Swagelok AHSU Installation manual

www.swagelok.com
AHSU with base
Air-Actuated Hydraulic Swaging
Unit (AHSU)
Setup and Operating Instructions
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE USING THE AHSU.
Definitions
Statements and symbols are used in this document to identify safety concerns. Read the definitions below
before setting up and operating the AHSU.
 CAUTION!
Statements that identify conditions or
practices that could result in damage to the
equipment or other property.
 WARNING!
Statements that identify conditions or
practices that could result in personal injury
or loss of life.
 WARNING!
EYE PROTECTION
Safety glasses must be worn when setting
up and operating the AHSU.
CAUTION!
Do not tamper with or alter any
components of the AHSU.
 CAUTION!
Limit air inlet pressure to less than 90 psig
(6.2 bar). If the inlet pressure exceeds 90
psig, a pressure relief valve in the unit will
activate
Safety Precautions
 CAUTION!
Do not operate AHSU unless all tooling is
installed and the tubing, nut and ferrules
are properly positioned within tooling.
 CAUTION!
Return the AHSU to your independent
Swagelok sales and service representative
if any signs of hydraulic fluid leakage or
malfunction occur.

2Air-Actuated Hydraulic Swaging Unit (AHSU) Setup and Operating Instructions
Components (Unit with Die Heads and Base)
Safety glasses
Gap
inspection
gauge
Hex key
Nut retainer
Base Air input
decal
Air inlet
valve
Air pump
Indicator knob
set lever
Operating
instructions
Indicator knob
Die heads
Air input
Hydraulic housing
Adapter plates

Air-Actuated Hydraulic Swaging Unit (AHSU) Setup and Operating Instructions 3
5. For 1/4 and 3/8 in. and 6, 8, and 10 mm sizes,
insert the appropriate adapter plate into the nut
retainer. Refer to the mark on the plate for size
information.
6. Connect the appropriate air source to the AHSU
air inlet valve.
7. Adjust the source pressure to the value shown
in the table or on the air input decal for the
tubing material and size.
 CAUTION!
Air inlet pressure should be limited
to 90 psig (6.2 bar) or less. If the inlet
pressure exceeds 90 psig, there is a
pressure relief valve in the unit that will
activate.
Setup
1. Select the proper size die head (reference the
size marking on each die head).
2. Remove the screw located in the bore of the
die head previously installed in the hydraulic
housing by turning counterclockwise with the
hex key.
Required Air Inlet Working Pressure, psig (bar)
Fitting/Tooling
Size
Stainless Steel or
Steel Tubing
Soft Copper
Tubing
Fractional Series
400 40 (2.8) 35 (2.4)
600 60 (4.2) 35 (2.4)
810 70 (4.9) 45 (3.1)
Metric Series
6M0 40 (2.8) 35 (2.4)
8M0 50 (3.5) 35 (2.4)
10M0 60 (4.2) 40 (2.8)
12M0 70 (4.9) 45 (3.1)
3. Depress the nut retainer to remove the die head.
4. Depress the nut retainer and install the selected
die head. Tighten the shaft screw sufficiently to
keep the die tight, being careful not to break the
screw by over-tightening it.
Die head
Size marking
Screw
Nut retainer
Adapter plate

