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

CABLE
TERMINAL
SWAGING KIT
AT520JK

Operating and Maintenance Manual

(Revised March 2005)
AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

AT520JK Cable Terminal Swaging Kit

Page 1 of 14
 AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

SETUP AND OPERATING PROCEDURE

1. Connect the air supply line to the foot valve. For efficient operation, use an inlet airline with at least 3/8” inside
diameter and 90 lbs minimum line pressure.

2. Connect swager airlines to the foot valve.

3. Do not insert or remove dies until the air supply connected to the swager is shut off.

4. Do not operate the swager until both dies are in position.

5. Referring to the chart on pages 6 & 7, select a matched pair of swaging dies listed by Part Number opposite the
Terminal Type and Cable Size.

6. Clean the dies, remove any steel particles which may have adhered to the die cavity and apply a light film of oil to
the entire die.

7. Insert dies into swaging position. (See figure 5)

8. Keep hands clear of the die chamber at all times, when air supply is connected.

9. Instructions on Page 4 should be read thoroughly before operating swager.

10. !!! CAUTION !!! : Do not operate the unit without safety guard in place.

PORTABLE SWAGING

If a flat surface is not available, omit use of the base plate.

The swager should be hand-held with the cap seated in the cradle of
the arm. (See Figure 1)

Note: The safety guard has been removed for clarity and
should be in place during operation.

BENCH SWAGING

When a flat surface is available, large enough to

accommodate the AT520CBP Base plate, place the swager on the
base plate with the pin engaging the underside of the yoke. Position
the swager with the yoke nose facing the operator.

Note: The safety guard has been removed for clarity and
should be in place during operation.

Page 2 of 14
 AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

CABLE CUTTING DIE INSTALLATION

1. Hold the AT520CP cutter to that the blade is in the vertical

position. Insert it, blade end first, into the yoke opening and
slide it back to the face of the power unit.

2. Position the spacer (AT520SP) in the forward end of the yoke

cavity. The spacer keeps the cutter and the die engaged to
prevent damage to the cutting edges.

3. Place the AT520CD die into the yoke opening so that the slot
engages the blade of the cutter. Push the die back against
the spacer.

CABLE CUTTING OPERATION

To cut cable; separate the dies, drop the cable into the slot
between the dies, position it at the desired cutoff point and depress the
foot valve firmly for a maximum of one second. When trimming ball end
terminals; separate the dies, firmly seat the ball and excess cable into
the die cavity and depress the foot valve for a maximum of one second.

Note: The safety guard has been removed for clarity and
should be in place during operation.

SWAGING DIE INSTALLATION

1. Insert either die through the yoke opening and into the die
cavity, with the keyway down and shank facing toward the
rear of the swager.

2. Slide the die back in order to clear the opening for insertion
of the mating die.

3. Insert the mating die, with the shank facing forward and
slide it to the forward position.

LUBRICATION

Unscrew the cap on the oiler and fill it with special air tool
lubricant after every eight hours of operation.

When ordering lubricant, specify:

AT520JL-1 (1 pint can)

AT520JL-2 (1 gallon can)
AT520JL-3 (5 gallon can)

Page 3 of 14
AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

SWAGING PROCEDURE FOR BALL TYPE TERMINALS

1. Position the terminal on the cable, allowing approximately 1 1/2” of excess to extend beyond the ball. Note: To
maintain the ball in the predetermined location, the cable may be kinked and the terminal positioned over the kink

2. Clean the terminal and apply a drop of light oil.

3. Grip the cable approximately one inch from either side of the ball. Position the terminal and cable in the cavity of
the front die and slide the rear die to its forward position using the slot provided in the yoke for the index finger.
Note: To prevent damage to the terminal and cable during the swaging cycle, maintain light pressure on the
cable toward the front of the swager, thereby holding the terminal and cable firmly in the forward die cavity.

4. Depress the foot valve firmly and rotate the cable back and forth in 180° arcs or complete revolutions for time
noted in the chart on Page 5. Note: If you are unable to rotate the terminal, stop swaging immediately, rotate the
terminal 90° and start swaging again.

5. Release the foot valve to stop swaging. Remove the terminal and check the ball and shank diameters against the
chart on Page 5. Note: If the diameters are oversized or the surface finish is too rough, repeat steps 1 through 5,
reducing the swaging time to ten seconds or less.

