PERMASWAGE TUBE SOP6-01-05

CONNECTING SYSTEM
INSTALLATION AND REV.: N
INSPECTION MANUAL
(OPEARATING PRESSURE: DATE:
0-3,000 PSI) E.O. # 191135
2/26/2015

A PCC COMPANY 

PERMASWAGE® TUBE CONNECTING SYSTEM

INSTALLATION AND INSPECTION MANUAL

(OPERATING PRESSURE: 0 – 3,000 PSI)

NOTICE: The information contained in this document is the property DMC Inc., dba Permaswage USA and may not be
transmitted, reproduced or disclosed without the explicit written authorization of Permaswage.
Printed copies of this document are uncontrolled and are for reference only.
 PERMASWAGE TUBE SOP6-01-05
CONNECTING SYSTEM
INSTALLATION AND REV.: N
INSPECTION MANUAL
(OPEARATING PRESSURE: DATE:
0-3,000 PSI) E.O. # 191135
2/26/2015

REVIEWED AND APPROVED BY:

NAME TITLE SIGNATURE DATE

May Danhash Dir. Engineering Signature on file 3/2/2015

George Teets Dir. Sales & Marketing Signature on file 3/2/2015

Gil Sassoon Dir. Quality Assurance Signature on file 3/11/2015

SOP6-01-05
REV: N
NOTICE: The information contained in this document is the property DMC Inc., dba Permaswage USA and may not be
transmitted, reproduced or disclosed without the explicit written authorization of Permaswage.
Printed copies of this document are uncontrolled and are for reference only.
TABLE OF CONTENTS

REVISION CHANGE SUMMARY...................................................................................................................1

1.0 INTRODUCTION.....................................................................................................................................7
1.1 REFERENCE DOCUMENTS............................................................................................................7
1.2 OTHER PERMASWAGE MANUALS................................................................................................7
2.0 PURPOSE...............................................................................................................................................7
2.1 TRAINING AND CERTIFICATION....................................................................................................8
3.0 DESCRIPTION OF EQUIPMENT...........................................................................................................8
4.0 SUMMARY OF OPERATION..................................................................................................................8
5.0 PREPARATION FOR SWAGING...........................................................................................................8
5.1 CHECK SIZES AND MATERIALS....................................................................................................8
5.2 TUBE CONDITION PRIOR TO INSTALLATION..............................................................................9
5.3 CUT TUBE (IF NEEDED)..................................................................................................................9
5.4 DEBURR TUBE.................................................................................................................................9
5.5 MARK INSERTION DEPTH ON TUBE.............................................................................................9
6.0 OPERATING INSTRUCTIONS FOR SWAGE TOOLING....................................................................10
6.1 DLT PRE-SWAGE INSPECTION PROCEDURE...........................................................................10
6.2 PREPARATION OF TOOLING.......................................................................................................11
6.3 SWAGE CONNECTION..................................................................................................................11
6.4 REMOVE TOOLING........................................................................................................................11
7.0 INSPECTION OF SWAGED CONNECTION........................................................................................12
8.0 TUBE REPAIR TECHNIQUES..............................................................................................................12
8.1 TYPE 1 – SMALL HOLE OR SHORT CRACK IN TUBE................................................................13
8.2 TYPE 2a – LENGTHWISE CRACK IN TUBE (CRACK LONGER THAN 0.30”).............................14
8.3 TYPE 2b – LENGTHWISE CRACK IN TUBE.................................................................................15
8.4 TYPE 3 – LEAKING TUBE OR FITTING ASSOCIATED WITH ELBOW, TEE, OR CROSS.........16
8.5 TYPE 4a – DAMAGED TUBE OR END FITTING (FLARED, FEMALE).........................................17
8.6 TYPE 4b – DAMAGED TUBE OR END FITTING (FLARELESS, FEMALE)..................................18
8.7 TYPE 4c – DAMAGED END FITTING (LIPSEAL, FEMALE, -3 THROUGH -16)...........................19
8.8 TYPE 4d – DAMAGED END FITTING (LIPSEAL, FEMALE, -20 AND -24)...................................20
8.9 TYPE 4e – DAMAGED END FITTING (LIPSEAL, FEMALE, REDUCER)......................................21
8.10 TYPE 4f – DAMAGED END FITTING (LIPSEAL, MALE ADAPTER............................................22
9.0 FREQUENTLY ASKED QUESTIONS...................................................................................................23
10.0BASIC MAINTENANCE........................................................................................................................24
10.1 INSPECTION AND CLEANING OF TOOLING.............................................................................24
10.2 STORING EQUIPMENT AFTER USE..........................................................................................24
10.3 HOW TO REPLACE CUTTER WHEEL OF TUBE CUTTER.......................................................24
11.0TROUBLESHOOTING..........................................................................................................................25
12.0SAFETY PRECAUTIONS.....................................................................................................................25
13.0RETURN OF TOOLING FOR EVALUATION OR REPAIR..................................................................26
14.0QUALITY ASSURANCE FOR SWAGE TOOLING...............................................................................26

i SOP6-01-05
REV: N
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reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
TABLE 1, MAXIMUM GAP LENGTH FOR EXTENDED LENGTH PERMASWAGE®................................15
TABLE 2, CUT-OFF LENGTHS FOR FLARED, FEMALE...........................................................................17
TABLE 3, CUT-OFF LENGTHS FOR FLARELESS, FEMALE....................................................................18
TABLE 4, CUT-OFF LENGTHS FOR LIPSEAL, FEMALE...........................................................................19
TABLE 5, CUT-OFF LENGTHS FOR LIPSEAL, FEMALE, REDUCER.......................................................21
TABLE 6, RECOMMENDED FITTING/ TUBE MATERIAL & WALL THICKNESS COMBINATIONS.........27
TABLE 7, DLT TOOL KITS...........................................................................................................................28
TABLE 8, MINIMUM STRAIGHT LENGTH REQUIRED BEFORE BEND...................................................30
TABLE 9, DEBURRING TOOL AND STEM ASSEMBLY.............................................................................31
TABLE 10, MAKING INSERTION MARKS WITHOUT INSERTION MARKING TOOL...............................32
TABLE 11a, FIRST GENERATION POWER UNIT, HEAD ASSEMBLY, DIE.............................................33
TABLE 11b, SECOND GENERATION POWER UNIT, HEAD ASSEMBLY, DIE........................................33
TABLE 11c, FIRST GENERATION DLT END PLATES AND SCREWS.....................................................34
TABLE 11d, SECOND GENERATION SHROUDS......................................................................................34
TABLE 12, INSPECTION GAUGE...............................................................................................................35
TABLE 13, TUBE CUTTER, SPARE CUTTER WHEEL, & MISC. COMPONENTS....................................36
TABLE 14, 10,000 psi HYDRAULIC PUMP KITS........................................................................................36
FIGURE 1, TYPE 1 REPAIR........................................................................................................................13
FIGURE 2, TYPE 2a REPAIR......................................................................................................................14
FIGURE 3, TYPE 2b REPAIR USING EXTENDED LENGTH PERMASWAGE®.......................................15
FIGURE 4, TYPE 3 REPAIR........................................................................................................................16
FIGURE 5, TYPE 4a REPAIR......................................................................................................................17
FIGURE 6, TYPE 4b REPAIR......................................................................................................................18
FIGURE 7, TYPE 4c REPAIR.......................................................................................................................19
FIGURE 8, TYPE 4d REPAIR......................................................................................................................20
FIGURE 9, TYPE 4e REPAIR......................................................................................................................21
FIGURE 10, TYPE 4f REPAIR.....................................................................................................................22
FIGURE 11, MINIMUM STRAIGHT LENGTH..............................................................................................30
FIGURE 12, DEBURR TOOL.......................................................................................................................31
FIGURE 13, INSERTION MARKING TOOL.................................................................................................32
FIGURE 14, INSPECTION GAUGE.............................................................................................................35
FIGURE 15, TUBE CUTTER........................................................................................................................36
FIGURE 16a, FIRST GENERATION HEAD ASSEMBLY, LOWER DIE/HOLDER ASSEMBLY AND POWER
UNIT.............................................................................................................................................................37
FIGURE 16b, SECOND GENERATION HEAD ASSEMBLY, LOWER DIE/HOLDER ASSEMBLY AND
POWER UNIT...............................................................................................................................................37
FIGURE 17, USING INSPECTION GAUGE.................................................................................................38

ii SOP6-01-05
REV: N
Notice – Designed Metal Connections (DMC) dba Permaswage claims proprietary rights in the Information disclosed hereon. This document may not be
reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
 REVISION CHANGE SUMMARY
DOCUMENT NUMBER: SOP6-01-05
DATE ECO NO. REV. DESCRIPTION OF CHANGE
04/26/89 124957 — RELEASED FOR USE.
07/12/90 127003 A Revised Table 4 to add newly assigned national stock numbers.
02/25/99 138182 B Entire document reformatted.
Table 10:
IS WAS

LENGTH "B" LENGTH "B"

+/- .005

DIAMETER "A" DIAMETER "A"

