblies and added instruction sheet referenced to Figure 5
Added jaw position to Figure 6
Removed obsolete items or items related to obsolete tool from Figure 9
Added Paragraph 2.1
Changed “rear plug” to “piston” in Paragraph 8.1, Step 12 and Paragraph 8.2, Step 18
Added lubrication symbol to jaw cam rollers in Figure 7
Added ordering parts information and changed customer repair service information in Section 8
Tyco Electronics Corporation
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