Snap-On ATI520J Operating instructions

PORTABLE
CABLE TERMINAL
SWAGER
ATI520J &
ATI520JK
Operating and Maintenance Manual
(Revised April 2019)
Shipping Dimensions: 17" x 31" x 16"
Shipping Weight: 90 lbs.

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 1 of 12
ATI520J Portable Cable Terminal Swager &
ATI520JK Cable Terminal Swaging Kit

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 2 of 12
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 psi 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 ATI520CBP 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.

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 3 of 12
CABLE CUTTING DIE INSTALLATION
1. Hold the ATI520CP cutter so 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 (ATI520SP) 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 ATI520CD 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 air tool lubricant
oil after every eight hours of operation. Check oil level frequently to
prevent premature failure of the swager.

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 4 of 12
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.

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 5 of 12
SWAGING TIME AND DIMENSIONAL DATA FOR SWAGED TERMINALS
TERMINAL
TERMINAL
AN
PART #
MS
DASH #
CABLE
DIA.
“L”
DIM.
MIN.
“Bs”
DIA
MAX.
MIN.
“As”
DIA.
MAX.
MIN.
DIE PART #
SWAGE
TIME IN
SEC.
MS21259
MS20667
MS20668
MS21260
-2
1/16
1.147
-
.138
.133
ATI520CS-2
15
-3
3/32
1.305
-
.190
.185
ATI520CS-3
15
-4
1/8
1.694
-
.219
.214
ATI520CS-4
20
-5
5/32
2.033
-
.250
.245
ATI520CS-5
35
-6
3/16
2.106
-
.313
.308
ATI520CS-6
45
-7
7/32
2.484
-
.375
.368
ATI520CS-7
30
-8
1/4
2.373
-
.438
.431
ATI520CS-8
100
AMERICAN
CHAIN &
CABLE
RA2487
-2
1/16
-
.1905
.1875
-
ATI520CB-2
5
-3
3/32
-
.253
.250
-
ATI520CB-3
6
-4
1/8
-
.315
.312
-
ATI520CB-4
8
MS20664
-2
1/16
.156
.190
.187
.112
.109
ATI520CSB-2
6
-3
3/32
.234
.253
.250
.143
.140
ATI520CSB-3
8
-4
1/8
.313
.315
.312
.190
.187
ATI520CSB-4
10
-5
5/32
.391
.379
.375
.222
.218
ATI520CSB-5
30
-6
3/16
.469
.442
.437
.255
.250
ATI520CSB-6
100
MS20663
-2
1/16
.390
.190
.187
.112
.109
ATI520CDB-2
6
-3
3/32
.578
.253
.250
.143
.140
ATI520CDB-3
8
-4
1/8
.765
.315
.312
.190
.187
ATI520CDB-4
10
-5
5/32
.953
.379
.375
.222
.218
ATI520CDB-5
30
-6
3/16
1.140
.442
.437
.255
.250
ATI520CDB-6
60

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 6 of 12
Figure 7
SWAGING DIES
FOR
DOUBLE SHANK BALL END TERMINALS
DIE NUMBER
CABLE DIA.
TERMINAL REF.
ATI520CDB-2
1/16
MS20663-2
ATI520CDB-3
3/32
MS20663-3
ATI520CDB-4
1/8
MS20663-4
ATI520CDB-5
5/32
MS20663-5
ATI520CDB-6
3/16
MS20663-6
Note: Use these dies in pairs
Figure 8
SWAGING DIES
FOR
SINGLE SHANK BALL END TERMINALS
DIE NUMBER
CABLE DIA.
TERMINAL REF.
ATI520CSB-2
1/16
MS20664-2
ATI520CSB-3
3/32
MS20664-3
ATI520CSB-4
1/8
MS20664-4
ATI520CSB-5
5/32
MS20664-5
ATI520CSB-6
3/16
MS20664-6
Note: Use these dies in pairs
Figure 9
SWAGING DIES
FOR
PLAIN BALL END TERMINALS
DIE NUMBER
CABLE DIA.
* TERMINAL REF.
ATI520CB-2
1/16
RA2487-2
ATI520CB-3
3/32
RA2487-3
ATI520CB-4
1/8
RA2487-4
* Manufactured by American Chain & Cable Company
Note: Use these dies in pairs

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 7 of 12
Figure 10
CABLE CUT-OFF AND TRIM DIES
DIE NUMBER
CABLE DIA.
CUTTER NUMBER
ATI520CD-2
1/16
ATI520CP-2
ATI520CD-3
3/32
ATI520CP-3
ATI520CD-4
1/8
ATI520CP-4
ATI520CD-5
5/32
ATI520CP-5
ATI520CD-6
3/16
ATI520CP-6
ATI520CD-7
7/32
ATI520CP-7
ATI520CD-8
1/4
ATI520CP-8
Note: ATI520SP Spacer must be used with these dies. See
Figure 3, Page 3.
Figure 11
SWAGING DIES
FOR
PLAIN SLEEVE TERMINALS
DIE NUMBER
CABLE
DIA.
TERMINAL
DASH #
MS21259, MS20667
MS20668, MS21260
TERMINAL
DASH #
BACT14A
ATI520CS-2
1/16
-2
ATI520CS-3
3/32
-3
-2 *
ATI520CS-4
1/8
-4
-3 *
ATI520CS-5
5/32
-5
-4 *
ATI520CS-6
3/16
-6
-5 *
ATI520CS-7
7/32
-7
-6 *
ATI520CS-8
1/4
-8
Note: Use these dies in pairs
* BACT14A Terminal dash numbers do not equal the dash number of
the ATI520CS dies
BACT14A Terminal Data
DASH
#
A
B
C
D
LS
-2
.224
.214
.221
.217
.190
.185
.076
.073
.290
.250
-3
.333
.323
.252
.248
.219
.214
.107
.104
.410
.370
-4
.416
.406
.298
.294
.250
.245
.146
.141
.540
.500
-5
.510
.500
.377
.373
.313
.308
.177
.172
.660
.620
-6
.635
.625
.439
.435
.375
.370
.208
.203
.790
.750