+/- .005

D12-9892-06 D12-9892-06
LENGTH "B" LENGTH "B"
.584 .530
Added Para. 5(a); DLT preswage inspection procedure.
Added Swage Lube application to Para.9.1.
Added Appendix 1; MSDS.
05/14/03 152376 C Entire document reformatted.
Added Para 1.1, reference documents.
Added repair type 2b, for repair using extended length PermaSwage®.
Updated all figures.
Corrected Table 1.
Replaced Table 3, select fitting size With DLT tool kits and DLT tool field repair
kits table
Replaced Table 4 with Table 5; added Skydrol stem assemblies to Table 5.
Replaced Table 8 with Table 7; added power unit, head assembly, die, end
plates, and screw to Table 7.
Combined Table 9 with Table 10.
Added Table 9 tube cutter, spare cutter wheel, & misc. components
Deleted Appendix 1; MSDS swage lube.
08/05/03 152665 D 1.1, Reverence Documents, Item 6 Is: SOP6-01-10, Was SOP604-025.
Para. 6.1, item 10 Is: …If using a pneumatic pump the pump inlet air pressure
should be 80 – 100 psi. Was:…and the pump inlet air pressure is at least 80 –
100 psi.
Table 7, Die Is: DLT05PSDI3003 Was: DLT05PSDI3103
DLT05PSDI3004 Was: DLT05PSDI3104
DLT10PSDI3005 Was: DLT10PSDI3105
DLT10PSDI3006 Was: DLT10PSDI3106
DLT20PSDI3008 Was: DLT20PSDI3108
DLT20PSDI3010 Was: DLT20PSDI3110
DLT30PSDI3012 Was: DLT30PSDI3112
DLT40PSDI3016 Was: DLT40PSDI3116
DLT40PSDI3020 Was: DLT40PSDI3120
DLT40PSDI4024 Was: DLT40PSDI3124
Table 8, Shift Fitting Size up one row and add –24.
Table 8, added “-“ to Permaswage Number for –08 thru -24

Form 8-008

SOP6-01-05
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 REVISION CHANGE SUMMARY (CON’T.)
DOCUMENT NUMBER: SOP6-01-05
DATE ECO NO. REV. DESCRIPTION OF CHANGE
09/11/03 153153 E Table 1, Deleted 304L or 316L CRES fitting mat’l and compatible tubing mat’l.
Table 1, Added note to reference SOP604-024 for 304L or 316L CRES fitting
mat’l and compatible tubing mat’l.
08/31/04 155988 F Para 1.1, IS: SOP604-006 SOP604-006 Soft Permaswage® Tube Connecting
System Installation and Inspection of D90000 Series WAS: SOP604-006
SOP604-006 Metric Permaswage® Tube Connecting System Installation
TABLE 1 IS: CANCELLED AND COMBINED WITH TABLE 2
TABLE 2:ADDED COLUMN FOR FITTING MATERIALS, MATERIAL
SPECIFICATIONS & UPDATED
TABLE 8,"B" IS:±.003 WAS:±.005
TABLE 9 IS: ¾” WAS: 7/8”
TABLE 9 IS: 7/8” WAS: 1”
TABLE OF CONTENTS, FIGURE 11, IS: MINIMUM STRAIGHT LENGTH; WAS:
TUBE CUTTERS & MISC. COMPONENTS
FIGURE 11, ADD Heading: MINIMUM STRAIGHT LENGTH
ADDED Para 5.2 “Tube Condition Prior to Installation…”
IS: PARA 5.3, 5.4, and 5.5 WAS: PARA 5.2, 5.3 and 5.4.
Section 5.1-1 IS: Table 2 WAS: Table 1
FIGURE 1,Added D10036 (-06 thru –16); D10136 (-20 and –24)
TABLE 14, IS: End 1 (Separable End) WAS: End 1

01/04/05 158316 G Para 8.3, Item 1, IS:”…required…” WAS:”…maximum…”

Table 10, Column Heading IS: “Req. Gap Length”;
WAS: “Max Gap Length”
Table 2, 21-6-9 fitting mat’l, 6061-T6 Tube mat’l, 1,500 psi, Size –20, IS: .065
WAS: .032
Table 7, All Sizes, Screw, Socket Head, Flat IS: DLT91253
WAS: MS24671-1
Table 7, Size –16, End Plates, IS: DLT40PS… WAS: DLT30PS…

06/13/06 165021 H Para 1.0, Added to caution statement “D98”

Re-sequence Tables: TABLE 1 WAS: TABLE 10; TABLE 2 WAS: TABLE 11;
TABLE 3 WAS: TABLE 12; TABLE 4 WAS: TABLE 13; TABLE 5 WAS: TABLE
14; TABLE 6 WAS: TABLE 2; TABLE 7 WAS: TABLE 3; TABLE 8 WAS:
TABLE 4; TABLE 9 WAS: TABLE 5; TABLE 10 WAS: TABLE 6; TABLE 11
WAS: TABLE 7; TABLE 12 WAS: TABLE 8; TABLE 13 WAS: TABLE 9
TABLE 6 Alum fitting, 6061-T6 Tube, 1000 psi, Deleted: .020 wall (Size –03),
.028wall (Size –05)
TABLE 6 C.P. Ti fitting, 3AL-2.5 V Tube, 3000 psi, Deleted: .016 wall (Size –03)
TABLE 6 C.P. Ti fitting, 3AL-2.5 V Tube, 2000 psi, Deleted: .022 wall (Size –05),
.020, .022 wall (Size –06), .020, .023 wall (Size –08), .023, .027 wall (Size –10),
.027, .032 wall (Size –12)
TABLE 6 21-6-9 CRES fitting, 21-6-9 CRES Tube, 3000 psi, Deleted: .016 wall
(Size –05), .032 wall (Size –10), .063 wall (Size –20)

Form 8-008

SOP6-01-05
2 of 38
Notice – Designed Metal Connections (DMC) dba Permaswage claims proprietary rights in the Information disclosed hereon. This document may not be
reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
REV: N
 REVISION CHANGE SUMMARY (CON’T.)
DOCUMENT NUMBER: SOP6-01-05
DATE ECO NO. REV. DESCRIPTION OF CHANGE
06/13/06 165021 H TABLE 6 21-6-9 CRES fitting, 21-6-9 CRES Tube, 2000 psi, Deleted: .054 wall
(Con’t) (Size –24)
TABLE 10, IS NOTE …Boeing Commercial applications; WAS NOTE …Boeing
applications…
TABLE 11, IS …Boeing Commercial applications. ; WAS …Boeing applications.
TABLE 11, ADDED NSN for DLT30PSKT3000, DLT40PSKT3002,
DLTFRPSKT3000, & DLTFRPSKT3009
TABLE 11, DELETED NSN for DLT30MAPSKT3000, & DLT40MAPSKT3000
TABLE 11, NSN for DLTFRPSKT3014 IS: 4920-01-514-8009; WAS: 5180-
P902089-2027
ADDED Proprietary document notice to each page
IS Designed Metal Connections; WAS Deutsch Metal Components
ADDED to Para 14.0 Caution statement and photos

10/28/10 176758 J Para 1.0, IS: THIS MANUAL APPLIES TO THE USE OF DMC PERMASWAGE DLT TOOLING
FOR INSTALLATION OF DMC PERMASWAGE FITTINGS WHOSE…; WAS: CAUTION:
THIS INFORMATION APPLIES ONLY TO DLT TOOLING AND FITTINGS WHOSE…
ADDED: in Para 1.0: NOTE: IN ALL CASES THE OEM’S INSTALLATION AND
MAINTENANCE SPECIFICATION TAKES PRECEDENCE. CONSULT THE OEM OR DMC TO
CLARIFY ANY VARIATIONS.
Added §1.2, OTHER PERMASWAGE MANUALS, with respective documents;
Para. 4.0, SUMMARY OF OPERATION,
Is, ‘…and then deburred.’
Para 5.2, Deleted: In all cases the O.E.M.’s installation and maintenance
specification take precedence.
Para 6.1, Step 2 IS: The Upper and Lower dies should have the same serial
number (a matched set). WAS: The two halves must be a matched set.
Para 6.1, Step 11 IS: Ensure that the two ends of the tubes being connected, or
a tube end being connected to a separable joint, are aligned without applying an
excess tube preload. Limit the tube offset to a maximum of ½” per 12” of tube
length from Union to Clamp. WAS: Ensure that the two ends of the tubes being
connected, or a tube end being connected to a separable joint, are aligned
within a reasonable amount;
Para. 6.2, Item 17:
Was, ‘portable’, Is ‘DMC’ and added ‘See Table 14);
Para 8.1 Step 1 IS: Check to assure that there is enough space available to
operate the swage tool.
Step 2 WAS: Step 1, & Step 3 WAS: Step 2
Para 8.2 Step 1 IS: Check to assure that there is enough space available to
operate the swage tool.
Step 2 WAS: Step 1; Step 3 WAS: Step 2, & Step 4 WAS: Step 3
Para 8.3 Step 1 IS: Check to assure that there is enough space available to
operate the swage tool.
Step 2 WAS: Step 1; Step 3 WAS: Step 2, & Step 4 WAS: Step 3
Step 2 IS: …for the maximum allowed tube gap between the tube…WAS: …for
the required gap length…

