Power Swager Manual

and Thermoplastic Hose

Assembly Instructions

This manual contains information

necessary for the proper operation
of the Swagelok power swager and
assembly of thermoplastic hose
products. The manual must be read
and understood by the person(s)
responsible for the setup and the
use of this equipment.

Model MS-PSR-110
110V Single Phase/60 Hz

www.swagelok.com
Power Swager

Table of Contents Operator’s Safety Summary

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Operating Instructions for
Swagelok Power Swager . . . . . . . . . . . . . . . 4
READ AND UNDERSTAND THIS MANUAL BEFORE
USING POWER SWAGER. This device is electrically
powered and must be operated in a safe environment to
avoid risk of fire, explosion, or electric shock.

Assembly Procedures for

Swagelok Thermoplastic Hose
using Power Swager . . . . . . . . . . . . . . . . . . . 5

End Connections, Pushers, and

General Maintenance . . . . . . . . . . . . . . . . . .8 Safety Information
Troubleshooting . . . . . . . . . . . . . . . . . . . . . .9
! Caution!
Indicates cautionary information.

~ Warning! Pinch Points!

Keep hands, loose clothing, and long
hair away from rotating or moving parts.
Serious injury can occur.

F Warning! Electrical Shock.

Read all enclosed safety instructions
and manuals prior to operation.

a Warning! Keep Dry.

Equipment and components are not
waterproof.

G Warning! Fire or explosion.

Do not use equipment in a combustible
or explosive atmosphere.

l Warning! Eye protection.

Eye protection must be worn while
operating or working near the equipment.

p Warning! Ear protection.

Ear protection may be required if
operating or working near the equipment
for prolonged periods of time.

. Warning! Hot surface.

The surface temperature of the oil reservoir
and adjacent parts will increase during
normal use. The temperature increase
may be excessive if proper maintenance
is not performed.

2
 Power Swager
Overview
Power Swager Model MS-PSR-110

No. Description Part No. No. Description Part No.

01 Plug 11 Die detent pins 453C-23007
02 Trip rod 453C-22013 12 Pal nut 453C-23009
03 Trip rod collar 453C-22014 13 Spring plunger 453C-23013
04 Trip latch 453C-22015 14 Reservoir replacement kit 453C-40008
05 Trip latch eccentric 453C-22016 15 Switch toggle on/off 453C-41015
06 Die lifting guide arm 453C-22047 16 Hydraulic cylinder 453C-00012 453C-11009
with insertion depth block(s) 17 Decal, oil specification 0112-49016
mounting holes 18 Decal, name (Swagelok) —
06A Die lifting guide arm 453C-22036 19 Breather cap 453C-40010
07 Eccentric guide bushings 453C-22037 20 Valve handle 453C-40014
08 Thumb screw 453C-23004 21 Frame➀ 453C-24006
09 Die lifting finger R.H. 453C-23005 22 Manual control valve —
10 Die lifting finger L.H. 453C-23006 ➀ Frame consists of top bar, guide bars, pusher block, angle iron supports, and
die bowl.

J, L

16

1 19
13

11

12

Die
bowl
14
Angle iron
21 22 supports 4 7

3
Power Swager

Letter Description
A Bolt hex 1/4-24 UNC ⫻ 1.75 long
B Nut hex 1/4 UNC
C Lock washer 1/4 in.
D Bolt hex 5/16-18 UNC ⫻ 2.00 long
E Bolt hex 5/16-18 UNC ⫻ 1.50 long
F Nut hex 5/16-18 UNC
G Lock washer 5/16 in.
H Washer, flat 5/16 in.
I Washer, star 5/16 in.
J Bolt hex 1/2-13 UNC ⫻ 2.00 long
K Socket head cap screw
5/16-18 UNC ⫻ 1.00 long
L Lock washer 1/2 in.
Top bar 18