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 8 of 12
SWAGING TOOL DISASSEMBLY PROCEDURE
1. Clamp the entire tool assembly in a vise.
2. Using a torch with non-oxidizing type gas, heat the area of the housing where the yolk / cap is seated. The
internal temperature needs to be high enough to soften the LOCTITE on the threads. If this step is not taken,
you may severely damage the tool.
3. Remove the yoke as outlined in Figure 12.
4. Remove the cap as show in Figure 13.
5. Remove Power unit as directed in Figure 14.
6. Disassemble Power unit as show in Figure 15.
7. Clean and check all detail parts of the Power Unit for excessive wear.
8. Replace defective or worn parts as needed.
9. Lubricate all internal working parts with air tool oil.
10. 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. Heat the unit in the area indicated here to
soften the LOCTITE and, using a 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. Heat the unit to soften the LOCTITE and,
using a 2 1/4” open-end wrench, turn the cap counter-clockwise to
loosen.
CAUTION: Do not crush the housing in the vise.

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 9 of 12
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
Page 11.
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.
SWAGING TOOL ASSEMBLY PROCEDURE
1. Clean and check all detail parts of the swaging unit. Replace defective parts where needed.
2. Place the ATI520C-18 pins into the yoke and install the ATI429DR-6 rings (2 required).
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. **THREADS MUST BE CLEAN AND DRY BEFORE
APPLYING LOCTITE**
4. After reassembly of the power unit, apply a light coat of grease to the “U” packer ATI520C-5. Hold the power unit
Assembly in the vertical position with the “U” packing down and position the ATI520CJP-2 saw tooth lock ring so
that there is a full face to face engagement of at least one tooth in the ATI520CJP-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” ring ATI520C-4 on the ATI520J-3 Cap after coating 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). **THREADS MUST BE CLEAN AND DRY BEFORE
APPLYING LOCTITE**
7. Using an open-end wrench, attach the ATI520CH airline securely to the ATI520J-3 Cap.
8. Allow the swager to impact against the dies for five minutes.
9. Re-tighten the entire thread assembly.

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 10 of 12
INSPECTION AND CHECK OUT PROCEDURE
1. Check the gap between the yoke, cap and housing. All joints must be tight.
2. Place the tool on the base plate ATI520CBP.
3. To check the swager, select a pair of ATI520CDB-5 dies. Clean the dies and apply a coat of light oil.
4. 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.
5. Connect the swager airline to the foot control valve.
6. Connect the foot control valve to a regulated pressure airline. IMPORTANT: the Swaging tool must operate on
90 psi of regulated air. Use a minimum 3/8” I.D. hose.
7. Check the lubricator for oil (See Figure 6, Page 4).
8. Read and familiarize yourself with the swager operating instructions on Page 4.
9. 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 shown
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.
** CUSTOMER ADVISORY NOTE **
Please note that the Piston ATI520BR-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.
PISTON
ATI520BR-3
ATI520 SERIES
SWAGING DIE

ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
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ATI520J –Portable Cable Terminal Swager Operating and Maintenance Manual
Page 12 of 12
SWAGING GAUGE
ATI520SG
This “GO” type gauge is designed to check all swaged
terminals within the capacity of the ATI520J swager.
CABLE TERMINAL SWAGING KIT
ATI520JK
The kit contains the ATI520J Swager, ATI520SG
Swage Gauge, Felco C7 Cable Cutters, ATISP1001
Turnbuckle Wrench, ATI520SP Spacer, ATI520CKB Carrying
Case, and all of the below listed dies:
Part Number
Terminal Type
Cable Size
ATI520CDB-2
Double Shank Ball End
1/16”
ATI520CDB-3
Double Shank Ball End
3/32”
ATI520CDB-4
Double Shank Ball End
1/8”
ATI520CDB-5
Double Shank Ball End
5/32”
ATI520CDB-6
Double Shank Ball End
3/16”
ATI520CSB-2
Single Shank Ball End
1/16”
ATI520CSB-3
Single Shank Ball End
3/32”
ATI520CSB-4
Single Shank Ball End
1/8”
ATI520CSB-5
Single Shank Ball End
5/32”
ATI520CSB-6
Single Shank Ball End
3/16”
ATI520CB-2
Plain Ball End
1/16”
ATI520CB-3
Plain Ball End
3/32”
ATI520CB-4
Plain Ball End
1/8”
ATI520CS-2
Sleeve Type
1/16”
ATI520CS-3
Sleeve Type
3/32”
ATI520CS-4
Sleeve Type
1/8”
ATI520CS-5
Sleeve Type
5/32”
ATI520CS-6
Sleeve Type
3/16”
ATI520CS-7
Sleeve Type
7/32”
ATI520CS-8
Sleeve Type
1/4”
Cable Cut-off and Trim Dies
Part Number (Die)
Cable Size
Part Number (Punch)
ATI520CD-2
1/16”
ATI520CP-2
ATI520CD-3
3/32”
ATI520CP-3
ATI520CD-4
1/8”
ATI520CP-4
ATI520CD-5
5/32”
ATI520CP-5
ATI520CD-6
3/16”
ATI520CP-6
ATI520CD-7
7/32”
ATI520CP-7
ATI520CD-8
1/4”
ATI520CP-8