4Air-Actuated Hydraulic Swaging Unit (AHSU) Setup and Operating Instructions
3.Insert tubing into the Swagelok end fitting to be
pre-swaged. Disassemble the nut from the end
connection, leaving the nut and ferrules on the
tubing. The orientation of the nut, rear ferrule,
and front ferrule should be as shown.
4. Insert the tubing into the die head. Make sure
that the tubing rests firmly on the shoulder of the
die head.
5. Depress the nut retainer and slide the nut over
the die head.
6. The front edge of the nut should line up with the
groove on the outside of the die head.
7. Allow the nut retainer to return to its starting
position.
8. Hold the tubing firmly in the die head and
depress the air inlet valve handle for three
seconds after the indicator knob is released.
The ferrules have now been preswaged onto the
tubing.
Hacksaw burrs
OD and ID
Tube cutter
burrs ID only
Tube
0.06 in.
(1.5 mm)
10º
Operation
1. Set the indicator knob by pivoting the indicator
knob set lever until the knob snaps into position
and is flush with the hydraulic housing.
2. Prepare tube ends as follows.
A. Cut tubing squarely. Use of a Swagelok
tube saw guide is recommended.
B. Remove any burrs. Use of Swagelok
deburring tools is recommended.
Tubing
Saw guide
WARNING!
Failure to deburr the OD of the tube
could prevent the tube from properly
resting against the piston shoulder. ID
burrs could break off and cause damage
in other components of the system.
C. If a file is used on the OD, make a 10° x
0.06 in. (1.5 mm) chamfer.
Indicator knob set lever
Tubing
Die head
Tubing
Die head Indicator knob set lever

Air-Actuated Hydraulic Swaging Unit (AHSU) Setup and Operating Instructions 5
9. Release the air inlet valve handle.
Note: Releasing the air inlet valve handle too
soon may result in an insufficiently preswaged
assembly.
10. Depress the nut retainer to remove the
preswaged assembly.
11. Install the preswaged assembly into the fitting
body. Turn the nut onto the fitting body until it is
finger-tight.
12. Mark the nut at the 6 o’clock position.
13. While holding the fitting body steady, tighten
the nut one-half turn until the mark reaches the
12 o’clock position.
Nut retainer
Gauging Instructions
Position the Swagelok AHSU gap inspection gauge
adjacent to the gap between the nut and body hex.
■
If the gauge will not enter the gap, the fitting is
sufficiently tightened.
■If the gauge will enter the gap, additional tightening
is required.
Note: 3-sided AHSU gap gauge is for fractional
fittings.4-sided AHSU gap gauge is for metric
fittings.
Inspect the fitting with a gap inspection gauge
Tightening is requiredSufficiently tightened
AHSU gap
inspection gauge

6Air-Actuated Hydraulic Swaging Unit (AHSU) Setup and Operating Instructions
Swagelok—TM Swagelok Company
© 2002 - 2021 Swagelok Company
Printed in U.S.A
MS-12-38 RevD, October 2021
Troubleshooting
Symptom Causes Remedy
Tubing is difficult to remove from
the AHSU after preswaging.
Tubing wall may be below
recommended minimum wall
thickness.
Gently rock the tubing back and forth to remove it.
Use tubing that is thicker than the minimum
recommended wall thickness.
 CAUTION!
Do not rotate the tubing.
The indicator knob does not
release.
Improper inlet pressure being used for
tubing material and size.
Adjust inlet pressure to the correct value for the tubing
size and material.
Oil is leaking from unit. Return the unit to your independent Swagelok sales
and service representative.
The front edge of the Swagelok
nut does not line up with the
groove on the outside of die
head.
Improper die head being used.
The ferrules are not oriented properly.
Use the proper die head.
Place the ferrules in proper orientation.
The unit fails to swage
sufficiently as indicated by the
gap inspection gauge after
assembly.
The working pressure is too low.
Verify the working air pressure is set to the appropriate
pressure recommended on the air input decal.
 CAUTION!
Do not swage a tube more than once.
Warranty Information
Swagelok products are backed by The Swagelok Limited
Lifetime Warranty. For a copy, visit swagelok.com or contact
your authorized Swagelok representative.
The AHSU cannot be used for alloy 2507 tubing or for medium-pressure tubing.
Refer to Swagelok Gaugeable Tube Fittings and Adapter
Fitting catalog, MS-01-140, for additional information.
Refer to Swagelok Tube Fitters manual, MS-13-03, for
additional information.
Refer to Swagelok Tubing Data catalog, MS-01-107, for
additional information.