Specialty Tools = 254-460 CABLE TERMINAL SWAGING KIT ms | AT520JK / Operating an — inten: Manual (Revised Mar rch 2008)ATS20JK — Cable Terminal Swaging Kit Operating and Maintenance Manual AT520JK Cable Terminal Swaging Kit Page 1 of 14‘accommodate the ATS20CBP Base plate, place the swager on the bbase plate with the pin engaging the underside of the yoke. Position the swager with the yoke nose facing the operator. ATS20JK — Cable Terminal Swaging Kit Operating and Maintenance Manual SETUP AND OPERATING PROCEDURE 4. 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 Ibs minimum line pressure. 2. Connect swager airlines to the foot valve 3. Do not insert or remove dies unti the air supply connected to the swager is shut off 4. Do not operate the swager until both dies are in position 5. Reterring 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 fim of oil to the entire die. 7. Insert dies into swaging position. (See figure 5) 8 Keep hands clear of the die chamber at allimes, when air supply is connected. 9. Instructions on Page 4 should be read thoroughly before operating swager. 10. 1!!! CAUTION !!!: Do not operate the unit without safety guard in place. PORTABLE SWAGING Ifa 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, ae ea BENCH SWAGING When a fiat surface is available, large enough to Note: The safety guard has been removed for clarity and should be in place during operation Figure 2 Page 2 of 14ATS20JK — Cable Terminal Swaging Kit Operating and Maintenance Manual CABLE CUTTING DIE INSTALLATION 1, Hold the ATS20CP 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 (ATS20SP) 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 ATS20CD die into the yoke opening so that the slot engages the blade of the cutter. Push the die back against Figure 3 the spacer. Figure 4 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 Figure 5 side to the forward postion LUBRICATION Unscrew the cap on the oiler and fil it wth special air too! lubricant after every eight hours of operation When ordering lubricant, specify ATS2OJL~4 (1 pint can) ATS20JL-2 (1 gallon can) ATS20JL-3 (6 gallon can) Page 3 of 14 Figure 6ATS20JK ~ Cable Terminal Swaging Kit Operating and Maintenance Manval SWAGING PROCEDURE FOR BALL TYPE TERMINALS 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 Clean the terminal and apply a drop of light ol. 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. Depress the foot vaive 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, 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 Position the terminal on the cable, allowing approximately 1" to extend through on the MS20867 Terminal. Bottom out the cable in the MS21259, MS2668 and MS21260 Terminals. Note: To prevent the terminal from slipping, insert the cable approximately 74" into the terminal and, using the terminal for leverage, kink the cable {and position the terminal over the kink Clean the terminal and add a drop of oil Grip forked or threaded end of the terminal and position itso that the shank end is extending approximately 2 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. Depress the foot valve and rotate the terminal continuously (if the cable fength 