SWAGING PROCEDURE FOR SLEEVE TYPE TERMINALS

1. Position the terminal on the cable, allowing approximately ¼” to extend through on the MS20667 Terminal.
Bottom out the cable in the MS21259, MS2668 and MS21260 Terminals. Note: To prevent the terminal from
slipping, insert the cable approximately ¾” into the terminal and, using the terminal for leverage, kink the cable
and position the terminal over the kink.

2. Clean the terminal and add a drop of oil.

3. Grip forked or threaded end of the terminal and position it so that the shank end is extending approximately ¾”
into the bell mouth side of the die. Slide the rear die to its forward position using the slot provided in the yoke for
the index finger. Guide and rotate the cable during the swaging cycle. Exert a light pressure on the terminal and
cable toward the front of the swager, holding the terminal and cable firmly in the forward die cavity.

4. Depress the foot valve and rotate the terminal continuously (if the cable length prevents complete revolutions,
turn the terminal back and forth in 180° arcs) at the same time feeding the terminal slowly through the die. When
the full length of the shank has been swaged, continue swaging, reversing the direction of feed until the starting
position has been reached. Repeat this motion for the time noted in the chart on Page 5.

5. Release the foot valve to stop swaging. Remove the terminal and check the shank diameter against the chart of
Page 5.

Page 4 of 14
AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

SWAGING TIME AND DIMENSIONAL DATA FOR SWAGED TERMINALS

“Bs” “As”
TERMINAL “L” SWAGE
MS CABLE DIA DIA.
TERMINAL AN DIM. DIE PART # TIME IN
DASH # DIA. MAX. MAX.
PART # MIN. SEC.
MIN. MIN.

.138
-2 1/16 1.147 - AT520CS-2 15
.133
.190
-3 3/32 1.305 - AT250CS-3 15
MS21259 .185
.219
-4 1/8 1.694 - AT520CS-4 20
.214
MS20667
.250
-5 5/32 2.033 - AT520CS-5 35
.245
MS20668
.313
-6 3/16 2.106 - AT520CS-6 45
.308
MS21260 .375
-7 7/32 2.484 - AT520CS-7 30
.368
.438
-8 1/4 2.373 - AT520CS-8 100
.431

.1905
-2 1/16 - - AT520CB-2 5
AMERICAN .1875
CHAIN &
.253
CABLE -3 3/32 - - AT520CB-3 6
.250
RA2487 .315
-4 1/8 - - AT520CB-4 8
.312

.190 .112
-2 1/16 .156 AT520CSB-2 6
.187 .109

.253 .143
-3 3/32 .234 AT520CSB-3 8
.250 .140

MS20664 .315 .190

-4 1/8 .313 AT520CSB-4 10
.312 .187
.379 .222
-5 5/32 .391 AT520CSB-5 30
.375 .218
.442 .255
-6 3/16 .469 AT520CSB-6 100
.437 .250

.190 .112 AT520CDB-

-2 1/16 .390 6
.187 .109 2

.253 .143 AT520CDB-

-3 3/32 .578 8
.250 .140 3

MS20663 .315 .190 AT520CDB-

-4 1/8 .765 10
.312 .187 4
.379 .222 AT520CDB-
-5 5/32 .953 30
.375 .218 5
.442 .255 AT520CDB-
-6 3/16 1.140 60
.437 .250 6

Page 5 of 14
AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

SWAGING DIES
FOR
DOUBLE SHANK BALL END TERMINALS
DIE NUMBER CABLE DIA. TERMINAL REF.
AT520CDB-2 1/16 MS20663-2
AT520CDB-3 3/32 MS20663-3
AT520CDB-4 1/8 MS20663-4
AT520CDB-5 5/32 MS20663-5
AT520CDB-6 3/16 MS20663-6
Note: Use these dies in pairs

Figure 7

SWAGING DIES
FOR
SINGLE SHANK BALL END TERMINALS
DIE NUMBER CABLE DIA. TERMINAL REF.
AT520CSB-2 1/16 MS20664-2
AT520CSB-3 3/32 MS20664-3
AT520CSB-4 1/8 MS20664-4
AT520CSB-5 5/32 MS20664-5
AT520CSB-6 3/16 MS20664-6
Note: Use these dies in pairs

