Dixon 100 TON RAM User Manual SEC05

Section 5

100 Ton Ram Operating Instructions

for

Cam & Groove

Holedall 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

Install Main Pusher (M011-065) on cylinder rod cap.
Make sure that the pusher is fully installed on the
rod cap.

Install the Cam & Groove pusher necessary to do
the size and style of coupling to be swaged into the
Main Pusher (M011-065).
Additional pushers may be required.
Reference the chart at the end of this section for
proper pusher selection.

1

2

Install the required die holders ensuring that the
seams between the die holder halves do not line up.
The die holders are designed to fit one inside the
other.

A guideline for selecting die holders is:

DH6-003 1/4" - 1" I.D. hose
M012-002 4" - 6" I.D. hose
M012-003 6" - 8" I.D. hose
M012-004 8" - 10" I.D hose

Caution!

Secure the die holders with tie down bars to prevent
the die holders from slipping out of the die bed
unexpectedly.

Never use a swaging die as a die holder!

3a

3b

Cam & Groove Holedall Couplings

customer service 800•355•1991

1Section 5

100 Ton Ram Instruction Manual

Accurately measure the hose O.D. with a diameter
tape. Each end of the hose should be measured to
guarantee the correct ferrule and die selection.
Select the correct ferrule and die based upon the
hose free O.D. just measured from the die chart.
Make sure that the hose end is cut square. If the
hose is to be static grounded, follow hose
manufacturers procedure for proper static
grounding.

4

5

Align the end of the hose with the stem shoulder i
mark the hose at the end of the stem

Place a mark on the outside of the ferrule that
corresponds with the

center

of one of the turned
over sections of the ferrule. This mark will act a
guide for correct engagement with the stem collar.

When using the Notched Stem and Ferrule system
these guidelines must be followed:

A. Before stem insertion, assemble the ferrule onto
the stem by sliding the turned over portion of the ferrule
past the notched sections of the stem collar. Rotate the
ferrule 90° (1/4 turn).

B. Before starting the swaging process, make sure
that the turned over portion of the ferrule and the collar
are fully engaged.

C. For “C” style couplings (requiring spacer rings),
make sure that the two ring halves meet over the turned
over portion of the ferrule which should be under the cam
arms.

6

7

2 Section 5

Cam & Groove Holedall Couplings

customer service 800•355•1991

100 Ton Ram Instruction Manual

Cut the hose end square and if the assembly
requires static grounding, follow the hose
manufacturer’s procedure for proper static
grounding. Lubricate the hose I.D. and the O.D. of
the stem with Dixon Coupling Lubricant or
equivalent. Insert the Cam and Groove fitting with
ferrule onto the hose until the ferrule is even with the
mark closest to the hose end. This is the second
mark made on the hose.

Bring the hose with the stem and ferrule through the
die bed. Insert the coupling into or onto the pusher
(depending upon coupling style). Make sure that
there is sufficient room between the die holders and
the end of the ferrule to comfortably insert the die
halves into the die holders.

8

9

Lubricate the outside of the ferrule with Crisco®
(recommended) or high viscosity oil or heavy duty
grease.

Lubricate the I.D. of both die halves with Crisco®
(recommended) or high viscosity oil or heavy duty
grease.

10a

10b

Cam & Groove Holedall Couplings

customer service 800•355•1991

3Section 5

100 Ton Ram Instruction Manual

Lifting up the hose, insert one die half under the
hose. Lower the hose so that it rests on the die.
Insert the other die half. Make sure that the seams
of the die do not line up with the seams on the die
holders.

While holding the die in place with one hand, place
one of the tie down bars over the die so that it does
not come out of the die holder unexpectedly. Secure
the tie down bar by tightening the bolt.

11a

11b

For style "C" couplings go to step 12.
For style "E" couplings go to step 13.

4 Section 5

Cam & Groove Holedall Couplings

customer service 800•355•1991

100 Ton Ram Instruction Manual

For “C” style couplings requiring spacer rings:

Release both cam arms.

12a

12b

Remove the gasket from the coupler.

Put the spacer rings between the ferrule and coupler
head, making sure that the two ringhalves meet over
the turned over portion of the ferrule.

12c

12d

Insert the proper pusher into the coupler (reference
the chart at the end of this section for proper pusher
selection).

Cam & Groove Holedall Couplings

customer service 800•355•1991

5Section 5

100 Ton Ram Instruction Manual

Check the ferrule engagement with the stem collar.
The mark on the ferrule (
positioned under the cam arm.