Form 8-008

SOP6-01-05
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reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
REV: N
 REVISION CHANGE SUMMARY (CON’T.)
DOCUMENT NUMBER: SOP6-01-05
DATE ECO NO. REV. DESCRIPTION OF CHANGE
10/28/10 176758 J Table 1 IS: Max Gap Length, WAS: Req. Gap Length; -04 IS: 2.55 WAS: 2.25; -
05 IS: 2.62 WAS: 2.25; -06 IS: 2.70 WAS: 2.25; -10 IS: 3.80 WAS: 3.70; -12 IS:
4.00 WAS: 3.70
Para 8.4 Step 1 IS: Check to assure that there is enough space available to
operate the swage tool.
Step 2 WAS: Step 1; Step 3 WAS: Step 2, & Step 4 WAS: Step 3
Para 8.6, Step 1: IS: Cut off the flareless end …WAS: Cut off the flared end …
Para 9.0, Item 2: IS: … weep or leak, first verify the original swage with the after
swage inspection gauge, and then re-swage the fitting and check gauge again.
The leakage will often be stopped by swaging the fitting again. WAS: … weep
or leak, the leakage will often be stopped by swaging the fitting again.
IS: www.permaswage.com WAS: www.dmcusa.com
Para. 10.0:
Was ‘…Tools, and DMC-1320, DLT Preventive Maintenance’;
Is, ‘Swage Head Assembly, and SOP604-030, Permaswage® DLT Maintenance
Procedure and Service Schedule’;
Para. 13.0, Was AS9100, Rev. A, Is AS9100;
Table 7, DLTFRPSKT3009: ADDED tube size –05
Table 9, DELTED Footnote 2: (2) Replaced footnote (3) with footnote (2)
Size 1-1/4, IS: D9757-13-20; WAS: D9857-13-20
Size 1-1/2, IS: D9757-13-24; WAS: D9857-13-24
Table 11, Size –24, ADDED Footnote 2: (2) Use DLT40PSHA4024A,
DLT40PSDI4024A for Airbus applications
Table 13, IS: 3/16" through 3/8"; WAS: 1/4" through 3/8";
Added Table 14, 10,000 psi Hydraulic Pump Kits;
Deleted from Table 6 .020” titanium tube for size 05 (21-6-9 fitting)
09/30/13 188283 K Added columns PLT Tools, Permaswage Number, National Stock Number to
Table 7.
Table 6.
Added Tube wall thickness for all materials to conform with DMC test
compilation data in DMC-1841. DMC-1900 & DMC-1901
Table 6.
Added Tube wall thickness for AL fitting with AL Tube at 1,000 psi 035
Added Note: * This tube wall is qualified with D10609D06 and D10611D06 for
1000 Psi only. Other shapes are qualified for 1500 Psi operation pressure.
Para 6.1 Step 6 is: Part of the insertion mark must be visible with the fitting in
place. Was: Part of the insertion mark must be visible with the fitting is in place.
Para 6.1 Step 12 is: When B-nuts are involved, tighten the B-nuts first, and then
perform the swage in the preferred sequence. Was: When B-nuts are involved
tighten the B-nuts first, and then perform the swage is the preferred sequence.
Para 6.1 Step 10 is: Verify that the needle on the gage is in the green band
(9,800 to 10,400 psi) when the pump is pressurized. Was: Verify that the
pump develops 10,000 ± 250 psi hydraulic pressure.
Para 6.2 Step 13 is: Select proper power unit and head assembly based on tube
OD (See Table 11a-d). Was: Select proper power unit and head assembly
based on tube OD (See Table 11).
Form 8-008

SOP6-01-05
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reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
REV: N
 REVISION CHANGE SUMMARY (CON’T.)
DOCUMENT NUMBER: SOP6-01-05
DATE ECO NO. REV. DESCRIPTION OF CHANGE
09/30/13 188283 K Table 7 foot note is: DLT and PLT Tool Kits contain swage tools, marking
templates and inspection gauges for each size listed. Also included are tube
cutters, de-burring tools with stem assemblies, a hex key and marking pen. For
DLT and PLT Tool Kits not listed, contact Designed Metal Connections. Was:
DLT Tool Kits contain swage tools, marking templates and inspection gauges
for each size listed. Also included are tube cutters, de-burring tools with stem
assemblies, a hex key and marking pen. For DLT Tool Kits not listed, contact
Designed Metal Connections.
Table 7 foot note is: Note: DLTFRPSKTF*** and PLTFRPSKTF*** Contains NO
tools. Was: Note: DLTFRPSKTF*** Contains NO tools.
Table 11 is: split into first and second generation tooling configurations with a
Table 11a, 11b, 11c, 11d. Was: first generation only.
Figure 16 is: Figure 16a FIRST GENERATION HEAD ASSEMBLY, LOWER DIE
BLOCK ASSEMBLY AND POWER UNIT. Was: Figure 16 HEAD ASSEMBLY,
LOWER DIE BLOCK ASSEMBLY AND POWER UNIT.
Added Figure 16b SECOND GENERATION HEAD ASSEMBLY, LOWER DIE
BLOCK ASSEMBLY AND POWER UNIT.
Updated Figure 17 to show insertion mark in correct location.
Para 6.2 step 17 is: Connect one end of the hydraulic hose to the DMC hydraulic
pump (See Table 14). Was: Connect one end of the hydraulic hose to the DMC
hydraulic pump. Make sure pump delivers 10,000 ± 250 psi (See Table 14).
Para 6.3 step 23 is: Apply hydraulic pressure (9,800 to 10,400 psi) to the
swage tool. Keep the power unit, fitting, and tube in the positions described in
steps 19 and 22 of 6.2. Was: Apply hydraulic pressure (10,000 ± 250 psi) to the
swage tool. Keep the power unit, fitting, and tube in the position described in
steps 19 and 22 of 6.2.
Updated Table of Contents to reflect changes.
Para 9.0; step 1, added “…to a maximum 3 times…”
Trouble Shooting Table Possible Cause is: Pump not supplying 9,800 to 10,400
psi to swage tool. Was: Pump not supplying 10,000 +/- 250 psig to swage tool.
Figure 17 has been redrawn to fix error in positioning mark.

02/25/14 189224 L Updated Footnote

Updated table of contents to include sub-sections and corresponding page
numbers
Updated Table 6 to include: .027” wall for size -12 1,000 psi 3AL-2.5V tubing and
.028” wall for size -16 1,000 psi 3AL-2.5V tubing
Deleted section 14.0 Warranty Information. Moved the CAUTION text and
corresponding images to appear after section 6.4 Remove Tooling.
Added flag note reference (1) in Table 11a (Column DIE) to die P/N
DLT40PSDI3016.
Revised Note (1) under Table 11a to add DLT40PSDI4016 for Boeing
commercial applications.
09/05/14 190227 M Added CE marks to para 2.1, 6.0, 6.2, 6.4
Added (676 to 717 bar) to para 6.1.10, 6.3 & 11.0
Added para 12.0 Safety Precautions
IS para 13.0 Return of tooling for Evaluation or Repair WAS para 12.0
IS para 14.0 Quality Assurance for swage tooling WAS para 13.0

SOP6-01-05
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reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
REV: N
 REVISION CHANGE SUMMARY (CON’T.)
DOCUMENT NUMBER: SOP6-01-05
DATE ECO NO. REV. DESCRIPTION OF CHANGE
2/26/2015 191135 N IS para 7.0, 3. Remove gauge. Rotate gauge 90°, and repeat step 2 above.
NOTE: If inspection gauge does not fit properly over the swaged fitting, rotate
fitting 30° - 90° from the first swage position and reswage the fitting. If
dimensions of swaged fitting are still not satisfactory, contact your Designed
Metal Connections representative for assistance.
IS Table 13, Hex Key DLT5103-104-00
Table 7 corrected Permaswage Number: IS: PLT06, PLT11, PLT21, PLT31,
PLT41 WAS:PLT05, PLT10, PLT20, PLT30, PLT40
Table 11b, Added note: (3) Use DLT41PSHA4016, DLT41PSDI4016 for Boeing
Commercial applications.

Form 8-008

SOP6-01-05
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reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
REV: N
 SOP6-01-05
®
PERMASWAGE TUBE CONNECTING SYSTEM
INSTALLATION AND INSPECTION
(OPERATING PRESSURE 0 - 3000 PSI)

1.0 INTRODUCTION
The Permaswage® system is a tube connecting system that mechanically attaches a Permaswage®
fitting to a tube by radial swaging. The system is used to make permanent and separable
connections between metal tubes. It works by deforming the metal fitting onto a tube radially, 360°
around the circumference, using the DMC Lightweight Tool (DLT). The interference between the
fitting and tube produce a leak resistant seal that is structurally sound. This system can be used to
produce new tubing systems, or to repair existing ones. Because the system is portable, it can be
used in the field as well as at the user's facility.

THIS MANUAL APPLIES TO THE USE OF DMC PERMASWAGE DLT TOOLING FOR INSTALLATION OF DMC PERMASWAGE
FITTINGS WHOSE PART NUMBERS BEGIN WITH "D10", "D11", "DD0", "D20", "DFL", "D98” OR "DLG". IF YOU ARE
UNSURE AS TO WHETHER THIS IS THE CORRECT PERMASWAGE® MANUAL TO USE, CONTACT DESIGNED METAL
CONNECTIONS AT (800) 338-8724.

NOTE: IN ALL CASES THE OEM INSTALLATION AND MAINTENANCE SPECIFICATION TAKES PRECEDENCE. CONSULT THE
OEM OR DMC TO CLARIFY ANY VARIATIONS.

1.1 REFERENCE DOCUMENTS

1) MCP-016 Inspection Criteria of DLT Series Swage Head Assembly
2) SOP604-030 Permaswage® DLT Maintenance Procedure and Service Schedule
3) SOP604-005 Operating Instructions for DLT05MAPM1000 Manual Pump
4) SOP6-00-10 Operating Instructions Air Driven Pump
5) SOP604-029 Portable Electric Pump Operating Instructions

1.2 OTHER PERMASWAGE MANUALS

1) SOP604-006 Soft Permaswage® Tube Connecting System Installation and Inspection of
D90000 Series
2) SOP604-024 Soft Permaswage® Tube Connecting System Installation and
InspectionD80000 Series
3) SOP6-01-10 Permaswage® Tube Connecting System Installation and Inspection,
DNR Series (Operating Pressure 4,000 – 5,000 PSI)

2.0 PURPOSE
This manual contains instructions for using the Permaswage® Tube Connecting System. It explains
how to use DLT series swage tool kits to swage DMC Permaswage® fittings. This manual applies to
fittings rated up to 3,000 psi. Basic maintenance instructions for the tool kits are also included.

