Dixon 100 TON RAM User Manual SEC09

Section 9

100 Ton Ram Operating Instructions

for

Internal Expansion of

H520 Couplings

Dixon Valve & Coupling Company

800 High Street • Chestertown, MD 21620

ph: 800•355•1991 fax: 800•283•4966

www.dixonvalve.com

100 Ton Ram Instruction Manual

(refer to the

Before you begin, move the directional control lever
to the "FORWARD” position, depress the button on
the remote and fully extend the ram cylinder. Return
the directional control lever to the “NEUTRAL”
position. Select the proper Pull Rod.
For 1" through 1 1/2" use
through 4" use

Screw the short threaded end of the rod or the rod
adapter into the IX Master Bar.

Install the Master IX Adapter (001-0072) into the Die
Bed Plate (0010-001). Secure in place using two
Adapter Straps (001-0072A) and 3/4" - 10 UNC x 8"
rods.

Converting the 100 Ton Ram from Swaging to Internal Expansion

25RODSMALL

For 2"

25RODLARGE

section of the instruction manual)

1

2

Install the 100ROSTPA into the Master IX Adapter
opening and secure with Adapter Straps (001-
0072A) and two 1/2" - 13 UNC Hex Bolts 1-5/8"
long.

Select the corresponding Thrust Plate for the size
fitting you are installing. Assuring that the recess is
facing outward toward the operator, slide the Thrust
Plate over the Pull Rod until it reaches the
100ROSTPA. Align the holes in the Thrust Plate
with the dowel pins on the 100ROSTPA and slide
the Thrust Plate over the pins. Tighten the wing nut
to lock in place.

3

4

Internal Expansion of H520 Couplings

customer service 800•355•1991

1Section 9

100 Ton Ram Instruction Manual

Slide the stem over the Pull Rod and into the recess
of the Thrust Plate with the connection side of the
stem facing the ram. For male stems, insert the hex
into the recess of the Thrust Plate. For female
stems, insert the first hex into the Thrust Plate so
that the second hex will fit into the recess of the
Thrust Plate.

Note! There is no need to lubricate the plug or

stem. The stems are pre-lubricated at the factory

Screw or slide the IX plug, small end first, onto the
Pull Rod and into the shank of the stem. For 2” and
above screw the retaining nut on until it contacts the
plug. Move the stem slightly to allow for slack and
hand tighten the plug or nut until it is snug.

.

5

6

Accurately measure the hose O.D. with a diameter
tape. Select the correct Holedall Petroleum Ferrule
from the DPL based upon the Hose O.D. just
measured.

Note! Always measure both hose ends for accurate
ferrule selection.

Make sure the hose end is cut square. Slide the
ferrule over the hose until the turned over end of the
ferrule contacts the end of the hose. Place a mark
on the hose at the junction of the ferrule and hose.
Move the ferrule away from the hose end 1/8” and
place another mark at the junction of the hose and
ferrule. This will insure that the proper rubber
displacement or pocket is maintained during the
expansion process.

7

8

2 Section 9

Internal Expansion of H520 Couplings

customer service 800•355•1991

100 Ton Ram Instruction Manual

Slide the hose with the ferrule on over the shank
until the ferrule contacts the shoulder of the stem.
Make sure you align the ferrule with the second
mark from step 6. Make sure the pocket has been
maintained.

Important! If there is an insufficient pocket for the
rubber to displace into, damage may occur to the
stem, ferrule, and /or hose.

While holding the hose and ferrule firmly against the
stem shoulder, engage the ram cylinder by stepping
on the foot pedal (or depressing the “ON” button on
the remote control.) The internal expansion
operation is complete when the hose and stem
assembly is pushed completely over the internal
expansion plug. Releas the foot pedal or “ON”
switch.

9

10

Note: If the gauge reads 10,000 PSI before internal expansion is complete, stop. Contact Dixon for further

assistance. During internal expansion never stand directly in front of the ram. Visually inspect the coupling.

Internal Expansion of H520 Couplings

customer service 800•355•1991

3Section 9