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 §, 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ATS20JK ~ Cable Terminal Swaging Operating and Maintenance Manual _ SWAGING TIME AND DIMENSIONAL DATA FOR SWAGED TERMINALS fp a ae - TERMINAL 7 swase TERMINAL AN — CABLE | iy, DIA | DIA. | pie PART # | TIMEIN pity | once |oa. | PM | sax | sac. we | wk T 199 eee tee 2 | ane [ater] - | 138 | avsooes2 | as 799 | eommr&1 za | sz1259 : are to | ee eet aa [a Tw seme [| -28 Tarszocse | 20 |S | ts" a 20 a | sxe | 200| - | 2 | arsaocss | os | 1 As Typical 20668 6 | ane zi) | S13 | atszocse | as ms21260 375 cael cm 1 7 | ta | 288 35 | arsoocs.7 | 20 | | ou | 2arm) | 38 | atszocse | 100 1005 awencan) 2 | | - [A08] = [atsonca2 | 5 Can = | ox a ee eee aacss7 4 [| | - | SR | - [arses | I i 2 | 12 ie 2 | ane | 56 | 192 | 42 | arszocse2 | 6 ma lf 3 | ase | 2m | 23 | MS | arszocses | 6 Zn fi L 6 | soa | aor | 72 | 222 | arszocses| a0 | 2 | ane | eo | 42 | 2 | arezocess | 10 : too 112 | arszoco8. | 2 | ane | seo | 190 | 112 | Arsen 5 | 253 143 | ATS20CDB- | A 2 [om | oe [BS [ ag [ter] | ewoeea [ ais | 100 | aTs20006- | sve | 222 | aTs20c08- | oe pee S| saz | 983 | 75 | 218 | eat i aa | 258 | aT=20008- | 3 | ane | amo | 4 | 355 | RIGOR |g Page 5 of 14ATS520JK ~ Cable Terminal Swaging Kit Operating and Maintenance Manual SWAGING DIES FOR DOUBLE SHANK BALLEND TERMINALS DIENUMBER CABLE DIA. TERMINAL REF. /__ATS20CDB-2 76 MS20663-2——_—| AT520CDB-3 3/32 ‘MS20663-3 AT520CDB-4 1/8. MS20663-4 ATS20CDB-5 5/32 MS20663-5 | AT520CDB-6 316 MS20663-6 | Note: Use these dies in pairs SWAGING DIES FOR SINGLE SHANK BALL END TERMINALS CABLE DIA. TERMINAL RE! EN | ATS20CSB-2 : i716 Ms20664-2 | he ! ATS20CSB-3 3/32 _ MS20664-3 | Ee, J ‘AT520CSB-4 118 MS20664-4 @. __ATS20CSB. 5/32 |ws20664-5 AT520CSB-6 316 Ms20664-6 | Se Note: Use these dies in pairs Figure 8 SWAGING DIES FOR BALL END TERMINALS sett DIE NUMBER CABLE DIA. TERMINAL REF. AT520CB-2 6 Hae RA2487 AT520CB-3 3/32_ RA2487 _ATS520CB-4 418 RA2487 * Manufactured by American Chain & Cable Company Note: Use these dies in pairs Figure 9 Page 6 of 14ATS20JK ~ Cable Terminal Swaging Kit Operating and Maintenance Manual CABLE CUT-OFF AND TRIM DIES = DIENUMBER CABLE DIA. ‘ATS20CD-2 1116 | ‘AT520CD-3 3/32 [ATS206P-3 ‘ATS20CD-4 118 ‘ATS20CP-4__| ‘AT520CD. 5/32 ‘ATS20CP-5 | ATS20CD-6 316 ATS20CP-6 __ATS20CD-7 732__| _ATS20CP-7_ [__aTs20cD-8 114 ATS20CP. ae) Note: AT520SP Spacer must be used with these dies. J See Figure 3, Page 3. Figure 10 SWAGING DIES FOR PLAIN BALL END TERMINALS. —— IN ALLE TERMINAL DIE NUMBER CABLEDIA, | DasH# a ‘ATS20CS-2 16 [ATs20C8-3__| 3/32 ] ‘ATS20CS-4 eer /ecaeeea acerca) ‘ATS20C8-5 | __5/32 =a '520C8-7 7132 A. AT520CS-8 1/4 0a Note: Use these dies in pairs ae AT520CS-6 36 6 | Note: TERMINAL REF. ms21259 Ms20667 Ms20668 Figure 11 Ms21260 Page 7 of 14ATS20JK — Cable Terminal Swaging Operating and Maintenance Manual 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 / caps 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 outined in Figure 12. 4, Remove the cap as show in Figure 13. 5. Remove Power unitas 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 wom parts as needed. 