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 2.1 TRAINING AND CERTIFICATION
The equipment in this system should only be used by personnel who have received factory
authorized training and were certified in its use.
The training and certification are both supplied (at no cost) by DMC representatives for customers
who procure tools through DMC, its authorized distributors and agencies. The certification
consists of a DMC Level "A" Training card, issued to those who have received the training. This
training can be provided at the customer's work site at no additional charge.

CAUTION:
THE EQUIPMENT IN THIS SYSTEM IS SUBJECTED TO EXTREMELY HIGH PRESSURES DURING SWAGING.
IMPROPER USE MAY RESULT IN TOOL FAILURE OR PERSONAL INJURY. THE EQUIPMENT DESCRIBED IN
THIS MANUAL SHOULD BE USED ONLY BY QUALIFIED PERSONNEL IN POSSESSION OF A DMC LEVEL "A"
TRAINING CARD.

3.0 DESCRIPTION OF EQUIPMENT

The system consists of a hydraulic pump and tool kit containing the swage tool and other
accessories. There are several different tool kits. Each one is used for swaging a different range of
fitting sizes within a particular pressure limit.

4.0 SUMMARY OF OPERATION

The operation starts by preparing the tube. The tube to be connected is cut, and then deburred.
The installation depth is properly marked and the chosen fitting is placed on the tube. Next, the
swage tool is placed so it surrounds the fitting. The swage tool is then activated by pressure from a
pump. This causes the swage tool to radially compress the fitting and tube. Enough pressure is
applied to swage the fitting onto the tube. The swaged connection is then inspected.

5.0 PREPARATION FOR SWAGING

5.1 Check Sizes and Materials
1.
Check material compatibility between tubing and fittings. (See Table 6)
2.
Check for satisfactory thickness of tube walls, based on tube OD, material, and system/line
operating pressure. (See Table 6)
3. Select fitting size, based on tube OD.
4. Select tool kit, based on tube OD and system/line pressure.
(See Table 7 or Table 8)
5.2 Tube Condition Prior to Installation
The tube should be clean from any paint or other foreign material (Swaging is permitted on Alodine
finish).
There should not be any flat spots, scratches and/ or nicks on the tube.
Cleaning operation on the O.D. of the tube can take place prior to installation. Lightly clean the
tube with a rag or Scotch Bright, provided that in all cases the area of the swage remains within
the tube tolerance.

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 5.3 Cut Tube (If Needed)
NOTE: A minimum length of straight tube (before a bend) is required to produce a
satisfactory swaged connection. (See Table 8)
5. Mark cutting point on tube.
6. Retract cutting wheel of tube cutter by turning drive screw counter-clockwise. Use
screwdriver or Allen wrench. (See Figure 15).
7. Open cutter head by rotating tube cutting assembly inside cutter handle.
8. Slide tube cutter over tube.
9. Extend cutting wheel of tube cutter by turning drive screw clockwise until cutting wheel
touches tube. Further extend cutting wheel by turning drive screw in tube cutter
(approximately 1/6 turn clockwise).
10. Rotate tube cutter handle around tube until there is a noticeable ease of rotation.
11. Further extend cutting wheel by turning drive screw in tube cutter 1/20 to 1/10 turn clockwise.
12. Repeat steps 10 and 11 (of Section 5.2) until tube has been cut.
CAUTION: Do not overturn the cutting wheel in order not to deform the tube.

5.4 Deburr Tube

13. Select deburring tool stem assembly, based on tube OD. (See Table 9)
14. Insert stem assembly into deburring tool handle. Turn stem assembly clockwise until finger
tight, while depressing plunger.
15. Release plunger, and check to see that rubber plug is expanded. Lightly lubricate rubber
plug of stem assembly with swage lube.
16. Depress plunger of deburring tool and insert deburring tool into end of tube. Release
plunger.
17. Hold tube, and rotate knurled handle of deburring tool clockwise while applying slight
pressure towards tube. Continue to rotate until end of tube is deburred.
18. WITHOUT DEPRESSING PLUNGER, withdraw deburring tool from tube until first ridge of
rubber plug is exposed. Wipe ridge clean. Check end of tube for satisfactory deburring.
(Leave deburring tool in tube until step 20.)
If tube is not satisfactorily deburred, push tool back into tube and repeat steps 17 and 18 (of
Section 5.4).
19. Wipe outside of tube clean.
20. Remove deburring tool from tube.
21. Depress plunger of deburring tool and unscrew stem from handle. Wipe stem clean, lightly
lubricate and store.

5.5 Mark Insertion Depth on Tube

NOTE: If the insertion marking tool is not available, mark the insertion depth per the
dimensions (See Table 10).
22. Mark tube as indicated by insertion marking tool. (See Figure 13) Use marking pen supplied
in tool kit, or any other suitable marking method.

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 NOTE: Be sure to use correct slot in marking guide and mark tube the entire length of
slot in marking guide.

Mark tube in at least two places, 180 degrees apart.

CAUTION:
DO NOT USE MARKING PENS CONTAINING CHLORIDE OR GRAPHITE ON TITANIUM TUBING, AS EITHER
CHEMICAL CAN DAMAGE TITANIUM.
23. Slide fitting onto tube.

6.0 OPERATING INSTRUCTIONS FOR SWAGE TOOLING

CAUTION:
THIS TOOLING IS SUBJECT TO EXTREMELY HIGH PRESSURE DURING SWAGING. IMPROPER USE MAY RESULT
IN TOOL FAILURE OR PERSONAL INJURY. THIS TOOLING SHOULD ONLY BE USED BY PERSONNEL WHO ARE
IN POSSESSION OF A DMC LEVEL "A" TRAINING CARD.

6.1 DLT Pre-swage Inspection Procedure

1. Inspect the tube ends to be swaged for burrs on the outer diameter and the inner diameter.
If not deburred properly, it will cut the silicone seal and scratch the I.D. of the fittings.
2. Check the swage dies for size and to ensure they are free of foreign material between slots.
The Upper and Lower dies should have the same serial number (a matched set).
3. Check the power unit model number and head assembly part number.
4. Check to ensure the head and the dieblock are positioned correctly with respect to the dies
and the fitting.
5. Check the insertion mark using the proper DMC marking tool for the tube size.
6. Ensure proper insertion of the fitting. Part of the insertion mark must be visible with the fitting
in place.
7. Ensure that the stop endplate on the head assembly is not pushed by the fitting. The fitting
must just touch the stop endplate prior to the swaging.
8. Verify that the material, size and wall thickness of the tube are as specified.
9. Ensure correct fitting part number and size.
10. Verify that the needle on the gage is in the green band 9,800 to 10,400 psi (676 to 717 bar)
when the pump is pressurized. If using a pneumatic pump the pump inlet air pressure should
be 80 - 120 psi (5.5 – 8.3 bar).
11. Ensure that the two ends of the tubes being connected, or a tube end being connected to a
separable joint, are aligned without applying an excess tube preload. Limit the tube offset to
a maximum of ½” per 12” of tube length from Union to Clamp. No more than finger pressure
must be applied to align the two tube ends.
12. When B-nuts are involved, tighten the B-nuts first, and then perform the swage in the
preferred sequence.

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 6.2 Preparation of Tooling
13. Select proper power unit and head assembly based on tube OD (See Table 11a-d).
14. Push lower die/holder assembly out of head assembly.
15. Make sure upper and lower halves of die have same serial number.
16. Join lower die/holder assembly to top of power unit. (See Figure 16a-b) (Note that this
assembly will fit on power unit only one way.)
17. Connect one end of the Permaswage/ DMC 10,000 psi hydraulic hose to the DMC hydraulic

pump (See Table 14). Note: Section 12.0 Safety Precautions

18. Connect other end of Permaswage/ DMC 10,000 psi hydraulic hose to power unit. Note:

Section 12.0 Safety Precautions

POSITION FITTING ON TUBE
19. Position the fitting on the tube so that part of the tube insertion mark is covered by the fitting.
Make sure part of the tube insertion mark is also outside the fitting.
POSITION SWAGE TOOL
20. Slide head assembly over fitting and tube. Ensure beveled end of die is towards center of
fitting.
21. Slide head assembly into power unit. Head assembly will fit on power unit only one
way—position knurled strip on head assembly on same side as knurled strip on power unit.
(See Figure 16)
22. Move the power unit toward the center of the fitting, until the fitting hits the end plate stop.

6.3 Swage Connection

23. Apply hydraulic pressure 9,800 to 10,400 psi (676 to 717 bar) to the swage tool. Keep the
power unit, fitting, and tube in the positions described in steps 19 and 22 of 6.2.

6.4 Remove Tooling

24. Release the pressure to allow the dies to open. After the dies halves have opened, slide the
head assembly out of the power unit. The two parts do not require much pressure to
separate.
25. Remove the head assembly from the swaged fitting/tube.

CAUTION: Always position yourself during swaging as shown below in “CORRECT” Picture.

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 CORRECT INCORRECT
Proper position to stand during Improper position to stand
swaging during swaging

7.0 INSPECTION OF SWAGED CONNECTION

1. Select inspection gauge, based on size of fitting. (See Table 12)
NOTE: Inspect swaged fittings only with inspection gauges supplied by Designed Metal
Connections--use no other method. To verify dimensions of inspection gauges, see Table
12.
Swage fittings must be inspected after swaging. This action verifies the fitting has been
compressed accurately.
2. Place inspection gauge over swaged end of fitting. Ensure internal shoulder of gauge contacts
end of fitting (See Figure 17)
Outside diameter of fitting must be smaller than ID of gauge. Part of the die marks on fitting must
be visible outside of gauge.
3. Remove gauge. Rotate gauge 90°, and repeat step 2 above.
NOTE: If inspection gauge does not fit properly over the swaged fitting, rotate fitting 30° -
90° from the first swage position and reswage the fitting. If dimensions of swaged fitting
are still not satisfactory, contact your Designed Metal Connections representative for
assistance.