Figure 8

SWAGING DIES
FOR
PLAIN BALL END TERMINALS
DIE NUMBER CABLE DIA. * TERMINAL REF.
AT520CB-2 1/16 RA2487
AT520CB-3 3/32 RA2487
AT520CB-4 1/8 RA2487
* Manufactured by American Chain & Cable Company
Note: Use these dies in pairs

Figure 9

Page 6 of 14
AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

CABLE CUT-OFF AND TRIM DIES

CUTTER
DIE NUMBER CABLE DIA.
NUMBER
AT520CD-2 1/16 AT520CP-2
AT520CD-3 3/32 AT520CP-3
AT520CD-4 1/8 AT520CP-4
AT520CD-5 5/32 AT520CP-5
AT520CD-6 3/16 AT520CP-6
AT520CD-7 7/32 AT520CP-7
AT520CD-8 1/4 AT520CP-8

Note: AT520SP Spacer must be used with these dies.

See Figure 3, Page 3.

Figure 10

SWAGING DIES
FOR
PLAIN BALL END TERMINALS
TERMINAL
DIE NUMBER CABLE DIA.
DASH #
AT520CS-2 1/16 -2
AT520CS-3 3/32 -3
AT520CS-4 1/8 -4
AT520CS-5 5/32 -5
AT520CS-6 3/16 -6
AT520CS-7 7/32 -7
AT520CS-8 1/4 -8
Note: Use these dies in pairs

Note: TERMINAL REF.

MS21259
MS20667
MS20668
Figure 11 MS21260

Page 7 of 14
 AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

SWAGING TOOL DISASSEMBLY PROCEDURE

1. Clamp the entire tool assembly in a vise and remove the yoke as outlined in Figure 12.

2. Remove the cap as show in Figure 13.

3. Remove Power unit as directed in Figure 14.

4. Disassemble Power unit as show in Figure 15.

5. Clean and check all detail parts of the Power Unit for excessive wear.

6. Replace defective or worn parts as needed.

7. Lubricate all internal working parts with special oil (See Figure 6, Page 4)

8. Reassemble as outlined on Page 9.

YOKE DISASSEMBLY

Remove the yoke by clamping the housing in a vise as

shown in Figure 12. Notice the 3/8” square blocks used to prevent
damage and rotation. Using a standard 2 1/4” open-end wrench,
turn the yoke counter-clockwise to loosen.

CAUTION: Do not crush the housing in the vise.

CAP DISASSEMBLY

Remove the cap by clamping the housing in a vise as shown

in Figure 13. Notice the 3/8” square blocks used to prevent damage
and rotation. Using a standard 2 1/4” open-end wrench, turn the cap
counter-clockwise to loosen.

CAUTION: Do not crush the housing in the vise.

Page 8 of 14
AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

POWER UNIT REMOVAL

After the cap has been removed, as shown in Figure 13, the entire power
unit and spring can be extracted from the housing by pulling it out as
shown in Figure 14.

POWER UNIT BREAKDOWN

1. Refer to Figure 15 and parts reference drawing on Page11.

2. Remove the spring, lock ring and piston from the barrel.

3. Place the barrel in a vise. Use flats for clamping.

4. Use a 2” open-end wrench to remove the house from the barrel,

turning counter-clockwise.

5. Slide the valve assembly out of the barrel.

6. Disassemble the valve as shown in Figure 15.

SWAGING TOOL ASSEMBLY PROCEDURE

1. Clean and check all detail parts of the swaging unit. Replace defective parts where needed.

2. Place the AT520C-10 pins into the yoke and install the AT510A-11 rings.

3. Screw the yoke and housing together and tighten (See Figure 12). On the threads, use LOCTITE Grade AV-mil-
S-22473B – Federal Stock number 8030-081-2337. *

4. After reassembly of the power unit, apply a light coat of grease to the “U” packing. Hold the power unit Assembly
in the vertical position with the “U” packing down and position the AT52CJP-2 saw tooth lock ring so that there is
a full face to face engagement of at least one tooth in the AT520CJP-1 housing. Slide the spring onto the barrel
of the power unit (do not allow the saw tooth lock to become disengaged). Slide the power unit and spring into
the housing and yoke assembly.