Guide bar Guide bar

Pusher
block
17

D, F, G, H
K

2 6

6A

15

20
A, B, C

5 10 Die bowl 9 E, F, G, I

4

Section I
Swagelok Power Swager
Operating Instructions
Note: The swager may be lifted by rigging a suitable fabric
sling around the guide bars and hydraulic cylinder below the
top bar.
! Caution
Do not lift or move the swager by its die lifting fingers,
arms, or hydraulic hoses.
Setup
1. Place the swager on a sturdy platform or table.
2. Position the swager so the die bowl clears the platform or
table to allow clearance for the moving parts of the swager.
3. Secure the swager with suitable fasteners through the bolt
holes located in the angle iron supports on the base of the
swager.
Electrical Requirements
■ The electrical requirements for the swager are as follows:
■ 110/220 V (ac)
■ 13/6 A
■ 1 phase 60 Hz, wired for 110 V
■ The swager must be grounded to guard against electrical
shock. The unit is equipped with a three-wire conductor and
three-prong plug to fit a grounded receptacle.
■ When turning on the swager unit for the first time, verify that
the motor is rotating in the direction of the arrow on the
motor.
■ A swager’s voltage can be changed from 110 to 220 V using
the wiring diagram on the inside of the switch cover. (It is
recommended that a qualified electrician perform this task.)
! Caution
Never connect the green or green/yellow wire to a live
terminal!
Breather Cap Installation
The breather cap is shipped in the bag attached to the swager.
1. Remove the plug from the oil reservoir. Note: Do not discard
the plug. To reduce loss of hydraulic oil through the breather
cap, reinstall the plug when shipping the swager or when
tilting it or placing it on its side.
2. Check the hydraulic fluid level. It should be 1 to 1 1/2 in.
(25 to 38 mm) below the breather hole. Note: The swager
is shipped with the proper type and amount of oil in the
reservoir. However, if additional fluid is required, it should be
equivalent to Mobil® D.T.E. 26 (325 SUS at 100°F, 37°C)
3. Install the breather cap.
! Caution
Do not operate the swager without the breather cap
in place.
! Caution
The motor should always be disconnected from the
power source whenever servicing the machine or
performing troubleshooting.
Power Swager
Valve Handle Installation
The handle is shipped in the bag attached to the swager.
1. Raise and secure the trip rod mechanism (2, 3, 4, 8,
and 12) out of the way of the swager.
Roll pin
Valve
stem
Valve handle
Roll pin hole
Note: The valve is on the left side of the swager.
2. Position the valve handle so that the hole is in line with the
roll pin in the valve stem. (See drawing above.)
3. Use a hammer to carefully tap the roll pin down through
the hole in the handle until the pin is flush with the top of
the stem.
Dies and Pushers
Use the chart in Section II to determine the proper dies and
pushers needed for each end connection. The dies have been
adapted to fit in the die lifting fingers on the swager.
Adjustment of the Automatic
Return Stop Position
1. Install the proper dies and pusher for the hose and end
connection desired.
2. Turn on the swager.
3. Pull the valve handle toward you to bottom the pusher onto
the dies.
4. Push the valve handle in the opposite direction, raising the
pusher.
5. Insert the hose and end connection assembly up between
the dies and so that it can be held in the pusher. Note: See
Section II for hose pre-assembly instructions.
6. Push or pull the valve handle so that the bottom of the end
connection shell is 3/4 to 1 in. (19 to 25 mm) above the top
of the dies.
7. Loosen the thumb screw on the trip rod collar.
8. Allow the trip rod collar and trip rod to descend to the low-
est position.
9. Tighten the thumb screw.
10. Remove the hose and connection.
11. Run the swager a full cycle to make sure the trip rod prop-
erly releases the valve handle.
The swager is now ready for use.
Note: Different sizes and types of hose and end connections
may require additional adjustments.
! Caution
Always adjust the trip rod collar so that the return
stop functions before the pusher block retracts into
the bottom of the cylinder. The swager may be
damaged otherwise.
5
Power Swager

Alignment of Dies in the Swager Die Bowl Proper Cut Improper Cut
The dies are aligned at the factory. However, if at any time the Hose Axis Hose Axis
Cut Plane Cut Plane
dies are not of equal height when seated in the die bowl, they
must be readjusted. To readjust the dies:
1. Loosen the four (4) mounting bolts on the die lifting fingers.
2. Push each die lifting finger assembly down as far as the bolt Cut Plane
holes will allow. Cut Plane

3. Turn on the swager. Cut is not square and

4. Pull the valve handle until the pusher bottoms on the dies,
leaving the pusher in contact with the dies.
5. Retighten the bolts.
Adjustment of Eccentric Guide Bushings
This adjustment is made at the factory. However, the eccentric
guide bushings may be readjusted if the dies are catching on
the top edge of the frame. To adjust:
1. Place the swager in the full downward position.
2. Locate the eccentric guide bushings on the lower outside
bars of the frame.
3. Loosen the mounting bolts.
4. Rotate the bushings counter-clockwise to tighten.
Note: The die lifting arms must slide freely.
Cut is square and perpendicular with hose axis.
perpendicular with hose axis.
End Connection Preparation
Remove all plastic caps, plugs, nuts, and ferrules prior to
swaging an end connection.
Inserting End Connections
1. Mark each hose end with the correct insertion depth.
2. Use the appropriate depth insertion gage:
■ MS-IGB-1 for 1/4, 3/8, and 1/2 in. hose.
■ MS-IGB-2 for 3/4 and 1 in. hose.
3. Insert hose until it bottoms out.
4. Mark the hose. Note: The bottom of the mark should line up
with the top of the insertion gage.