8.0 TUBE REPAIR TECHNIQUES

Four basic types of tubing system failures lend themselves to permanent repair using Permaswage®
techniques. The failure types and recommended repair procedures (one per page) are as follows:

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 8.1 TYPE 1 - Small Hole or Short Crack in Tube

1. Check to assure that there is enough space available to operate the swage tool.
2. Make one or two cuts as necessary to allow removal of damaged tube section. (If two cuts
are required, and the distance between cuts exceeds 0.30", use repair TYPE 2.)
3. Replace removed section of tube with a compatible Permaswage® union fitting.

FIGURE 1
Type 1 Repair

DAMAGED SECTION

.30

COMPLETED REPAIR

D10036 (-06 thru –16) & D10136 (-20 and –24)

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 8.2 TYPE 2a - Lengthwise Crack in Tube (Crack Longer Than 0.30")

1. Check to assure that there is enough space available to operate the swage tool.
2. Make two cuts to allow removal of damaged section of tube.
3. Use a tube splice and two compatible Permaswage® union fittings to recreate the
section of tubing which was removed. Assemble these parts into the line being
repaired before you swage the fittings.
4. Swage each end of the fittings.

FIGURE 2
Type 2a Repair, Crack is longer than 0.30”

DAMAGED SECTION

.30

COMPLETED REPAIR

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 8.3 TYPE 2b - Lengthwise Crack in Tube
Repair using Extended Length Permaswage®. Part number D10339
1. Check to assure that there is enough space available to operate the swage tool.
2. Make one cut to allow removal of damaged section of tube. Use Table 1 (Below) for
the maximum allowed tube gap between the tube ends required to repair the
defective tube.
3. Use one compatible Extended Permaswage® union fitting to recreate the section of
tubing which was removed. Assemble this part onto the line being repaired before
you swage either end of the fitting.
4. Swage each end of the fitting.

FIGURE 3
Type 2b Repair using extended length Permaswage®
DAMAGED SECTION

.30” Min.
COMPLETED REPAIR

Max. Gap
Length
TABLE 1
MAXIMUM GAP LENGTH FOR
EXTENDED LENGTH PERMASWAGE®
Max. Gap
Tube
Fitting Length
Size
Size “L”
(inches)
(inches)
3/16 -03 2.25
1/4 -04 2.55
5/16 -05 2.62
3/8 -06 2.70
1/2 -08 3.70
5/8 -10 3.80
3/4 -12 4.00
1 -16 5.25
1-1/4 -20 5.25
1-1/2 -24 5.25

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 8.4 TYPE 3 - Leaking Tube or Fitting Associated with Elbow, Tee, or Cross

1. Check to assure that there is enough space available to operate the swage tool.
2. Cut out defective elbow, tee, or cross.
3. Swage tube splices to a compatible Permaswage® elbow, tee, or cross fitting. Do
this to re-create section of tubing system which was removed.
4. Swage each leg (tube) of this assembly to the tubing being repaired. Use
Permaswage® union fittings.

FIGURE 4
Type 3 Repair
DAMAGED SECTION

Tube
Crack
Fitting
Crack

COMPLETED REPAIR

D9855
TEE

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 8.5 TYPE 4a - Damaged Tube or End Fitting (flared, female)

1. Cut off the flared end of the tube as shown in Figure 5 (Below). Refer to Table 2
(Below) to determine the cut-off length ("L"). Use of these cut-off lengths permits
repair of the line without splicing new tubing into the line.
2. Replace the removed fitting with a compatible Permaswage® D10010 flared sleeve
and D10006 coupling nut. (Insert the end of the tube being repaired into the flared
sleeve as far as possible before swaging. This will duplicate the original overall
length of the assembly.)

FIGURE 5
Type 4a Repair TABLE 2
CUT-OFF LENGTHS FOR
DAMAGED SECTION FLARED, FEMALE
Tube Fitting
Size "L" (+/- .010)
Size
(inches)
3/16 -03 .282"
1/4 -04 .275"
5/16 -05 .275"
MS20819, Flared Sleeve 3/8 -06 .226"
1/2 -08 .243"
5/8 -10 .204"
3/4 -12 .234"
1 -16 1.647"
1-1/4 -20 1.035"
“L” 1-1/2 -24 1.045"

COMPLETED REPAIR

D10010

D10006

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 8.6 TYPE 4b - Damaged Tube or End Fitting (flareless, female)

1. Cut off the flareless end of the tube as shown in Figure 6 (Below). Refer to Table 3
(Below) to determine the cut-off length ("L"). Use of these cut-off lengths permits
repair of the line without splicing new tubing into the line.
2. Replace the removed fitting with a compatible Permaswage® D10007 flareless sleeve
and D10006 coupling nut. (Insert the end of the tube being repaired into the flared
sleeve as far as possible before swaging. This will duplicate the original overall
length of the assembly.)

FIGURE 6
Type 4b Repair

DAMAGED SECTION

“L”

TABLE 3
CUT-OFF LENGTHS FOR
MS21922
FLARELESS SLEEVE
FLARELESS, FEMALE
Tube Fitting "L"
Size (+/- .010)
Size
(inches)
3/16 -03 .432"
1/4 -04 .541"
5/16 -05 .557"
COMPLETED REPAIR
3/8 -06 .508"
1/2 -08 .588"
5/8 -10 .600"
3/4 -12 .628"
1 -16 2.110"
1-1/4 -20 1.456"
1-1/2 -24 1.504"
D10006
D10007

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 8.7 TYPE 4c - Damaged End Fitting (lipseal, female, -3 through -16)

(Replacing MR54040 and MR44000P internally swaged, and R44275PT butt- welded,
female lipseal assemblies in sizes -3 through -16)

1. Cut off the damaged fitting at a distance ("L") from the sealing surface as shown in
Figure 7 (Below). Refer to Table 4 (Below) to determine the cut-off length ("L").
2. Replace the removed fitting with a compatible Permaswage® DD00200A lipseal
fitting. (Insert the end of the tube being repaired into the lipseal fitting as far as
possible before swaging. This will duplicate the original overall length of the
assembly.)

FIGURE 7
Type 4c Repair

DAMAGED SECTION

“L”
R44275PT,
MR54040, or
MR44000P

TABLE 4
CUT-OFF LENGTHS FOR
LIPSEAL, FEMALE
Tube
Size Fitting "L" (+/- .010)
(inches)
3/16 -03 .940"
COMPLETED REPAIR
1/4 -04 .970"
5/16 -05 .972"
3/8 -06 .995"
1/2 -08 1.075"
5/8 -10 1.120"
3/4 -12 1.105"
1 -16 1.280"
1-1/4 -20 .940"
DD00200A -24 .970"
1-1/2

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 8.8 TYPE 4d--Damaged End Fitting (lipseal, female, -20 and -24)
(Replacing MR54040 and MR44000P internally swaged, and R44275PT butt-welded,
female lipseal assemblies in sizes -20 and -24. Also applies to D11200 externally
swaged female lipseal assemblies in all sizes.)

1. Cut off damaged fitting at a point where there is enough space in which to operate
the swage tool.
2. Swage a compatible Permaswage® union fitting to one end of a tube splice. Swage a
Permaswage® D11200 or DD00200A lipseal fitting to the other end of the same tube
splice.
3. Connect the end of this assembly with a union fitting to the end of the tube being
repaired.

FIGURE 8
Type 4d Repair

DAMAGED SECTION

MR54040,
MR44000P,
R44275PT, or
D11200

COMPLETED REPAIR

D10036 (-06 THRU –16) D11200 (-06 THRU –16)

D10136 (-20 AND –24) D00200A (-20 AND –24)

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 8.9 TYPE 4e--Damaged End Fitting (lipseal, female, reducer)
(Replacing R44277PT butt-welded female lipseal reducer assemblies.)

1. Cut off the damaged fitting at a distance ("L") from the sealing surface as shown in
the Figure 9 (Below). Refer to Table 5 (Below) to determine the cut-off length ("L").
2. Replace the removed fitting with a compatible Permaswage® DD00300A lipseal
fitting. (Insert the end of the tube being repaired into the lipseal assembly as far as
possible before swaging. This will duplicate the original overall length of the
assembly.)

FIGURE 9
Type 4e Repair TABLE 5
CUT-OFF LENGTHS FOR
DAMAGED SECTION LIPSEAL, FEMALE, REDUCER

End 1 End 2 "L"

(Separable
“L” End)
(Swage End) (+/- .010)
-04 -03 .702"
-05 -04 .635"
-06 -04 .710"
-08 -04 .710"
-08 -06 .725"
-10 -06 .740"
R44277PT
-10 -08 .797"
-12 -06 .860"
COMPLETED REPAIR -12 -08 .832"
-12 -10 .862"
-16 -8 .927"
-16 -10 .957"
-16 -12 .887"

DD00300A

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 8.10 TYPE 4f--Damaged End Fitting (lipseal, male adapter)
(Replacing internally swaged, butt-welded or externally swaged male lipseal fittings:
MR54100, MR44100P, or D11007.)

1. Cut off damaged fitting at a point where there is enough work area in which to
operate the swage tooling.
2. Swage a compatible Permaswage® union fitting to one end of a tube splice. Swage a
Permaswage® D11007 male lipseal adapter fitting to the other end of the same tube
splice.
3. Swage the end of this assembly with a union fitting to the end of the tube being
repaired.

