Swagelok TC72 series User manual

www.swagelok.com
Tube Cutting Tool
This manual contains important information for the safe and
effective operation of the Swagelok®TC72 series tube cutting
tool. Users should read and understand its contents before
operating the tube cutting tool.

2Tube Cutting Tool User’s Manual

Tube Cutting Tool User’s Manual 3
Contents
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Summary . . . . . . . . . . . . . . . . . . . . . . . 5
Environmental Protection/Disposal . . . . . . . . . . . . . 7
Product Information . . . . . . . . . . . . . . . . . . . . . . 8
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 10
Application range. . . . . . . . . . . . . . . . . . . . . . 10
Tube materials . . . . . . . . . . . . . . . . . . . . . . . 10
Technical data . . . . . . . . . . . . . . . . . . . . . . . 10
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unpacking the Tube Cutting Tool . . . . . . . . . . . . . 12
Storage and Transport . . . . . . . . . . . . . . . . . . . 12
Mounting the Tube Cutting Tool . . . . . . . . . . . . . . 13
Mounting the Clamping Jaws to the Vise . . . . . . . . . 14
Mounting the Saw Blade . . . . . . . . . . . . . . . . . . 14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjusting for Tube Size . . . . . . . . . . . . . . . . . . . 16
Tool Speed Range . . . . . . . . . . . . . . . . . . . . . 17
Cutting the Tube . . . . . . . . . . . . . . . . . . . . . . 18
Operating in Space-Restricted Environments . . . . . . . 19
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 21

4Tube Cutting Tool User’s Manual

Tube Cutting Tool User’s Manual 5
Safety
Safety Summary
Read the entire safety information section and
Tube Cutting Tool User’s Manual before using this
product. Failure to do so can result in serious injury
or death.
Signal Words and Safety Alert Symbols
Used in this Manual
WARNING Statements that indicate a hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION Statements that indicate a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE Statements that indicate a hazardous situation
which, if not avoided, could result in damage to
the equipment or other property.
Safety alert symbol indicating a potential personal injury
hazard.
 Safety alert symbol indicating a potential for personal
injury from electrical shock.
Safety Information
 WARNING
Danger of death by electric shock
■If the power cord is damaged, electrically live parts may
cause death if touched directly.
■Do not allow the tool to run unattended.
■The tool should be connected to a ground fault circuit
interrupt (GFCI) protected outlet.
■Work on electrical equipment must be done by a
qualied electrician.
■Switch off the tool and remove the plug from the
power outlet before changing tooling, maintaining, or
transporting the tool.

6Tube Cutting Tool User’s Manual
 WARNING
Danger of eyes being injured by hot and sharp-edged
metal chips.
Eye protection must be worn while operating or working
near the equipment.
 WARNING
Excessive noise possible while operating the
equipment.
Ear protection must be worn while operating or working
near the equipment.
WARNING
Keep dry. Equipment and components are not
waterproof.
Do not use electric tools in a damp or wet environment.
WARNING
Fire or Explosion
Do not use in close proximity to ammable liquids or
gases.
WARNING
Danger of being injured by sharp cutting edges
■Do not touch the saw blade while the tool is
operating.
■Wear safety gloves.
■Do not remove chips or tubing from the work area
when the tube cutting tool is still running and the
tool is not yet at rest.
WARNING
Danger of being injured by rotating parts.
Keep hands, loose clothing, and long hair away from
rotating and moving parts.

Tube Cutting Tool User’s Manual 7
WARNING
Observe the following safety measures in order to
protect against risk of injury.
■Inspect the tube cutting tool daily for visible
signs of damage or defects. Have any damage or
defects repaired immediately.
■Always ensure that the machine is in good working
order and comply with these notes on safety.
■Only use the tube ODs, wall thicknesses, and
materials specied in these instructions. Other
materials should be used only after consulting
your authorized Swagelok sales and service
representative.
■Check that the tube is correctly clamped.
■Do not carry the tube cutting tool by the power
cord and do not use the cord to pull out the plug.
Protect the cord from heat, oil and sharp edges
(chips).
■Before cutting tubing, ensure that the saw blade
guard is attached.
■Do not have saw blades in both sawing positions
at the same time.
■Ensure that the cut piece of tube will not fall.
■When work is complete, turn the tool off and let it
run until the blade stops rotating.
Environmental Protection/Disposal
■ Dispose of chips and used gear lubricant oil according to
local regulations.
Electric tools and accessories contain a large share of valuable
raw and synthetic materials, which can be recycled. Therefore:
■ Electrical (electronic) devices that are marked with the
symbol in Fig. 1, may not be disposed of with household
waste in accordance with European Union (EU) regulations.
■ By using local return and collection systems, you contribute
to the reuse, recycling and utilization of electrical (electronic)
devices.
■ Electrical (electronic) used devices contain parts, which
must be handled selectively according to EU regulations.
Separate collection and selective treatment is the basis for
environment-friendly disposal and the protection of human
health.
■ Batteries that are marked with the symbol in Fig. 2 may not
be disposed of with household garbage according to EU
directive 91/157/EEA.
■ In batteries containing harmful substances, the chemical
sign for the heavy metal contained is indicated below the
garbage can:
Cd = Cadmium Hg = Mercury Pb = Lead
Fig. 1 RL 2002/96/EC Symbol