5. Install “O” rings on the AT520C-3 Cap after coating them with grease.

6. Holding the power unit securely in the housing, apply LOCTITE (Grade AV-mil-S-22473B – FSH 8030-081-2337
on the threads of the cap and assemble (See Figure 13). *

7. Using an open-end wrench, attach the AT520CAH airline securely to the AT520C-3 Cap.

8. Allow the swager to impact against the dies for five minutes.

9. Re-tighten the entire thread assembly.

* THREADS MUST BE CLEAN AND DRY BEFORE APPLYING LOCTITE

Page 9 of 14
AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

AIR FILTER
The purpose of the air filter is to prevent dirt and other
foreign matter from entering the valve chamber of the power unit. It
should be cleaned after every forty hours of swaging. To service
the filter, remove the housing as show in Figure 16 and pull out the
cartridge. Wash the filter in solvent and air blast the filter clean.
When reassembling, be sure the “O” ring is in the proper position.

INSPECTION AND CHECK OUT PROCEDURE

1. Check the gap between the yoke, cap and housing. All joints must be tight.

2. Snap rings (AT210A-11) must be securely locked in place.

3. Place the tool on the base plate (AT520CBP).

4. To check the swager, select a pair of AT520DBC-5 dies. Clean the dies and apply a coat of light oil.

5. Insert the rear die into the yoke with the keyway facing down and shank facing toward the rear of the tool. Slide
the die back in order to clear the opening for insertion of the forward die. Insert the forward die, with the shank
facing forward, and slide it into the forward position.

6. Connect the swager airline to the foot control valve.

7. Connect the foot control valve to a regulated pressure airline. IMPORTANT: the Swaging tool must operate on
90 psi. of regulated air. Use a 3/8” I.D. hose.

8. Check the lubricator for oil (See Figure 6, Page 4).

9. Read and familiarize yourself wit the swager operating instruction on Page 4.

10. Swage an MS20663-5 double shank ball type terminal to a 5/32” cable for 30 seconds, noting whether the swager
operates smoothly or erratically. If a malfunction is indicated, or terminal is not swaged to the dimensions show in
the chart of Page 5, reject the power unit.

!!!!! CAUTION !!!!!

DO NOT OPERATE THIS TOOL WITHOUT SWAGING DIES IN PLACE.

DO NOT PLACE HANDS IN THE DIE CHAMBER AT ANY TIME.

DO NOT OPERATE THIS TOOL WITHTOUT THE SAFETY GUARD IN PLACE.

Page 10 of 14
AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

Page 11 of 14
AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

CODE # PART # PART NAME # REQ DESCRIPTION Manufacturer

1 AT520CDB Die 10 Spec. Mfg. Part ATI
2 AT520CSB Die 10 Spec. Mfg. Part ATI
3 AT520CB Die 6 Spec. Mfg. Part ATI
4 AT520CS Die 14 Spec. Mfg. Part ATI
5 AT520CP Die 7 Spec. Mfg. Part ATI
6 AT520CD Die 7 Spec. Mfg. Part ATI
7 AT520SP-2 “O” Ring 1 AN6227-23 Standard
8 AT520SP-1 Spacer 1 Spec. Mfg. Part ATI
9 AT520CKB-5 Pad 1 Spec. Mfg. Part ATI
10 AT800K-1 Pin 4 1/8” Cotter Standard
11 AT520CKB-2 Tray 1 Spec. Mfg. Part ATI
12 AT520CKB-3 Box 1 Spec. Mfg. Part ATI
13 AT520CH Hose 1 Spec. Mfg. Part ATI
14 AT520C-15 Valve 1 Roberts #50-3/8 I.P.S. D.M.S.
15 AT520JAH Hose 1 Spec. Mfg. Part ATI
16 AT520JG Guard 1 Spec. Mfg. Part ATI
17 AT510A-11 “O” Ring 3 AN6227-3 Standard
18 AT520C-18 Pin 2 Spec. Mfg. Part ATI
19 AT520C-9 Yoke 1 Spec. Mfg. Part ATI
20 AT520C-3 Cap 1 Spec. Mfg. Part ATI
21 AT520C-4 “O” Ring 1 AN6227-3 Standard
22 AT520C-13 Quad Ring 1 MRQI-Q15 Standard
23 AT520C-5 “U” Packer 1 AN6226-26 Standard
24 AT520J-1 Housing 1 Spec. Mfg. Part ATI
25 AT520C-6 Spring 1 Spec. Mfg. Part ATI
26 AT520CJP-2 Lock Ring 1 Spec. Mfg. Part ATI
** 27 AT520BR-3 Piston 1 Spec. Mfg. Part ATI
28 AT520CJP-1 Handle 1 Spec. Mfg. Part ATI
29 AT520BR-8 Cap 1 Spec. Mfg. Part ATI
30 AT520BR-5 Sleeve 1 Spec. Mfg. Part ATI
31 AT520BR-6 Collar 1 Spec. Mfg. Part ATI
32 AT520BR-7 Pin 1 Spec. Mfg. Part ATI
33 AT520BR-2 Barrel 1 Spec. Mfg. Part ATI
34 AT520CBP-3 Cushion 1 Spec. Mfg. Part ATI
35 AT520CBP-5 Nut 1 AN364-820 Standard
36 AT520CBP-2 Pin 1 Spec. Mfg. Part ATI
37 AT520CBP-1 Pad 1 Spec. Mfg. Part ATI
38 AT520CBC Cover 1 Spec. Mfg. Part ATI
39 AT520C-19 Plug 1 Foster #40-4 F.M.C.
40 AT520FA-1 Housing 1 Spec. Mfg. Part ATI
41 AT520C-11 “O” Ring 1 AN6227-17 Standard
42 AT520FA-3 Cartridge 1 Spec. Mfg. Part ATI
43 AT520FA-2 Cap 1 Spec. Mfg. Part ATI
44 AT520C-20 Chuck 1 Foster #4104 F.M.C.
45 AT520CFC-7 Oiler 1 #1665 A.E.C.
46 AT225ALP-6 Nipple 2 1/4” Close Standard
47 AT520CFC-3 Pad 1 Spec. Mfg. Part ATI