Section II depth insertion Proper Mark Position

Assembly Procedures for gage

Swagelok 7N, 7P, 7R, and 8R

Thermoplastic Hose using the
Power Swager Improper Mark Position
Pre-Assembly
1. Be sure the hose and all components are in good condition.
Note: The lead end of the hose should be cut squarely.
2. Verify that the swager is in proper working order as outlined
in Section I.
Cutting Bulk Hose 5. If acceptable for the application, apply a thin coat of clean,
1. Determine the desired hose and end connection size and SAE 20 weight lubricating oil to approximately the first 1/2 in.
type. (12 mm) depth of the hose ID.
2. Determine the desired hose assembly overall length.
! Caution!
3. See the End Connections and Pushers chart on page 8 to
determine the fitting cut-off length. Never use oil in 7P (poly pure) hose.
4. Subtract the desired fitting cut-off lengths from each end of
the hose assembly overall length. Note: The result is the
overall cut length.
5. Measure and mark the hose at the overall cut length.
6. Cut the hose squarely at the mark.

6
 Power Swager

6. Insert the hose into the end connection up to, but not past, Selecting Die Sets and Pushers
the insertion depth mark. Note: The bottom of the mark 1. Select the appropriate matched swaging die sets.
should line up with the edge of the shell.
Hose Size Die Set
in. Hose Series Number
Proper Insertion
1/4 7N, 7R, 8R, 7P MS-7R8R-4
shell
3/8 7N, 7R, 8R, 7P MS-7R8R-6

Improper Insertions 1/2 7N, 7R, 8R, 7P MS-7R8R-8

3/4 8R, 7P MS-8R-12
1 8R MS-8R-16
Not inserted enough
1 7P MS-7P-16

2. Select the correct pusher for the end connection type and
Inserted too far size. (See the End Connections and Pushers chart for the
correct pusher selection.)
Note: For end connections that do not appear in the chart,
If insertion is difficult, the following accessories may be contact your Swagelok sales representative.
required: 3. Secure the pusher in the swager.
■ Vise blocks (MS-VB-1 for 1/4, 3/8, and 1/2 in. hose
or MS-VB-2 for 3/4 and 1 in. hose)
■ Pusher
■ Vise
■ Rubber mallet
1. Clamp the vise block slot around the hose, leaving at least
twice the distance of the insertion depth mark exposed.
2. Insert the end connection into the hose.
3. Place the pusher over the end connection. (See the End
Connections and Pushers chart for the correct pusher
ordering number.)
4. Tap the pusher with the mallet to insert the hose into the
end connection up to, but not past, the insertion depth mark. ! Caution
Each die set consists of two matching halves, each
of which is stamped with the same identification
number. Failure to use matching die halves may result
in improper swaging, leading to hose failure. Die set
must match appropriate hose series and size.

Die Set and Fitting Lubrication

Before the initial swage, apply a light coat of lubricant to the
die halves. Note: The suggested lubricant is MS-TP-LUBE.

7
Power Swager

Lubricant Hints Swaging Process

Lubrication will increase die life and improve the shell’s surface 1. Verify that the hose is inserted properly into the end
appearance. Before using any lubricant, read all labels and connection.
instructions.
2. Insert the hose through the die halves and end connection
MS-TP-LUBE inside the pusher. Note: Make sure that the end of the
When applying MS-TP-LUBE on non-lubricated die sets, shell is 3/4 to 1 in. (19 to 25 mm) from the top of the die
apply a light coating to the entire surface of both die halves. If it is not, see Section 1, Adjustment of the
halves. Lubrication transferred from lubed swage shells Automatic Return Stop Position.
during the swaging process will keep the dies lubricated.
3. Begin the swaging process while applying upward force
Swage Shells on the hose. Note: The swaging process is complete when
When applying MS-TP-LUBE to swage shells, liberally the pusher bottoms on top of the die surfaces.
coat the bottom half of the external surface of the swage
shell.
! Caution
Do not pinch hose between die halves.

4. Return the swager to the starting position.

5. Remove the swaged hose.
6. Turn off the swager.
7. Measure the swage diameter and bell dimensions to verify
that the hose is assembled properly. Note: Measurements
must be within the limits listed in Table A.