Fig. 2 Battery Symbol

8Tube Cutting Tool User’s Manual
Product Information
Fig 3 TC72 Series
1 Clamping jaw adjustment wheel 9 Hex key (not shown)
2 Saw blade position 1 10 Motor
3 Saw blade position 2 11 Speed adjustment dial
4 Clamping screw cover 12 Slide
5 Blade adjustment wheel 13 Saw blade housing
6 Saw blade guard 14 Vise
7 ON/OFF switch 15 Clamping jaws
8 ON/OFF lock 16 Mounting vise
1
2
3
4
6
7
8
9
10
11
13
14
12
5
14
16
15

Tube Cutting Tool User’s Manual 9
Accessories
TC Series Saw Blade
A saw blade is supplied already installed. The tube wall
thickness capability of the installed saw blade is 0.039 to 0.118
inch (1.0 to 3.0 mm).
Clamping Jaws
A set of coated aluminum-cast clamping jaws is included.
Mounting Plate with Screw Clamps
This optional mounting plate can be attached to the bottom of
the tube cutting tool to aid in mounting the tool to a bench. Use
the four included socket screws to attach the mounting plate to
the tool.
Tripod
This optional stainless steel tripod can provide a space-saving,
easily-moved mounting location for the tube cutting tool.
See the Swagelok Tube Cutting Tool—TC Series catalog,
MS-02-427,for additional information on the optional
accessories.
Fig 4 TC Series Saw Blade
Fig 5 Clamping Jaws
Fig 6 Mounting Plate with Screw Clamps
Fig 7 Tripod

10 Tube Cutting Tool User’s Manual
Specifications
Application range
Material Shape Saw Position Tube OD,
inch / mm
Wall Thickness,
inch / mm
Tube 1 1/4 to 4 1/2 /
6 to 120 0.039 to 0.118 /
0.99 to 3
Elbow 2 1 3/16 to 4 1/2 /
30 to 120
Tube materials
■ Stainless steel
■ Nickel chrome molybdenum alloys
Contact your authorized Swagelok representative for information on additional materials.
Technical data
Characteristic TC72 Tube Cutting Tool
Dimensions,
in. (mm)
20.4 W, 9.1 H, 23.6 L
(518, 230 H, 600 L)
Weight Without Accessories,
lb (kg)
52 (23.6)
Input Voltage Single-phase alternating
current, protection class II
110 V 50/60 Hz
230 V 50/60 Hz
Power,
W
1100
Speed,
r/min
30 to 160
Sound Level (EN23741),
dB
approx. 75
Vibration Level (EN 28662, Part 1),
m/s²
< 2.5
Service Current Requirement,
A
10 minimum
Insulation Class Double insulated in
accordance with Class II,
DINVDE 0740

Tube Cutting Tool User’s Manual 11
Setup
Description
The tube cutting tool is designed in conformance with industry
standards. It has the following features:
■ Two saw blade positions to allow cutting of both straight
tubing and elbows
■ A variable-speed electric motor with restart protection
■ Low-maintenance gearing
■ A quick change system for saw blades
■ Self-centering vise with all-purpose aluminum-coated
clamping jaws
■ Space-saving assembly
■ Increased safety due to the stationary tube and rotating tool
■ Right-angled and deformation-free cuts.