9 10. Reassemble as outlined on Page S Lubricate all internal working parts with special oll (See Figure 6, Page 4) 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 inthe 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 Figure 12 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: D0 not crush the housing in the vise ; Figure 13 Page 8 of 14ATS20JK — Cable Terminal Swaging Kit Operating and Maintenance Manual POWER UNIT REMOVAL. Alter 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, Figure 14 POWER UNIT BREAKDOWN 1. Refer to Figure 15 and parts reference drawing on = = - 2. Remove the song, eck ing and piston om the bere ANAMAND 7 VV J 3. Place the barelin vise. Use fas for clamping 4, Use a2" open-end wrench to remove the house from ees = Ms the barrel, turning counter-clockwise. >a ™ ta 5. Slide the valve assembly out of the barrel 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 ATS20C-18 pins into the yoke and install the AT429DR-6 rings (3 required). 3. Screw the yoke and housing together and tighten (See Figure 12). On the threads, use LOCTITE Grade AV-mil- 8.224738 ~ Federal Stock number 8030-08 1-237. * 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 ATS2CJP-2 saw tocth lock ring so that there is a full face to face engagement of at least one tooth in the ATS20CJP-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 ATS20CAH airline securely to the AT520C-3 Cap. 8. Allow the swager to impact against the dies for five minutes, 9. Restighten the entire thread assembly * THREADS MUST BE CLEAN AND DRY BEFORE APPLYING LOCTITE Page 9 of 14ATS20JK ~ 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 atter every forty hours of swaging. To service the filter, remove the housing as show in Figure 16 and pull out the cartridge. Wash the fiter in solvent and air blast the fiter clean, When reassembling, be sure the "O” ring is in the proper position é Figure 16 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 (ATS20CBP), 3. To check the swager, select a pair of ATS20DBC-5 dies. Clean the dies and apply a coat of light oll 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 3/8°1.D. hose. 7. Check the lubricator for oil (See Figure 6, Page 4), 8. Read and familiarize yourself wit the swager operating instruction 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 show in the chart of Page §, reject the power unit. IWIN CAUTION II! 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ATS20JK ~ Cable Terminal Swaging Kit Operating and Maintenance Manual Page 11 of 14ATS20JK ~ Cable Terminal Swaging Kit Operating and Maintenance Manual —CODE# | PART# | PARTNAME | #REQ| _ DESCRIPTION Manufacturer 1 ‘ATS20CDB Die 10 | Spec. Mfg. Part AT! 2 | ATS20CsB Die 10 | Spec. Mfg. Part Aql 3 ATS20CB Die 6 | Spec. Mfg. Part aTl 4 AT520CS Die 14 | Spec. Mfg. Part atl 5 ATS206P Die 7 | Spec. Mfg. Part ATI 6 AT520CD Die 7 | Spec. Mig. Part ATl 7 ATS20SP-2 “O° Ring + | aN6227-23 Standard 8 AT520SP-1 | Spacer 1 | Spec. Mfg. Part ATI 9 ATS20CKB-5 | Pad 1 | Spec. Mfg. Part ATI 10 ATBOOK-1 Pin 4 || We" Cotter Standard 1" ATS200KB-2 | Tray 1 | Spec. Mig. Part ATI 1 ATS20CKB-3 | Box 1 | Spec. Mig. Part ATI 7 1 | Spec. Mig. Part ATL 44 ATS20C-15 valve 1 | Roberts #50-3/8 IPS. DMs. “15 ~|ATS20/AH Hose 4 | Spec. mig. Part ATi -16 AT520JG Guard 1 | Spec. mig. Part ATI 7 ATSIOA-11 ‘O° Ring 3 | AN6227-3 Standard | “ | 2 | Spec. Mig. Part ATI ATS20C-9 Yoke 1 | Spee. Mfg. Part ATI 20 ‘AT520€-3 Cap 1 | Spec. mtg. Part atl -21 AT520C-4 “O" Ring 1 | aN6227-3 Standard -2 ATS20C-13 Quad Ring 1 | MRQi-a1s Standard -23 AT520C-5 “U" Packer 1 | AN6226-26 Standard 24 ATS20N-1 Housing 1 | Spec. Mfg. Part ATI 25 ATS20C-8 Spring 1 | Spec. Mig. Part ATi 26. AT520CJP-2 Lock Ring 1 | Spec. Mig. Part atl 2 ATS20BR-3 Piston 1 | Spec. mfg. Part aml | 28. ATS20CJP-1 Handle 1 | Spec. Mig. Part ATL 29" ‘ATS20BR-8 Cap 1 IRCO AT520BR-6 Sleeve 1 IRcO | | ATS208R-6 Collar 1 IRCO | 32 AT520BR-7 Pin | oa IRCO 33 ATS20BR-2 Barrel 1 IRCO 34 ATS20CBP-3 | Cushion 1 | Spec. Mfg. Part ATI | 35 ATS20CBP-5 | Nut 1 | AN364-820 Standard 36 AT520CBP-2 Pin 1 | Spec. Mig. Part aT! 37 ATS20CBP-1 Pad | 1 | Spec. Mig. Part AT 38 ‘AT520CBC, Cover 1 | Spec. Mfg. Part ATi 39 | ars20¢-18 Plug | 1 | Foster #40. FMC 40 ATS20FA-1 | Housing 1 | Spec. Mfg. Part ATI 41 ATS200-11 “O° Ring 1 | aNe227-17 Standard 42 ATS20FA-3 Cartridge 1 | Spec. Mfg. Part Tl 43 ATS20FA-2 Cap 1 | Spec. Mig. Part ATL 44 ‘ATS20C-20 ‘Chuck 1 | Foster #4104 FMC. | 45 ATS20CFC-7 | Oiler 1 | #1665 AEC. 46 AT225ALP-6 Nipple 2 | 1/4" Close Standard 47 ATS20CFC-3_| Pad | 4 | Spec’ mig. Part ATI Page 12 of 14ATS20JK ~ Cable Terminal Swaging Kit Operating and Maintenance Manual CoDE# PART# | PARTNAME | #REQ | _ DESCRIPTION 48 ‘ATS20GFC-4_| Hex Cap Screw 2 | SHe-1ex 12 49 ATS20CFC-1 | Guard 1 | Spec. Mfg, Part Standard 50? ATS20CFC-2_ | Vane 1 | Spec. Mfg, Part ATI ATS20CFC-28 | Snap Ring 2 | Ross #195166 | RAC ATS20CFC-2A | Pin 1 | Ross #80015 | RAC | ATS20GFC-2H | Treadle 1 | Ross #6002M2 RAG ATS20CFC-20 | Spring (1 | Ross #158013 RAG ATS20CFC-2G | Plug 2 | Ross #30011 RAG | ATS20CFC-2F | Gasket | 2 | Ross #60043 RAG ATS20CFC-2E | Spring 2 | Ross #6004 RAC ATS20CFC-2C | Poppetw/-O" Ring | 2 | Ross #6008 RAC No Number Body 4 | NoNumber RAC 60 ATS20SH Gauge 1 | Spec. Mfg, Part AT z Manufacturer's Codes a ATL ‘ATI Tools, Escondido, California DMs. Ducommun Metal & Supply, Los Angeles, California FMC. Foster Manufacturing Company, St Louis, Missouri ASC ASCO Sintering Company, Los Angeles, California | AEC Ato Equipment Company, Los Angeles, California RAC. Ralph Atkinson Company, Los Angeles, California | IRCO Ingersoll-Rand Compan BaEce General Notes: “Items 29 through 32 are not available as individual detailed components. The complete unit is available for purchase as Part Number ATS20BR. * Items 51 through 59 are not available as individual detailed components. The complete unit is available for purchase as Part Number ATS20CFC-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 4 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 ATS20BR-3 z g ATS20-SERIES Page 13 of 14ATS20JK ~ Cable Terminal Swaging Kit Operating and Mai SAFETY GUARD AT520JG ‘This Safety Guard is designed to prevent accidental injury Itaffords maximum protection without interfering with the operation of the Swaging Too! SWAGING GAUGE AT520SG This "GO" type gauge is designed to check all swaged terminals within the capacity of the ATS20J swager. Page 14 of 14