Measuring
Insert lubricated die halves securely within the swager die Swage Diameter
Parting Line
fingers. Begin at a point between
1/4 to 1/2 in. (6 to 13 mm) Swage
from the end of the swage Diameter
Swager Start-Up shell and measure 360°
around the shell. Do not
~ Warning! measure at the parting lines.
Keep hands and fingers away from all moving parts
Measuring
Bell Length Bell
Manual Valve Handle Operation Length
Measure from behind the hex
1. Pull the control handle to start the swaging process. to the point where the bell
Note: The pusher block will move downward. stops or where the swage
2. Release the control handle to stop the swaging process. diameter ends.
3. Push the handle to return the swager to the full up posi- Table A
tion. Note: The trip latch, if adjusted properly, will automati-
cally disengage the swager. Hose
4. Turn on the swager. Size Hose Swage Diameter Bell Length
in. Type in. (mm) in. (mm)
5. Cycle the swager once or twice, stopping just before the
pusher makes contact with the die surfaces. 1/4 0.563 to 0.573 0.66 to 0.72
(14.2 to 14.5) (16.8 to 18.3)
6. Turn off the swager. 7N,
3/8 7R, 0.689 to 0.699
7. Verify that the dies are seated evenly and securely within 8R, (17.5 to 17.8)
the die base. Note: If the die halves are not aligned, see 7P
Section I, Alignment of Dies in the Die Bowl. 1/2 0.843 to 0.853 0.72 to 0.78
(21.3 to 21.6) (18.3 to 19.8)
8. Turn on the swager.
9. Cycle through a full swaging stroke. Note: If the die halves 8R, 1.155 to 1.170
3/4 7P (29.5 to 29.7)
are still not aligned, repeat steps 1 through 4.
10. Return the swager to the full up position. 1 8R 1.483 to 1.493 0.91 to 0.97
(37.6 to 37.8) (23.1 to 24.6)

1 7P 1.450 to 1.460 0.78 to 0.84

(36.8 to 37.1) (19.8 to 21.3)

8. Repeat the swaging process, steps 1 through 6, to complete

the hose assembly.
9. Verify that the hose meets overall length requirements.

8
 Power Swager
End Connections and Pushers

End Connection Cut-Off➁ Pusher

Hose Basic Length Ordering
Type Size, in. Size Ordering Number➀ in. (mm) Number
1/4 in. -TP4-TA4 MS-P-TA4
1/4 1.43 (36.3)
-TP4-TA6 MS-P-4TA6
3/8 in.

fractional
3/8 -TP6-TA6 1.50 (38.1) MS-P-TA6
1/2 in. -TP8-TA8 MS-P-SLTA8
1/2 1.79 (45.5)
5/8 in. -TP8-TA10 MS-P-8TA10
Swagelok
tube adapter 3/4 in. 3/4 -TP12-TA12 1.89 (48.0) MS-P-TA12
1 in. 1 -TP16-TA16 2.18 (55.4) MS-P-TA16
6 mm -TP4-TM6 MS-P-TA4
1/4 1.43 (36.3)

metric
8 mm -TP4-TM8 MS-P-4TM8
10 mm 3/8 -TP6-TM10 1.50 (38.1) MS-P-TA6
fractional 12 mm 1/2 -TP8-TM12 1.79 (45.5) MS-P-SLTA8
1/4 in. 1/4 -TP4-SL4 1.54 (39.1) MS-P-SL4
3/8 in. 3/8 -TP6-SL6 1.63 (41.4) MS-P-SL6
1/2 in. 1/2 -TP8-SL8 1.72 (43.7) MS-P-SLTA8
Swagelok 6 mm -TP4-SM6 1.54 (39.1) MS-P-SL4
tube fitting 8 mm 1/4 -TP4-SM8 1.55 (39.4) MS-P-4SM8
metric