12 Tube Cutting Tool User’s Manual
Unpacking the Tube Cutting Tool
Shipping Case Contents
■ 1 Tube cutting tool
■ 1 Saw blade (installed)
■ 1 Set of clamping jaws
■ 1 Open-end wrench (22 mm)
■ 4 Socket screws
■ 3 Hex keys (5 mm [on cutting tool], 6 mm, and 8 mm)
■ 1 Lubricant brush
■ 1 Tube of cutting lubricant with MSDS
■ 1 Package of 1.5 V alkaline cell batteries (for laser)
■ 1 Tool bag
■ 1 User manual
Report any missing or damaged parts to your authorized
Swagelok sales and service representative immediately.
Storage and Transport
Storage
To properly t the tube cutting tool in the shipping case:
1. The vise should lie parallel to the long side of the shipping
case.
2. The saw blade housing must be rotated approximately 70°
clockwise. See Fig. 8.
Transport
For safe transportation of the tube cutting tool, hold the tool as
shown in Fig 9. Fig 8 Cutting Tool in Shipping Case
Fig 9 Transporting the Cutting Tool

Tube Cutting Tool User’s Manual 13
Mounting the Tube Cutting Tool
Mounting to a Work Bench without Quick
Mounting Plate
1. Set the tube facing tool on the work bench.
2. Mark holes on the work bench using the tube cutting tool as
a template. See Fig. 10.
3. Drill four holes 23/64 in. or 9 mm in diameter.
4. Secure the tube cutting tool to the work bench using the
four provided socket screws. See Fig. 11.
Mounting to a Work Bench with Quick Mounting
Plate
1. Set the quick mounting plate on the work bench.
2. Tighten the two screw clamps of the mounting plate. See
Fig. 12.
3. Secure the tube cutting tool to the mounting plate using the
four provided socket screws.
Mounting to a Tripod
Secure the tube cutting tool to the tripod using the four
provided socket screws.
Fig 10 Marking Holes on the Work Bench
Fig 11 Attaching the Tube Cutting Tool to
the Workbench
Fig 12 Mounting a Quick Mounting Plate
Fig 13 Mounting to a Tripod

14 Tube Cutting Tool User’s Manual
Mounting the Clamping Jaws to the Vise
The tube cutting tool is delivered with the clamping jaws
mounted in the position needed to cut tubing with an OD
greater than 1.772 inch (45 mm). Follow these steps to rotate the
clamping jaws to enable cutting tubing with an OD smaller than
1.772 inch (45 mm).
1. Remove the wing thumb screw on either side of the vise
(Fig.14).
2. Remove the clamping jaws and position each jaw on the
side opposite it was previously positioned.
3. Thread the wing thumb screw into place until nger-tight.
Mounting the Saw Blade
 WARNING
Do not touch the saw blade while the tool is in
operation.
 WARNING
Switch off the tool and remove the plug from the
power outlet before changing tooling, performing
maintenance, or transporting the tool.
 WARNING
Never mount a saw blade in both blade positions at
the same time.
 WARNING
Keep hands away from the saw blade edge. Wear
safety gloves.
NOTICE
The saw blade must be free of chips and dirt.
It is not possible to mount or replace a saw blade if a tube has
been clamped into the clamping jaws.
Saw Blade Position 1
1. Open the clamping jaws by turning the clamping jaw
adjustment wheel counterclockwise until it stops.
2. Move the saw blade housing up by turning the blade
adjustment wheel clockwise until it stops.
Fig 14 Clamping Jaw Wing Thumb Screws
Wing thumb
screw
Blade adjustment
wheel
Clamping jaw
adjustment wheel
Slide
Fig 15 Tube Cutting Tool Adjustment
Wheels

Tube Cutting Tool User’s Manual 15
3. Remove the saw blade nut with the provided 22 mm wrench
(Fig. 16).
Note: The saw blade nut is a reverse-threaded nut.
4. Clean the saw blade shaft and the surrounding area with a
brush.
5. Mount the saw blade on the shaft with the marking on the
blade facing the clamping plate (Fig. 17).
6. Thread the saw blade nut onto the shaft and tighten
wrench-tight with the provided wrench.
Saw Blade Position 2
1. Remove the clamping screw cover (Fig. 18).
2. Loosen the clamping screw using the provided 8 mm hex
key.
3. Clean the saw blade shaft and the surrounding area with a
brush.
4. Mount the saw blade on the shaft with the marking on the
blade facing the saw blade guard.
5. Tighten the clamping screw using the provided hex key
(Fig.19).
6. Replace the clamping screw cover.
Saw blade nut
Fig 16 Saw Blade Position 1
Fig 18 Clamping Screw Cover
Clamping screw
cover
Clamping screwSaw blade
guard
Fig 19 Saw Blade Position 2
Fig 17 Clamping Plate
Clamping plate