Page 12 of 14
 AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

CODE # PART # PART NAME # REQ DESCRIPTION Manufacturer

48 AT520CFC-4 Bolt 2 1/4-20 Hex Standard
49 AT520CFC-1 Guard 1 1/4-20 X 1” 82° Flat Head Standard
* 50 AT520CFC-2 Valve 1 Spec. Mfg. Part ATI
51 AT520CFC-2B Snap Ring 2 Ross #195166 R.A.C
52 AT520CFC-2A Pin 1 Ross #60015S R.A.C
53 AT520CFC-2H Treadle 1 Ross #6002M2 R.A.C
54 AT520CFC-2D Spring 1 Ross #158A13 R.A.C
55 AT520CFC-2G Plug 2 Ross #30011 R.A.C
56 AT520CFC-2F Gasket 2 Ross #60043 R.A.C
57 AT520CFC-2E Spring 2 Ross #6004 R.A.C
58 AT520CFC-2C Poppet w/ “O” Ring 2 Ross #6008 R.A.C
59 No Number Body 1 No Number R.A.C
60 AT520SH Gauge 1 Spec. Mfg. Part ATI

Manufacturer’s Codes
ATI ATI Tools, Escondido, California
D.M.S. Ducommun Metal & Supply, Los Angeles, California
F.M.C. Foster Manufacturing Company, St. Louis, Missouri
A.S.C. ASCO Sintering Company, Los Angeles, California
A.E.C. Aro Equipment Company, Los Angeles, California
R.A.C. Ralph Atkinson Company, Los Angeles, California

General Notes:

Items 29 through 32 are not available as individual detailed components. The complete unit is available for purchase as
Part Number AT520BR.

* Items 51 through 59 are not available as individual detailed components. The complete unit is available for purchase as
Part Number AT520CFC-2 (Listed as Item 50).

**

CUSTOMER ADVISORY NOTE:

Please note that the Piston (AT520BR-3) can be inadvertently installed backwards in the Swaging Tool. The piston has a
45° chamfer on one end that is designed to match the shank diameter of the swaging die. If the un-chamfered end is
used against the swaging die, the piston will become swollen and distorted. This action will significantly affect the
performance of the swager and could cause permanent damage to the swaging tool.

Page 13 of 14
 AT520JK – Cable Terminal Swaging Kit Operating and Maintenance Manual

SAFETY GUARD
AT520JG
This Safety Guard is designed to prevent accidental injury.
It affords maximum protection without interfering with the operation
of the Swaging Tool.

SWAGING GAUGE
AT520SG
This “GO” type gauge is designed to check all swaged
terminals within the capacity of the AT520J swager.

Page 14 of 14