-TP4-SM10 1.80 (45.7) MS-P-4SM10

10 mm
3/8 -TP6-SM10 1.64 (41.7) MS-P-SL6
12 mm 1/2 -TP8-SM12 1.74 (44.2) MS-P-SLTA8
1/4 in. 1/4 -TP4-AS4 1.59 (40.4) MS-P-AS4
37°
JIC/AN 37° 3/8 in. 3/8 -TP6-AS6 1.71 (43.4) MS-P-AS6
female swivel
1/2 in. 1/2 -TP8-AS8 1.77 (45.0) MS-P-AS8
1/4 in. 1/4 -TP4-BM4 1.42 (36.1) MS-P-BM4
60° male cone
60° female swivel 3/8 in. 3/8 -TP6-BM6 1.57 (39.9) MS-P-BM6
BSP/ISO parallel
1/2 in. 1/2 -TP8-BM8 1.67 (42.4) MS-P-BM8
30° 1/4 in. 1/4 -TP4-BS4 1.53 (38.9) MS-P-BS4
30° female swivel
BSP/ISO/JIS 3/8 in. 3/8 -TP6-BS6 1.69 (42.9) MS-P-BS6
parallel
1/2 in. 1/2 -TP8-BS8 1.81 (46.0) MS-P-BS8
14 mm 1/4 -TP4-MC14 1.35 (34.3) MS-P-MC14
Universal metric 18 mm 3/8 -TP6-MC18 1.46 (37.1) MS-P-MC18
female swivel
22 mm 1/2 -TP8-MC22 1.52 (38.6) MS-P-MC22
1/4 -TP4-PM4 1.25 (31.8) MS-P-PM4
1/4 in.
-TP6-PM4
Male NPT 3/8 1.34 (34.0) MS-P-PM6
3/8 in. -TP6-PM6
1/2 in. 1/2 -TP8-PM8 1.53 (38.9) MS-P-PM8
1/4 in. 1/4 -TP4-MT4 1.25 (31.8) MS-P-PM4
Male BSP/ISO 3/8 in. 3/8 -TP6-MT6 1.34 (34.0) MS-P-PM6
tapered (RT)
1/2 in. 1/2 -TP8-MT8 1.53 (38.9) MS-P-PM8
1/4 in. 1/4 -TP4-MS4 1.50 (38.1) MS-P-MS4
Male BSP/ISO
60° parallel (RS) 3/8 in. 3/8 -TP6-MS6 1.38 (35.1) MS-P-MS6
1/2 in. 1/2 -TP8-MS8 1.44 (36.6) MS-P-MS8
➀ For a complete ordering number, add SS for 316 stainless ➁ To determine the correct length of hose, subtract the cut-off length for each end connection from
steel or S for steel as a prefix to the basic ordering number. the overall length of the assembly. Lengths are for reference only, subject to change.

Section III
General Maintenance
■ After use, clean dies, pusher, and other swager
components with isopropyl alcohol to remove lubricant.
■ Periodically check the hoses for cuts, tears, or
bagginess in the outer cover. Replace any hose
assembly that has such damage.
■ Periodically check the oil reservoir fluid level. The oil should be
about 1 to 1 1/2 in. (25 to 38 mm) below the breather cap hole
when the machine is turned off (see Section II, Breather Cap
Installation).
■ Periodically check the mechanical moving parts on the swager.
Replace any parts that are bent, loose, or show excessive wear.
9
Power Swager
Section IV
Troubleshooting
Condition:
! Caution: Before performing any adjustments, make There is a gap or movement between
sure the power is turned off and properly locked out. the cylinder and frame. This gap is
caused by a loose cylinder mounting bolt.
If the swager begins producing improperly swaged connections: Solution:
■ Confirm that the assembly procedure is being followed. Tighten the cylinder mounting bolt until
Proper lubrication of dies and fitting shells is especially the gap is eliminated (as shown below).
critical. (Refer to Section II.)
■ Inspect the swage dies. Swage dies have a finite life.
Axial scratches on fitting shells after
swaging may indicate worn dies.

Condition:
There is a gap between the pusher block
and piston shaft. This gap is caused by
a loose socket screw within the pusher
block cavity. gap
Solution:
Tighten the socket head cap screw
within the pusher cavity until the gap
is eliminated (as shown below). Condition:
The die lifting arms do not pivot freely.
Solution:
Adjust accordingly per
instructions in Section I.
gap Condition:
The swage die halves are
uneven when they are seat-
ed in the base. (Improper
die alignment is shown
below.) Note: Die alignment
must be checked before the
pusher touches the dies.
Solution:
See Section I of this manual
for the proper adjustment.

Condition:
The dies have vertical wear
lines that appear as scratches.
Wear lines can be felt on the
finish of the swaged fitting and dies
Solution:
Replace dies.

Condition:
There is not proper clearance for the die
lifting arms to slide freely between the
eccentric guide bushings and the swager
frame during the full swaging cycle.
Solution:
See Section I of this manual for
adjustment instructions to obtain
proper clearance (as shown to the right).
10
Power Swager

11
Warning
The Swagelok power swager is designed expressly for
swaging Swagelok end connections and hose using the
appropriate Swagelok dies and pushers. Swagelok Company
cannot be responsible for property damage or personal injury
that may result from swaging other brands of end connections
and hose, nor from the intentional misuse of the swager.
Swagelok—TM Swagelok Company
Mobil—TM Mobil Oil Corporation
© 2001 Swagelok Company
Printed in U.S.A., GLL
April 2001, R0
MS-13-144