Swagelok MS-PSR-110 User manual

Power Swager Manual
and Thermoplastic Hose
Assembly Instructions
This manual contains information
necessary for the proper operation
of the Swagelok power swager and
assembly of thermoplastic hose
products. The manual must be read
and understood by the person(s)
responsible for the setup and the
use of this equipment.
Model MS-PSR-110
110V Single Phase/60 Hz
www.swagelok.com

Power Swager
2
Warning! Electrical Shock.
Read all enclosed safety instructions
and manuals prior to operation.
Warning! Keep Dry.
Equipment and components are not
waterproof.
Warning! Fire or explosion.
Do not use equipment in a combustible
or explosive atmosphere.
Warning! Eye protection.
Eye protection must be worn while
operating or working near the equipment.
Warning! Ear protection.
Ear protection may be required if
operating or working near the equipment
for prolonged periods of time.
Warning! Hot surface.
The surface temperature of the oil reservoir
and adjacent parts will increase during
normal use. The temperature increase
may be excessive if proper maintenance
is not performed.
Operator’s Safety Summary
READ AND UNDERSTAND THIS MANUAL BEFORE
USING POWER SWAGER. This device is electrically
powered and must be operated in a safe environment to
avoid risk of fire, explosion, or electric shock.
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Operating Instructions for
Swagelok Power Swager . . . . . . . . . . . . . . . 4
Assembly Procedures for
Swagelok Thermoplastic Hose
using Power Swager. . . . . . . . . . . . . . . . . . . 5
End Connections, Pushers, and
General Maintenance . . . . . . . . . . . . . . . . . .8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . .9
Warning! Pinch Points!
Keep hands, loose clothing, and long
hair away from rotating or moving parts.
Serious injury can occur.
Caution!
Indicates cautionary information.
Safety Information
!
~
F
a
G
l
p
.

Power Swager
3
2
3
4
19
1
8
11
13
14
7
12
J, L
16
21 22
Overview
Power Swager Model MS-PSR-110
No. Description Part No.
01
02
03
04
05
06
06A
07
08
09
10
Plug
Trip rod
Trip rod collar
Trip latch
Trip latch eccentric
Die lifting guide arm
with insertion depth block(s)
mounting holes
Die lifting guide arm
Eccentric guide bushings
Thumb screw
Die lifting finger R.H.
Die lifting finger L.H.
453C-22013
453C-22014
453C-22015
453C-22016
453C-22047
453C-22036
453C-22037
453C-23004
453C-23005
453C-23006
Die
bowl
Angle iron
supports
➀Frame consists of top bar, guide bars, pusher block, angle iron supports, and
die bowl.
No. Description Part No.
11
12
13
14
15
16
17
18
19
20
21
22
Die detent pins
Pal nut
Spring plunger
Reservoir replacement kit
Switch toggle on/off
Hydraulic cylinder 453C-00012
Decal, oil specification
Decal, name (Swagelok)
Breather cap
Valve handle
Frame➀
Manual control valve
453C-23007
453C-23009
453C-23013
453C-40008
453C-41015
453C-11009
0112-49016
—
453C-40010
453C-40014
453C-24006
—

Power Swager
4
6A
A, B, C
20
18
910
17
15
5
KD, F, G, H
E, F, G, I
6
2
Guide bar Guide bar
Top bar
Die bowl
Letter Description
A
B
C
D
E
F
G
H
I
J
K
L
Bolt hex 1/4-24 UNC ⫻1.75 long
Nut hex 1/4 UNC
Lock washer 1/4 in.
Bolt hex 5/16-18 UNC ⫻2.00 long
Bolt hex 5/16-18 UNC ⫻1.50 long
Nut hex 5/16-18 UNC
Lock washer 5/16 in.
Washer, flat 5/16 in.
Washer, star 5/16 in.
Bolt hex 1/2-13 UNC ⫻2.00 long
Socket head cap screw
5/16-18 UNC ⫻1.00 long
Lock washer 1/2 in.
Pusher
block