Move the directional control lever to the
“FORWARD” position. Depress the button on the
remote and advance the cylinder until the end of the
ferrule is near the die opening. Using a wooden
board or metal pipe, lift the ferrule up. Jog the
cylinder by quickly depressing and releasing the
button on the remote. This will allow the ferrule to
enter the die slowly without contacting the die face.
Continue jogging the cylinder until the ferrule has
entered the die approximately one half inch.

from Step 6a) must

be

12e

12f

Loosen and move any tie down bars that may come
in contact with the coupler head. Depress and hold
the button on the remote until the spacer rings are
even with or about to contact the die face. Release
the button on the remote. Return the directional
control lever to the “NEUTRAL” position.

Note: If the gauge reads 10,000 PSI before swaging
is complete, stop. The ferrule or die used for that
hose end may be incorrect. Contact Dixon for
further assistance.

Move the directional control lever to the “REVERSE”
position. Depress and hold the button on the
remote retracting the cylinder until there is sufficient
room for the stem and ferrule to clear the die bed.

12g

12h

6 Section 5

Cam & Groove Holedall Couplings

customer service 800•355•1991

100 Ton Ram Instruction Manual

Position a rubber sheet or pad under the die bed.
While holding the die in place with one hand, loosen
the bolt on the tie down bar and move the tie down
bar so that it clears the die.

Slowly

slide the hose
towards the pusher. When the die clears the die
holder, one or both halves may fall to the floor. If
one half remains on the ferrule, tap it with a mallet
until it releases. If both halves remain on the ferrule,
it may require the halves be pried apart at the seam.

Remove the spacer rings from the coupling. Wipe
off excess lubricant from hose and ferrule. Bring the
hose with stem and ferrule back through the die bed.
Reinstall the gasket. Close the cam arms.

12i

12j

Note: Remove spacer ring from the 1-1/2" size only.

Cam & Groove Holedall Couplings

customer service 800•355•1991

7Section 5

100 Ton Ram Instruction Manual

For “E” style couplings:

Check the ferrule for proper alignment. Ensure that
the mark on the ferrule (from Step 6b) is in the
center of the stem collar.

Move the directional control lever to the
“FORWARD” position. Depress the button on the
remote and advance the cylinder until the end of the
ferrule is near the die opening. Using a wooden
board or metal pipe, lift the ferrule up. Jog the
cylinder by quickly depressing and releasing the
button on the remote. This will allow the ferrule to
enter the die slowly without contacting the die face.
Continue jogging the cylinder until the ferrule has
entered the die approximately 1-1/2"

13a

13b

Move any tie down bars from the die that may come in
contact with the pusher. While holding the hose and
coupling up against the pusher, depress the button on
the remote. Once the ferrule has started to be reduced
(approximately 1/3 the way) it is no longer necessary for
the operator to hold the hose. Continue the swage until
the pusher contacts the die face. When this occurs,
release the button on the remote and move the
directional control lever to the “NEUTRAL” position.

Note: If the gauge reads 10,000 PSI before swaging
is complete, stop. The ferrule or die used for that
hose end may be incorrect. Contact Dixon for
further assistance.

Move the directional control lever to the “REVERSE”
position. Depress and hold the button on the remote
retracting the cylinder until there is sufficient room
for the stem and ferrule to clear the die bed.

13c

13d

8 Section 5

Cam & Groove Holedall Couplings

customer service 800•355•1991

100 Ton Ram Instruction Manual

Position a rubber sheet or pad under the die bed.
While holding the die in place with one hand, loosen
the bolt on the tie down bar and move the tie down
bar so that it clears the die.

Slowly

slide the hose
towards the pusher . When the die clears the die
holder, one or both halves may fall to the floor. If
one half remains on the ferrule, tap it with a mallet
until it releases. If both halves remain on the ferrule,
it may require the halves be pried apart at the seam

Wipe excess lubricant from hose and ferrule. Bring
hose with stem and ferrule back through die bed.

13e

13f

Cam & Groove Holedall Couplings

customer service 800•355•1991

9Section 5

100 Ton Ram Instruction Manual

Pushers and Spacer Rings For Cam & Groove

Size Description Part Number

1”

1 1/2”

2”

3”

4”

Type “E” Pusher
Type “C” Pusher

Type “E” Pusher
Type “C” Pusher
Spacer Ring

Type “E” Pusher
Type “C” Pusher

Type “E” Pusher
Type “C” Pusher

Type “E” Pusher
Type “C” Pusher

100PUSHGCRC
100PUSHCGRC

100PUSHCG15E
100PUSHCG15 (
150CGSPACE

100PUSHCE2
100PUSHCG2

100PUSHCG3
100PUSHCG2

100PUSHCG4E
100PUSHCG4C

Note: Spacer Rings are to be used with Type “C” Couplings ONLY.

DO NOT use Spacer Rings with Type “E” Couplings, or bodily injury may result.

2 pieces

)

Dixon Valve and Coupling Company recommends that all

hose assemblies be tested as recommended by the Rubber Manufacturers Association.

10 Section 5

Cam & Groove Holedall Couplings

customer service 800•355•1991