FIGURE 10
Type 4f Repair

DAMAGED SECTION

MR54100,
MR44100P, or
D11007

COMPLETED REPAIR

D10036 (-06 THRU –16)

D10136 (-20 AND –24)

D11007 (-06 THRU –24)

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9.0 FREQUENTLY ASKED QUESTIONS
Here are some of the most frequently asked questions (and answers) regarding use of the
Permaswage® Tube Connecting System:

1. Is it OK to swage a fitting more than once?

Yes. It's OK to swage a fitting more than once, to a maximum 3 times --just be sure
that you're using the correct die set. And be sure that your hydraulic pump is
delivering the right amount of pressure to the swage tool.
2. If a joint is weeping or leaking, should the fitting be swaged again?
If a Permaswage® joint begins to weep or leak, first verify the original swage with the
after swage inspection gauge, and then re-swage the fitting and check with the gauge
again. The leakage will often be stopped by swaging the fitting again.
3. How many fittings can be swaged into a line?
As many as will fit. We recommend, though, that you allow a minimum distance of
one tube diameter between fittings.
4. Is it OK to glue fittings onto tubes?
No. Do not use glue at any time.

Refer any other questions to your Designed Metal Connections representative (web
address www.permaswage.com).

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10.0 BASIC MAINTENANCE
This section covers regular inspection, cleaning, and storage of the equipment. Also
covered is how to replace the cutter wheel of the tube cutter. Refer to: MCP-016, Inspection
Criteria of DLT Series Swage Head Assembly, and SOP604-030, Permaswage® DLT
Maintenance Procedure and Service Schedule.

10.1 Inspection and Cleaning of Tooling

NOTE: PARTS OF THIS TOOLING ARE SUBJECTED TO EXTREMELY HIGH FORCES -- THE FOLLOWING PROCEDURES
MUST BE PERFORMED AS OFTEN AS SPECIFIED TO ENSURE SAFE AND SUCCESSFUL OPERATION.
PROCEDURE PERFORMED HOW OFTEN

Check All Components.

If any deep scratches, gouges, dimples or other Before each use.
abnormalities appear, discontinue use and contact
Designed Metal Connections

Check Die Sets.

Upper and lower halves must be a serialized set.
They must be clean.
Before each use.
Apply DMC Swage Lube to the heads and die
blocks prior to installing the dies.

Check Connection Points.

Each time components are
Components must be clean in all areas where they connected.
contact each other.

Check Tube Cutter.

Cutting wheels must be sharp. Rollers must be Before each use.
parallel and not wobbly.

Lubricate Tube Cutter.

As required to ensure ease of
Lubricate ratchet, rollers and cutter wheel with light operation
oil.

10.2 Storing Equipment after Use

Replace protective caps over all connectors before storing equipment. Storing the
equipment without replacing the protective caps can cause the equipment to fail.

10.3 How to Replace Cutter Wheel of Tube Cutter (See Figure 15)
The cutter wheel in the tube cutter should be replaced whenever it becomes too dull to
cut efficiently. It should also be replaced if it becomes damaged in any way.

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 DISASSEMBLY
(1) Tighten drive screw until cutter pivot pin becomes accessible.
(2) Remove cutter pivot pin. Cutter wheel will now slide out easily.

REASSEMBLY
(3) Slide new cutter wheel into place and secure with pivot pin.
(4) Lubricate with light machine oil.
No other regular maintenance is required for any component in the tool kit.

11.0 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE SOLUTION

Pump not supplying 9,800 to
10,400 psi (676 to 717 bar) to Check output from pump.
swage tool.
Fitting does not swage properly. Using incorrect dies. Use correct dies. Reswage.
Dies are not clean. Clean dies. Reswage.
Dies are worn or damaged. Replace dies. Reswage.
QD failure. Fix or replace QD.
Gauge shoulder does not contact Components were not correctly Reswage, making sure the swage
end of fitting. positioned before swaging. tool is properly positioned.
Fitting was not properly located
End of fitting doesn't touch the
on the tube before pressure was Replace fitting.
insertion mark on the tube.
applied.

12.0 SAFETY PRECAUTIONS

WARNING: To help prevent personal injury:
 Before operating the pump, all hose connections must be tightened with the proper tools.
Do not over tighten. Connections need only be tightened securely and leak-free. Over
tightening may cause premature thread failure or high pressure fittings to split at
pressures lower than their rated capacities.
 Note that hose is pre-charged with hydraulic fluid and to operate swage components
properly they must be free of air. Do not damage or puncture hose; doing so can cause
loss of internal pressure and cause personal injury.
 Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately
release all pressure. Never attempt to grasp a leaking hose under pressure with your
hands. The force of escaping hydraulic fluid could cause serious injury.
 Do not use the hose to move attached equipment. Stress may damage the hose and
cause personal injury.
 Do not subject the hose to any potential hazard such as fire, extreme heat or cold, sharp
surfaces, or heavy impact. Do not allow the hose to kink, twist, curl, or bend so tightly
that the fluid flow within the hose is blocked or reduced. Periodically inspect the hose for
wear. Above-mentioned conditions can damage the hose and result in personal injury.
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reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
REV: N
  Hose material and coupler seals must be compatible with the pump hydraulic fluid. Hoses
also must not come in contact with corrosive materials, such as creosote-impregnated
objects and some paints. Consult the manufacturer before painting a hose. Never paint
the couplers. Hose deterioration due to corrosive materials may result in personal injury.
 All components in the hydraulic system must match the maximum pressure rating of the
pump.

13.0 RETURN OF TOOLING FOR EVALUATION OR REPAIR

Repairs are only authorized by DMC company certified mechanics.
Repair by an uncertified mechanic will void the warranty. Unauthorized repairs may cause
the equipment to perform in an unsatisfactory manner. Contact your DMC representative
for information regarding return of swage tooling for evaluation and/or repair.

14.0 QUALITY ASSURANCE FOR SWAGE TOOLING

Quality Assurance is one of the highest priorities at Designed Metal Connections. In-house
forging, manufacturing, and processing allow us to control quality from the raw material
stage to the finished product.
We use a single inspection system in accordance with ISO 9001/ AS 9100. Certification of
tooling at time of shipment is part of this system. This ensures that all tooling is
dimensionally and functionally in accordance with applicable blueprints and standards.

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REV: N
 TABLE 6
RECOMMENDED FITTING/ TUBE MATERIAL & WALL THICKNESS COMBINATIONS (0-3000 psi)
FITTING TUBE MAX. LINE TUBE OD (inch sizes)
MATERIAL MATERIAL PRESSURE 3/16 1/4 5/16 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2
-03 -04 -05 -06 -08 -10 -12 -16 -20 -24
.028/ .028/.0
1,500 psi --- .035
.035 35(1)
.035 --- .065 --- --- ---
.028 .028 .042
1,000 psi --- .020 .028 .035(1) .035
.035 .035 --- .065
.049
6061-T6
6061-T6
AL 750 psi --- --- --- --- --- .028 .028 --- --- ---
(AMS-QQ-A-
AL
(AMS4083) 600 psi --- --- --- --- --- --- --- --- --- .065
225)
.035
500 psi --- --- --- --- --- .028 .028 .035 .035 .049(2)
200 psi --- .020 --- .020 .020 .020 .020 .020 --- .035
.019/
3,000 psi --- .016 --- .019 .026
.032 .039 .051 --- ---
3AL-2.5V
2,000 psi --- --- --- --- --- --- --- .036 .045 .054
CWSR TI
(AMS4944 or --- --- --- --- --- --- .027 .028 .045 ---
AMS4945) 1,000 psi
500 psi --- --- --- --- --- --- --- --- --- .032
C.P. Ti
(AMS4921) 304 1/8HD
CRES 3,000 psi --- .020 --- .028 .035 --- --- --- --- ---
(AMS-T-6845 or
MIL-T-6845)
21-6-9
CRES 3,000 psi --- .016 --- --- --- --- --- --- --- ---
(AMS5561)
3,000 psi --- .035 .042 .049 .064 .065 .095 --- --- ---
.028/
6061-T6 1,500 psi --- .035
.035 .035 .035 --- --- --- .065 ---
AL 1,000 psi --- --- --- --- --- .035 .035 --- .065 ---
(AMS4083)
600 psi --- --- --- --- --- --- --- .035 --- ---
400 psi --- --- --- --- --- --- --- --- --- .049
--- .016 .019/ .026 .032 .039 .051 .065 ---
3AL-2.5V 3,000 psi --- .020
CWSR TI --- --- --- --- --- --- --- --- --- .042
(AMS4944 or 2,000 psi
21-6-9 AMS4945)
--- --- --- --- --- --- .027 .028 --- .042
1,000 psi
CRES
(AMS5656) 3AL-2.5V --- --- --- .028 .028/ .046 .058 .073 --- ---
3,000 psi .035
ANNEAL TI
(AMS4943 or --- --- --- --- --- --- --- --- --- .042
GM3118A) 1,200 psi
.016/
3,000 psi .016 .020
.020 .020 .026 .033 .039 .052 .054 ---
21-6-9
CRES 1,500 psi --- --- --- --- --- --- --- .020 .032 ---
(AMS5561) 1,000 psi --- --- --- --- --- --- --- --- .024 ---
500 psi --- --- --- --- --- --- --- --- .024 ---
304 1/8HD 3,000 psi .016 .020 .020 .028 .035 .042 .058 .065 --- ---
CRES 2,000 psi --- --- --- --- --- --- --- --- --- .065
(AMS5566 or
AMS5654) 1,500 psi --- --- --- --- --- --- --- --- .049 .065
1. This tube wall is qualified with permanent to flareless sleeve D10609D06 (D10428WD06 assembly) and permanent to flared sleeve D10611D06
(D10612WD06 assembly) for 1000 Psi only. For 1500 psi installations, use D10611D06 flareless sleeve (D10614WD06 flareless assembly) and
D10613D06 flared sleeve (D10617WD06 Flared assembly). All other shapes are qualified for 1500 Psi operation pressure.
2. This tube wall (.049”) is qualified by similarity to the thinner tubing .035” for the same operating pressure of 500 psi
For tube wall thicknesses not indicated contact Designed Metal Connections.
For tube material compatibility with 304L or 316L CRES fitting material reference SOP604-024.