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

6
Section II
Assembly Procedures for
Swagelok 7N, 7P, 7R, and 8R
Thermoplastic Hose using the
Power Swager
Pre-Assembly
1. Be sure the hose and all components are in good condition.
Note: The lead end of the hose should be cut squarely.
2. Verify that the swager is in proper working order as outlined
in Section I.
Cutting Bulk Hose
1. Determine the desired hose and end connection size and
type.
2. Determine the desired hose assembly overall length.
3. See the
End Connections and Pushers chart on page 8 to
determine the fitting cut-off length.
4. Subtract the desired fitting cut-off lengths from each end of
the hose assembly overall length. Note: The result is the
overall cut length.
5. Measure and mark the hose at the overall cut length.
6. Cut the hose squarely at the mark.
Improper CutProper Cut Hose Axis Hose Axis
Cut Plane
Cut Plane
Cut Plane
Cut Plane
Cut is not square and
perpendicular with hose axis.
Cut is square and
perpendicular with hose axis.
Alignment of Dies in the Swager Die Bowl
The dies are aligned at the factory. However, if at any time the
dies are not of equal height when seated in the die bowl, they
must be readjusted. To readjust the dies:
1. Loosen the four (4) mounting bolts on the die lifting fingers.
2. Push each die lifting finger assembly down as far as the bolt
holes will allow.
3. Turn on the swager.
4. Pull the valve handle until the pusher bottoms on the dies,
leaving the pusher in contact with the dies.
5. Retighten the bolts.
Adjustment of Eccentric Guide Bushings
This adjustment is made at the factory. However, the eccentric
guide bushings may be readjusted if the dies are catching on
the top edge of the frame. To adjust:
1. Place the swager in the full downward position.
2. Locate the eccentric guide bushings on the lower outside
bars of the frame.
3. Loosen the mounting bolts.
4. Rotate the bushings counter-clockwise to tighten.
Note: The die lifting arms must slide freely.
End Connection Preparation
Remove all plastic caps, plugs, nuts, and ferrules prior to
swaging an end connection.
Proper Mark Position
Improper Mark Position
Inserting End Connections
1. Mark each hose end with the correct insertion depth.
2. Use the appropriate depth insertion gage:
■MS-IGB-1 for 1/4, 3/8, and 1/2 in. hose.
■MS-IGB-2 for 3/4 and 1 in. hose.
3. Insert hose until it bottoms out.
4. Mark the hose. Note: The bottom of the mark should line up
with the top of the insertion gage.
depth insertion
gage
5. If acceptable for the application, apply a thin coat of clean,
SAE 20 weight lubricating oil to approximately the first 1/2 in.
(12 mm) depth of the hose ID.
!Caution!
Never use oil in 7P (poly pure) hose.
Power Swager

Power Swager
7
If insertion is difficult, the following accessories may be
required:
■Vise blocks (MS-VB-1 for 1/4, 3/8, and 1/2 in. hose
or MS-VB-2 for 3/4 and 1 in. hose)
■Pusher
■Vise
■Rubber mallet
1. Clamp the vise block slot around the hose, leaving at least
twice the distance of the insertion depth mark exposed.
2. Insert the end connection into the hose.
3. Place the pusher over the end connection. (See the
End
Connections and Pushers
chart for the correct pusher
ordering number.)
4. Tap the pusher with the mallet to insert the hose into the
end connection up to, but not past, the insertion depth mark.
2. Select the correct pusher for the end connection type and
size. (See the
End Connections and Pushers chart for the
correct pusher selection.)
Note: For end connections that do not appear in the chart,
contact your Swagelok sales representative.
3. Secure the pusher in the swager.
Die Set and Fitting Lubrication
Before the initial swage, apply a light coat of lubricant to the
die halves. Note: The suggested lubricant is MS-TP-LUBE.
Hose Size
in. Die Set
Number
1/4 MS-7R8R-4
3/8 MS-7R8R-6
1/2 MS-7R8R-8
3/4 MS-8R-12
1MS-8R-16
1MS-7P-16
!Caution
Each die set consists of two matching halves, each
of which is stamped with the same identification
number. Failure to use matching die halves may result
in improper swaging, leading to hose failure. Die set
must match appropriate hose series and size.
Selecting Die Sets and Pushers
1. Select the appropriate matched swaging die sets.
Hose Series
7N, 7R, 8R, 7P
7N, 7R, 8R, 7P
7N, 7R, 8R, 7P
8R, 7P
8R
7P
Improper Insertions
Not inserted enough
Inserted too far
Proper Insertion
6. Insert the hose into the end connection up to, but not past,
the insertion depth mark. Note: The bottom of the mark
should line up with the edge of the shell.
shell