16 Tube Cutting Tool User’s Manual
Operation
The tool should only be operated using a ground fault circuit
interrupt (GFCI) protected outlet.
Adjusting for Tube Size
 CAUTION
The tube cutting tool must be switched off before
adjusting the tool. The saw may revolve around the
tube automatically when it is switched on.
The saw blade should not touch the tube before the cutting
operation begins. Adjust the tube facing tool according to this
section as necessary.
1. Turn the blade adjustment wheel until the saw blade housing
is at the lowest position (Fig. 20).
2. Slide the tube towards the saw blade until it is right in front
of the blade. Clamp the tube by turning the clamping jaw
adjustment wheel (Fig. 21).
3. Rotate the motor to the cutting position, approximately 45°
clockwise.
4. Adjust the saw blade position by turning the blade
adjustment wheel until the teeth of the blade reach
approximately 0.039 to 0.079 inch (1 to 2 mm) into the tube
(Fig. 22).
5. Rotate the motor back to the original position.
6. Loosen the clamping jaw adjustment wheel and move the
tube forward until the cutting location is above the saw
blade. Fully clamp the tube by turning the clamping jaw
adjustment wheel clockwise until it stops.
Fig 22 Adjusting the Blade Position
Fig 21 Saw Blade Teeth Position
Fig 20 Moving the Saw Blade Housing
Blade adjustment
wheel
Clamping jaw
adjustment wheel

Tube Cutting Tool User’s Manual 17
Tool Speed Range
Adjusting the Speed
Set the speed by turning the speed adjustment dial.
TC72 Series
Level Tube material Spindle Speed,
rpm
E and G Stainless steel 114 to 160
B, C,
D, E
Nickel chrome molybdenum
alloys
42 to 114
Fig 23 Speed Adjustment Dial

18 Tube Cutting Tool User’s Manual
Cutting the Tube
 WARNING
Allow the machine to run until it stops rotating after
cutting tube to avoid injury.
 WARNING
Do not touch the saw blade while the tool is in
operation.
 WARNING
Eye protection must be worn while operating or
working near the equipment.
 WARNING
Do not operate the cutting tool without the saw
blade guard in place.
 CAUTION
Support long pieces of tubing with suitable fixtures
to avoid injury from tilting tool and/or falling tubing.
NOTICE
The tool can be damaged by incorrect setup or a
tube not cut at a right angle. Verify there is space
between the tool and the tube to prevent damage.
1. Mount the saw blade in the desired position according to
Mounting the Saw Blade.
2. Adjust for the tube size as necessary according to
Adjusting for Tube Size.
3. Mark the cut location on the tube.
4. Insert the tube in the cutting tool vise and move until cut
location is centered. Clamp the tube by turning the clamping
jaw adjustment wheel until it stops.
5. Set the tool speed range according to Adjusting the
Speed.
6. Apply cutting lubricant to the saw blade (Fig. 24).
7. Plug the cutting tool into a power outlet.
8. Press the ON/OFF switch to turn the tool on. The switch can
be locked into place with the ON/OFF lock (Fig. 25).
9. Hold the cutting tool by the motor grip and slowly turn the
cutting tool clockwise until the tube wall is pierced.
Fig 24 Lubricating the Saw Blade
Fig 25 ON/OFF Switch and Lock
ON/OFF switch
ON/OFF lock

Tube Cutting Tool User’s Manual 19
10. Continue to rotate the cutting tool clockwise to complete the
cut.
11. Rotate the cutting tool counter clockwise to the original
position.
12. Unlock the ON/OFF lock and turn off the cutting tool.
13. Apply cutting lubricant to the saw blade after each cut
(Fig.24).
Operating in Space-Restricted
Environments
1. Loosen the set screw with the provided 5 mm hex key
(Fig.26).
2. Rotate the motor 70°.
3. Tighten the set screw.
Fig 26 Rotating the Motor
Set screw

20 Tube Cutting Tool User’s Manual
Maintenance
 WARNING
Allow the tool to run to a stop and unplug the tool
before changing tooling, maintaining, or transporting
the tool.
Remove any chips and dirt from the saw blade, between the
saw blade and saw blade housing, and the blade shaft.