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REV: N
TABLE 7
DLT TOOL KITS
TOOL KIT PLT TOOL KIT
TUBE SIZE**
PERMASWAGE ®
NATIONAL STOCK PERMASWAGE® NATIONAL
(O.D.) STOCK NUMBER
NUMBER NUMBER NUMBER
-03 DLT05PSKT3001 (NOT YET ASSIGNED) PLT06PSKT3001
-04 DLT05PSKT3000 5180-01-321-7878 PLT06PSKT3000
-05 DLT10PSKT3001 (NOT YET ASSIGNED) PLT11PSKT3001
-06 DLT10PSKT3000 5180-01-321-7879 PLT11PSKT3000
-08 DLT20PSKT3002 (NOT YET ASSIGNED) PLT21PSKT3002
-10 DLT20PSKT3004 (NOT YET ASSIGNED) PLT21PSKT3004
-12 DLT30PSKT3000 5180-01-321-7881 PLT31PSKT3000
-16 DLT40PSKT3002 5180-01-455-5056 PLT41PSKT3002
-20 DLT40PSKT3003 (NOT YET ASSIGNED) PLT41PSKT3003
-24 DLT40PSKT3004 (NOT YET ASSIGNED) PLT41PSKT3004
-04, -05, -06, -08, -10 DLT30MAPSKT3000 5180-01-321-7881 PLT31MAPSKT3000
-04, -06, -08, -10, -12 DLT30MAPSKT3001 (NOT YET ASSIGNED) PLT31MAPSKT3001
-04, -05, -06, -08, -10,
DLT30MAPSKT3002 (NOT YET ASSIGNED) PLT31MAPSKT3002
-12
-03, -04, -05, -06, -08,
DLT30MAPSKT3004 (NOT YET ASSIGNED) PLT31MAPSKT3004
-10, -12
-03, -04, -05, -06 DLT30MAPSKT3011 (NOT YET ASSIGNED) PLT31MAPSKT3011
-04, -05, -06, -08 DLT30MAPSKT3015 (NOT YET ASSIGNED) PLT31MAPSKT3015
-04, -06, -08, -10 DLT30MAPSKT3017 (NOT YET ASSIGNED) PLT31MAPSKT3017
(NOT YET
-04, -06, -10, -12 DLT30MAPSKT3018 (NOT YET ASSIGNED) PLT31MAPSKT3018
ASSIGNED)
-04, -06, -08, -10, -12,
DLT40MAPSKT3000 (NOT YET ASSIGNED) PLT41MAPSKT3000
-16, -20, -24
-04, -06, -08, -10, -12,
DLT40MAPSKT3001 (NOT YET ASSIGNED) PLT41MAPSKT3001
-16, -20
-04, -05, -06, -08, -10,
DLT40MAPSKT3002 (NOT YET ASSIGNED) PLT41MAPSKT3002
-12, -16, -20, -24
-04, -05, -06, -08, -10,
DLT40MAPSKT3003 (NOT YET ASSIGNED) PLT41MAPSKT3003
-12, -16
-04, -06, -08, -10, -12,
DLT40MAPSKT3004 (NOT YET ASSIGNED) PLT41MAPSKT3004
-16
-03, -04, -05, -06, -08,
DLT40MAPSKT3005 (NOT YET ASSIGNED) PLT41MAPSKT3005
-10, -12, -16, -20, -24
-03, -04, -05, -08, -10,
DLT40MAPSKT3006 (NOT YET ASSIGNED) PLT41MAPSKT3006
-12, -16, -20, -24
-03, -04, -06, -08, -10,
DLT40MAPSKT3007 (NOT YET ASSIGNED) PLT41MAPSKT3007
-12, -16
-10, -12, -16 DLT40MAPSKT3008 (NOT YET ASSIGNED) PLT41MAPSKT3008
-04, -05, -06, -08, -10,
DLT40MAPSKT3011 (NOT YET ASSIGNED) PLT41MAPSKT3011
-12, -16, -20
DLT and PLT Tool Kits contain swage tools, marking templates and inspection gauges for each size listed. Also
included are tube cutters, de-burring tools with stem assemblies, a hex key and a marking pen.
For DLT and PLT Tool Kits not listed, contact Designed Metal Connections.

Note: ** Size represented in 1/16 inch increments.

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 TABLE 7
DLT TOOL KITS (CONTINUED)

FIELD REPAIR KIT PLT REPAIR KIT

TUBE SIZE** NATIONAL STOCK
PERMASWAGE® NATIONAL STOCK PERMASWAGE® NUMBER
(O.D.)
NUMBER NUMBER NUMBER

-04, -06, -08, -10, -12,

DLTFRPSKT3000 5120-01-472-9129 PLTFRPSKT3000
-16, -20, -24
-04, -06, -08, -10, -12 DLTFRPSKT3001 5180-01-341-4030 PLTFRPSKT3001
-04, -06, -08, -10 DLTFRPSKT3002 (NOT YET ASSIGNED) PLTFRPSKT3002
-04, -06 DLTFRPSKT3003 5180-01-115-7007 PLTFRPSKT3003
-04, -05, -06, -08, -10,
DLTFRPSKT3004 (NOT YET ASSIGNED) PLTFRPSKT3004
-12 (NOT YET ASSIGNED)
-03, -04, -05, -06, -08,
DLTFRPSKT3008 5120-01-374-6290 PLTFRPSKT3008
-10, -12
-03, -04, -05, -06, -08,
DLTFRPSKT3009 5180-01-374-8266 PLTFRPSKT3009
-10, -12, -16, -20, -24
-03, -04, -05, -06 DLTFRPSKT3010 (NOT YET ASSIGNED) PLTFRPSKT3010
-04, -06, -08, -10, -12,
DLTFRPSKT3014 4920-01-514-8009 PLTFRPSKT3014
-16

-04, -06, -08, -10, -12 DLTFRPSKTF301 (NOT YET ASSIGNED) PLTFRPSKTF301
-04, -06, -08, -10, -12,
DLTFRPSKTF302 (NOT YET ASSIGNED) PLTFRPSKTF302
-16
-03, -04, -05, -06, -08,
DLTFRPSKTF303 (NOT YET ASSIGNED) PLTFRPSKTF303
-10, -12, -16, -20, -24
-03, -04, -05, -06, -08 DLTFRPSKTF304 (NOT YET ASSIGNED) PLTFRPSKTF304
-04, -06, -08, -10, -12, (NOT YET ASSIGNED)
DLTFRPSKTF305 (NOT YET ASSIGNED) PLTFRPSKTF305
-16
-04, -06, -08, -10, -12 DLTFRPSKTF306 (NOT YET ASSIGNED) PLTFRPSKTF306
-04, -06, -08, -10, -12,
DLTFRPSKTF307 (NOT YET ASSIGNED) PLTFRPSKTF307
-16
-04, -06, -08, -10, -12,
DLTFRPSKTF308 (NOT YET ASSIGNED) PLTFRPSKTF308
-16, -20, -24
-04, -06, -08, -10 DLTFRPSKTF321 (NOT YET ASSIGNED) PLTFRPSKTF321
DLT and PLT Field Repair Kit - Contains all components of a regular kit plus a 10,000 psi hydraulic manual pump
(P/N: DLT05MAPM1001).
For DLT and PLT Field Repair Kits not listed, contact Designed Metal Connections.

Note: DLTFRPSKTF*** and PLTFRPSKTF*** Contains NO tools. Field repair kit contains elbow, tee, and
union fittings and a 12” long sample of CRES tubing for all sizes listed.

** Size represented in 1/16 inch increments.

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TABLE 8
MINIMUM STRAIGHT TUBE LENGTH
REQUIRED BEFORE BEND

“L”, MINIMUM STRAIGHT

TUBE OD
LENGTH

3/16" .773"
1/4" .915"
5/16" .955"
3/8" .990''
1/2" 1.493"
5/8" 1.533"
3/4" 1.603"
1" 1.748"
1 1/4" 1.850
1 1/2" 1.975"

FIGURE 11
Minimum Straight Length

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TABLE 9
DEBURRING TOOL AND STEM ASSEMBLY

PART NUMBERS FOR STANDARD STEM ASSEMBLIES: STEM ASSEMBLY

SIZE ONLY,
DEBURRING NATIONAL STOCK SKYDROL(1)
STEM ASSEMBLY
TOOL NUMBER (NO NSN)(2)
3/16 D9851-14 D9851-13-03 5110-00-163-5980 D9759-13-03
1/4 D9851-14 D9851-13-04 5110-00-005-5650 D9759-13-04
5/16 D9851-14 D9851-13-05 5110-00-006-0491 D9759-13-05
3/8 D9851-14 D9851-13-06 5110-00-133-1477 D9759-13-06
1/2 D9850-14 D9850-13-08 5110-00-003-0535 D9758-13-08
5/8 D9850-14 D9850-13-10 5110-00-003-0536 D9758-13-10
3/4 D9850-14 D9850-13-12 5110-00-003-0537 D9758-13-12
1 D9849-15 D9849-13-16 5110-00-784-7946 D9757-13-16
1 1/4 D9849-15 D9849-13-20 5110-00-784-7947 D9757-13-20
1 1/2 D9849-15 D9849-13-24 5110-00-784-7950 D9757-13-24
(1) These stem assemblies are compatible with Skydrol or similar fluids.
(2) Stem utilizes same Deburring tool.