Power Swager
8
Table A
8. Repeat the swaging process, steps 1 through 6, to complete
the hose assembly.
9. Verify that the hose meets overall length requirements.
Hose
Size
in. Swage Diameter in. (mm) Bell Length in. (mm)
1/4 0.563 to 0.573
(14.2 to 14.5) 0.66 to 0.72 (16.8 to 18.3)
3/8 0.689 to 0.699
(17.5 to 17.8)
0.72 to 0.78
(18.3 to 19.8)
1/2 0.843 to 0.853
(21.3 to 21.6)
3/4 1.155 to 1.170
(29.5 to 29.7)
11.483 to 1.493
(37.6 to 37.8) 0.91 to 0.97 (23.1 to 24.6)
11.450 to 1.460
(36.8 to 37.1) 0.78 to 0.84 (19.8 to 21.3)
Hose
Type
7N,
7R,
8R,
7P
8R,
7P
8R
7P
Lubricant Hints
Lubrication will increase die life and improve the shell’s surface
appearance. Before using any lubricant, read all labels and
instructions.
MS-TP-LUBE
When applying MS-TP-LUBE on non-lubricated die sets,
apply a light coating to the entire surface of both die
halves. Lubrication transferred from lubed swage shells
during the swaging process will keep the dies lubricated.
Swage Shells
When applying MS-TP-LUBE to swage shells, liberally
coat the bottom half of the external surface of the swage
shell.
Insert lubricated die halves securely within the swager die
fingers.
4. Return the swager to the starting position.
5. Remove the swaged hose.
6. Turn off the swager.
7. Measure the swage diameter and bell dimensions to verify
that the hose is assembled properly. Note: Measurements
must be within the limits listed in
Table A .
Swager Start-Up
!Caution
Do not pinch hose between die halves.
~Warning!
Keep hands and fingers away from all moving parts
Manual Valve Handle Operation
1. Pull the control handle to start the swaging process.
Note: The pusher block will move downward.
2. Release the control handle to stop the swaging process.
3. Push the handle to return the swager to the full up posi-
tion. Note: The trip latch, if adjusted properly, will automati-
cally disengage the swager.
4. Turn on the swager.
5. Cycle the swager once or twice, stopping just before the
pusher makes contact with the die surfaces.
6. Turn off the swager.
7. Verify that the dies are seated evenly and securely within
the die base. Note: If the die halves are not aligned, see
Section I,
Alignment of Dies in the Die Bowl.
8. Turn on the swager.
9. Cycle through a full swaging stroke. Note: If the die halves
are still not aligned, repeat steps 1 through 4.
10. Return the swager to the full up position.
Swage
Diameter
Parting Line
Bell
Length
Measuring
Swage Diameter
Begin at a point between
1/4 to 1/2 in. (6 to 13 mm)
from the end of the swage
shell and measure 360°
around the shell. Do not
measure at the parting lines.
Measuring
Bell Length
Measure from behind the hex
to the point where the bell
stops or where the swage
diameter ends.
Swaging Process
1. Verify that the hose is inserted properly into the end
connection.
2. Insert the hose through the die halves and end connection
inside the pusher. Note: Make sure that the end of the
shell is 3/4 to 1 in. (19 to 25 mm) from the top of the die
halves. If it is not, see Section 1,
Adjustment of the
Automatic Return Stop Position
.
3. Begin the swaging process while applying upward force
on the hose. Note: The swaging process is complete when
the pusher bottoms on top of the die surfaces.