FIGURE 12
Deburr Tool

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TABLE 10
MAKING INSERTION MARKS WITHOUT INSERTION MARKING TOOL
TUBE OD “A” “B” PART NUMBER
3/16" .473" .773"
1/4" .615" .915"
DLT5302-013-01
5/16" .655" .955"
3/8" .690" .990"
1/2" 1.193" 1.493"
5/8" 1.233" 1.533" DLT5302-031-01
3/4" 1.303" 1.603"
1" 1.448" 1.748"
1 1/4" 1.550" 1.850" DLT5302-040-01
1 1/2" 1.675" 1.975"

Locate points at “A” and “B” distances from the end of the tube. The distance “A” is the minimum insertion depth,
and “B” is the maximum insertion depth. The insertion mark made on the tube must extend between “A” and “B”.
NOTE: Part numbers for Boeing Commercial applications are D12580-1, D12580-2 and D12580-3.

FIGURE 13
Insertion Marking Tool

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TABLE 11a
FIRST GENERATION DLT POWER UNIT, HEAD ASSEMBLY AND DIE
(0 - 3,000 psi max.)
TUBE FITTING
SIZE POWER UNIT HEAD ASSEMBLY DIE
OD
3/16" -03 DLT05MAPW0000 DLT05PSHA3003 DLT05PSDI3003
1/4" -04 DLT05MAPW0000 DLT05PSHA3004 DLT05PSDI3004
5/16" -05 DLT10MAPW0000 DLT10PSHA3005 DLT10PSDI3005
3/8" -06 DLT10MAPW0000 DLT10PSHA3006 DLT10PSDI3006
1/2" -08 DLT20MAPW0000 DLT20PSHA3008 DLT20PSDI3008
5/8" -10 DLT20MAPW0000 DLT20PSHA3010 DLT20PSDI3010
3/4" -12 DLT30MAPW0000 DLT30PSHA3012 DLT30PSDI3012
(1)
1" -16 DLT40MAPW0000 DLT40PSHA3016 DLT40PSDI3016 (1)
1 1/4" -20 DLT40MAPW0000 DLT40PSHA3020 DLT40PSDI3020
(2)
1 1/2" -24 DLT40MAPW0000 DLT40PSHA4024 DLT40PSDI4024 (2)
(1)
Use DLT40PSHA4016, DLT40PSDI4016 for Boeing Commercial applications.
(2)
Use DLT40PSHA4024A, DLT40PSDI4024A for Airbus applications

TABLE 11b
SECOND GENERATION DLT POWER UNIT, HEAD ASSEMBLY AND DIE
(0 - 3,000 psi max.)
TUBE FITTING
SIZE POWER UNIT HEAD ASSEMBLY DIE
OD
3/16" -03 DLT06MAPW0000 DLT06PSHA3003 DLT06PSDI3003
1/4" -04 DLT06MAPW0000 DLT06PSHA3004 DLT06PSDI3004
5/16" -05 DLT11MAPW0000 DLT11PSHA3005 DLT11PSDI3005
3/8" -06 DLT11MAPW0000 DLT11PSHA3006 DLT11PSDI3006
1/2" -08 DLT21MAPW0000 DLT21PSHA3008 DLT21PSDI3008
5/8" -10 DLT21MAPW0000 DLT21PSHA3010 DLT21PSDI3010
3/4" -12 DLT31MAPW0000 DLT31PSHA3012 DLT31PSDI3012
1" -16 DLT41MAPW0000 DLT41PSHA3016 (3) DLT41PSDI3016 (3)
1 1/4" -20 DLT41MAPW0000 DLT41PSHA3020 DLT41PSDI3020
1 1/2" -24 DLT41MAPW0000 DLT41PSHA4024 DLT41PSDI4024
(3)
Use DLT41PSHA4016, DLT41PSDI4016 for Boeing Commercial applications.

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TABLE 11c
FIRST GENERATION DLT END PLATES AND SCREWS
END PLATES SCREW,
FITTING INBOARD INBOARD OUTBOARD OUTBOARD SOCKET
SIZE UPPER LOWER UPPER LOWER HEAD, FLAT
-03 DLT05PSEU3004 DLT05PSEL3004 DLT05PSFU3003 DLT05PSFL3004 DLT91253
-04 DLT05PSEU3004 DLT05PSEL3004 DLT05PSFU3004 DLT05PSFL3004 DLT91253
-05 DLT10PSEU4006 DLT10PSEL4006 DLT10PSFU3005 DLT10PSFL4006 DLT91253
-06 DLT10PSEU4006 DLT10PSEL4006 DLT10PSFU4006 DLT10PSFL4006 DLT91253
-08 DLT20PSEU4008 DLT20PSEL4008 DLT20PSFU4008 DLT20PSFL4008 DLT91253
-10 DLT20PSEU4010 DLT20PSEL4010 DLT20PSFU4010 DLT20PSFL4010 DLT91253
-12 DLT30PSEU4012 DLT30PSEL4012 DLT30PSFU4012 DLT30PSFL4012 DLT91253
-16 DLT40PSEU3016 DLT40PSEL3016 DLT40PSFU3016 DLT40PSFL3016 DLT91253
-20 DLT40PSEU3020 DLT40PSEL3020 DLT40PSFU3020 DLT40PSFL3020 DLT91253
-24 DLT40PSEU4024 DLT40PSEL4024 DLT40PSFU4024 DLT40PSFL4024 DLT91253

TABLE 11d
SECOND GENERATION DLT SHROUDS
FITTING
UPPER SHROUD LOWER SHROUD
SIZE
-03 DLT06PSSU3004 DLT06PSSLA3003
-04 DLT06PSSU3004 DLT06PSSLA3004
-05 DLT11PSSU3006 DLT11PSSLA3005
-06 DLT11PSSU3006 DLT11PSSLA3006
-08 DLT21PSSU3008 DLT21PSSLA3008
-10 DLT21PSSU3010 DLT21PSSLA3010
DLT31PSSU3012 DLT31PSSLA3010
-12 DLT31PSSU3012 DLT31PSSLA3012
-16 DLT41PSSU3016 DLT41PSSLA3016
-20 DLT41PSSU3020 DLT41PSSLA3020
-24 DLT41PSSU40A24 DLT41PSSLA4024

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TABLE 12
INSPECTION GAUGE
(0 - 3,000 psi max.)
GAUGE INSIDE INSIDE
DIAMETER "A" LENGTH "B"
FITTING SIZE PERMASWAGE® NATIONAL STOCK +/- .002 +/- .003
NUMBER NO.
(Inches) (Inches)
-03 D12-9892-03 5220-00-005-5635 .247 .340
-04 D12-9892-04 5220-00-005-5636 .315 .460
-05 D12-9892-05 5220-00-005-5637 .381 .500
-06 D12-9892-06 5210-00-005-5638 .447 .584
-08 D12-9892-08 5210-00-004-4912 .606 1.020
-10 D12-9892-10 5210-01-251-3823 .735 1.020
-12 D12-9892-12 5210-00-004-4914 .863 1.020
-16 D12-9892-16 (1)
5220-00-882-7951 1.144 1.160
-20 D12-9892-20 5220-00-922-1445 1.390 1.406
-24 D12-9892-24 5220-00-003-0506 1.680 1.420

(1)
Use DNR9892-016 for Boeing Commercial applications.

FIGURE 14
Inspection Gauge

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TABLE 13
TUBE CUTTER, SPARE CUTTER WHEEL, & MISC. COMPONENTS

SPARE CUTTER
TUBE CUTTER MISC.
SIZES WHEEL PART PART NUMBER
PART NUMBER COMPONENTS(1)
NUMBER
3/16" through 3/8" D12530-001 D12530-109 Hex Key DLT5103-104-00
1/2" through 3/4" D12531-001 D12531-109 Marking Pen DLT5301-000-01
7/8" through 1 1/2" D12532-001 D12532-109 Swage Lube. DLTSWLUB0001

(1) Applies to all sizes.

FIGURE 15
Tube Cutter

TABLE 14
10,000 psi Hydraulic
Pump Kits

POWER SOURCE PART NUMBER

Manual (Hand) DLT05MAPM1000
Pneumatic (100 psi Shop Air) with switch DLT02MAPP1000
Pneumatic (80~120 psi Air) foot pedal DLT03MAPP1000
Electric (220 V.A.C.) DLT16MAPE1100
Battery Operated Pump (110 V.A.C. – 60Hz) DLT06MAPE3000
Battery Operated Pump (220 V.A.C. – 60 Hz) DLT06MAPE3100

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reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
REV: N
FIGURE 16a
FIRST GENERATION HEAD ASSEMBLY, LOWER DIE BLOCK ASSEMBLY
AND POWER UNIT

Note: The Head Assembly is the combination of the Lower Die Block Assembly and the Yoke Assembly.

FIGURE 16b
SECOND GENERATION HEAD ASSEMBLY, LOWER DIE BLOCK ASSEMBLY
AND POWER UNIT

Note: The Head Assembly is the combination of the Lower Die Block Assembly and the Yoke Assembly.

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Notice – Designed Metal Connections (DMC) dba Permaswage claims proprietary rights in the Information disclosed hereon. This document may not be
reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
REV: N
FIGURE 17

USING INSPECTION GAUGE

NOTE: If inspection gauge does not fit properly over the swaged fitting, re-swage the fitting. If dimensions of swaged fitting
are still not satisfactory, contact your Designed Metal Connections representative for assistance.

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Notice – Designed Metal Connections (DMC) dba Permaswage claims proprietary rights in the Information disclosed hereon. This document may not be
reproduced or copied in whole or in part, be disclosed to others, nor be used for manufacturing purposes without written permission from DMC.
REV: N