Power Swager
9
➀For a complete ordering number, add SS for 316 stainless
steel or Sfor steel as a prefix to the basic ordering number. ➁To determine the correct length of hose, subtract the cut-off length for each end connection from
the overall length of the assembly. Lengths are for reference only, subject to change.
Section III
General Maintenance
■After use, clean dies, pusher, and other swager
components with isopropyl alcohol to remove lubricant.
■Periodically check the hoses for cuts, tears, or
bagginess in the outer cover. Replace any hose
assembly that has such damage.
■Periodically check the oil reservoir fluid level. The oil should be
about 1 to 1 1/2 in. (25 to 38 mm) below the breather cap hole
when the machine is turned off (see Section II,
Breather Cap
Installation
).
■Periodically check the mechanical moving parts on the swager.
Replace any parts that are bent, loose, or show excessive wear.
End Connections and Pushers
End Connection Hose
Size Basic
Ordering Number➀
Cut-Off➁
Length
in. (mm)
Pusher
Ordering
NumberType Size, in.
Swagelok
tube adapter
1/4 in. 1/4 -TP4-TA4 1.43 (36.3) MS-P-TA4
-TP4-TA6 MS-P-4TA6
3/8 -TP6-TA6 1.50 (38.1) MS-P-TA6
1/2 in. 1/2 -TP8-TA8 1.79 (45.5) MS-P-SLTA8
-TP8-TA10 MS-P-8TA10
3/4 in. 3/4 -TP12-TA12 1.89 (48.0) MS-P-TA12
1 in. 1-TP16-TA16 2.18 (55.4) MS-P-TA16
6 mm 1/4 -TP4-TM6 1.43 (36.3) MS-P-TA4
-TP4-TM8 MS-P-4TM8
10 mm 3/8 -TP6-TM10 1.50 (38.1) MS-P-TA6
12 mm 1/2 -TP8-TM12 1.79 (45.5) MS-P-SLTA8
Swagelok
tube fitting
1/4 in. 1/4 -TP4-SL4 1.54 (39.1) MS-P-SL4
3/8 in. 3/8 -TP6-SL6 1.63 (41.4) MS-P-SL6
1/2 in. 1/2 -TP8-SL8 1.72 (43.7) MS-P-SLTA8
6 mm 1/4 -TP4-SM6 1.54 (39.1) MS-P-SL4
8 mm -TP4-SM8 1.55 (39.4) MS-P-4SM8
10 mm -TP4-SM10 1.80 (45.7) MS-P-4SM10
3/8 -TP6-SM10 1.64 (41.7) MS-P-SL6
12 mm 1/2 -TP8-SM12 1.74 (44.2) MS-P-SLTA8
JIC/AN 37°
female swivel
1/4 in. 1/4 -TP4-AS4 1.59 (40.4) MS-P-AS4
3/8 in. 3/8 -TP6-AS6 1.71 (43.4) MS-P-AS6
1/2 in. 1/2 -TP8-AS8 1.77 (45.0) MS-P-AS8
60° male cone
female swivel
BSP/ISO parallel
1/4 in. 1/4 -TP4-BM4 1.42 (36.1) MS-P-BM4
3/8 in. 3/8 -TP6-BM6 1.57 (39.9) MS-P-BM6
1/2 -TP8-BM8 1.67 (42.4) MS-P-BM8
30° female swivel
BSP/ISO/JIS
parallel
1/4 in. 1/4 -TP4-BS4 1.53 (38.9) MS-P-BS4
3/8 in. 3/8 -TP6-BS6 1.69 (42.9) MS-P-BS6
1/2 in. 1/2 -TP8-BS8 1.81 (46.0) MS-P-BS8
Universal metric
female swivel
14 mm 1/4 -TP4-MC14 1.35 (34.3) MS-P-MC14
18 mm 3/8 -TP6-MC18 1.46 (37.1) MS-P-MC18
22 mm 1/2 -TP8-MC22 1.52 (38.6) MS-P-MC22
Male NPT
1/4 in. 1/4 -TP4-PM4 1.25 (31.8) MS-P-PM4
3/8 -TP6-PM4 1.34 (34.0) MS-P-PM6
3/8 in. -TP6-PM6
1/2 in. 1/2 -TP8-PM8 1.53 (38.9) MS-P-PM8
Male BSP/ISO
tapered (RT)
1/4 in. 1/4 -TP4-MT4 1.25 (31.8) MS-P-PM4
3/8 in. 3/8 -TP6-MT6 1.34 (34.0) MS-P-PM6
1/2 in. 1/2 -TP8-MT8 1.53 (38.9) MS-P-PM8
fractional metric fractional
metric
3/8 in.
5/8 in.
8 mm
Male BSP/ISO
parallel (RS) 1/4 in. 1/4 -TP4-MS4 1.50 (38.1) MS-P-MS4
3/8 in. 3/8 -TP6-MS6 1.38 (35.1) MS-P-MS6
1/2 in. 1/2 -TP8-MS8 1.44 (36.6) MS-P-MS8
1/2 in.
30°
37°
60°
60°

Power Swager
10
If the swager begins producing improperly swaged connections:
■Confirm that the assembly procedure is being followed.
Proper lubrication of dies and fitting shells is especially
critical. (Refer to Section II.)
■Inspect the swage dies. Swage dies have a finite life.
Axial scratches on fitting shells after
swaging may indicate worn dies.
Condition:
There is a gap or movement between
the cylinder and frame. This gap is
caused by a loose cylinder mounting bolt.
Solution:
Tighten the cylinder mounting bolt until
the gap is eliminated (as shown below).
Condition:
The die lifting arms do not pivot freely.
Solution:
Adjust accordingly per
instructions in Section I.
Condition:
There is not proper clearance for the die
lifting arms to slide freely between the
eccentric guide bushings and the swager
frame during the full swaging cycle.
Solution:
See Section I of this manual for
adjustment instructions to obtain
proper clearance (as shown to the right).
!Caution: Before performing any adjustments, make
sure the power is turned off and properly locked out.
Condition:
The dies have vertical wear
lines that appear as scratches.
Wear lines can be felt on the
finish of the swaged fitting and dies
Solution:
Replace dies.
Section IV
Troubleshooting
Condition:
There is a gap between the pusher block
and piston shaft. This gap is caused by
a loose socket screw within the pusher
block cavity.
Solution:
Tighten the socket head cap screw
within the pusher cavity until the gap
is eliminated (as shown below).
Condition:
The swage die halves are
uneven when they are seat-
ed in the base. (Improper
die alignment is shown
below.)
Note: Die alignment
must be checked before the
pusher touches the dies.
Solution:
See Section I of this manual
for the proper adjustment.
gap
gap

Power Swager
11

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