Page 1
Section 3
100 Ton Ram Operating Instructions
for
1-1/4" through 4" Standard & Long
Flanged Holedall Swaged Couplings
using Collar with Jack Screws
Dixon Valve & Coupling Company
800 High Street • Chestertown, MD 21620
ph: 800•355•1991 fax: 800•283•4966
www.dixonvalve.com
Page 2
Page 3
100 Ton Ram Instruction Manual
Any coupling assembly (welding of stem, stub end, flange, etc.) must be done prior to
starting this procedure. Failure to do so (i.e. welding flange to stem after the swage)
can result in serious structural damage to the hose and premature assembly failure.
1a
Install the 4" main pusher (M011-065) by sliding it
onto the rod cap of the ram cylinder. Make sure that
the pusher is all the way on the rod cap.
For 1-1/4" - 3" couplings proceed to
For 4" couplings, proceed to
For 1-1/4" - 3" couplings insert the appropriate size
adapter pusher into the 4" main pusher (M011-065).
For example:
Shown here is the 2" adapter pusher (M011-113)
being inserted.
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.
Step 2
Step 1b
.
.
1b
2
Section 3
1-1/4" through 4" Standard & Long Flanged Holedall Swaged Couplings using Collar with Jack Screws
customer service 800•355•1991
1
Page 4
100 Ton Ram Instruction Manual
Assuring that the hose end is cut square, chamfer
the I.D. of the hose 1/8" at a 45° angle. This will aid
in stem insertion. If the hose is to be static
grounded, follow hose manufacturers procedure for
proper static grounding.
Lubricate the I.D. of the hose and the O.D. of the
stem with Dixon Coupling Lubricant or equivalent.
Insert the stem into the hose until the hose end
contacts the stem collar. Position the sight hole on
the ferrule so that this can be observed. After stem
insertion, slide the ferrule down until the turned-over
part of the ferrule contacts the stem collar.
3
4
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.
5a
5b
2 Section 3
1-1/4" through 4" Standard & Long Flanged Holedall Swaged Couplings using Collar with Jack Screws
customer service 800•355•1991
Page 5
100 Ton Ram Instruction Manual
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:
M012-001 1-1/4" - 3" I.D. hose
M012-002 4" - 6" I.D. hose
6a
Caution!
Never use a swaging die as a die holder!
Secure the die holders with tie down bars to prevent
the die holders from slipping out of the die bed
unexpectedly.
Bring the hose with the stem and ferrule through the
die bed. Insert the stem into the pusher so that the
ferrule contacts the pusher. 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.
6b
7
Ensuring that all of the jackscrews have been
threaded completely into the collar, install the collar
with jackscrews between the ferrule and the flange.
Position it so that the flat side of the collar is next to
the ferrule and the jackscrews are closest to the
flange lining up with the bolt holes. Secure both
collar halves with the “T” bolt.
Section 3
1-1/4" through 4" Standard & Long Flanged Holedall Swaged Couplings using Collar with Jack Screws
customer service
8a
3
800•355•1991
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100 Ton Ram Instruction Manual
Extend all of the jackscrews so that they are
contacting the flange. With a wrench, tighten one
jackscrew one half turn. Moving to the jackscrew
opposite of the one just tightened, tighten it one half
turn. Moving to the jackscrew immediately to the
right of the first one tightened, tighten it one half
turn. Moving to the jackscrew opposite of the one
just tightened, tighten it one half turn. Keep
repeating this process until all jackscrews are evenly
tensioned.
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.
8b
9a
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.
Move the directional control lever to the “Forward”
position and depress the button on the remote.
Advance the cylinder forward 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 depressing and releasing the button on
the remote. This will allow the ferrule to enter the
die slowly. After the ferrule has entered the die, stop
advancing the cylinder.
9b
10a
4 Section 3
1-1/4" through 4" Standard & Long Flanged Holedall Swaged Couplings using Collar with Jack Screws
customer service 800•355•1991
Page 7
100 Ton Ram Instruction Manual
Align the flange face with the pusher.
For 4" assemblies, the raised face on the flange will
fit into the recess of the 4" Main Pusher (M011-065).
For 1-1/4" - 3" assemblies ensure the flange face
and the pusher are flush.
Loosen the bolt on the tie down bar holding the die
in place. Move the tie down bar so that it clears the
collar. When this is done, snug the bolt on that tie
down bar.
10b
11a
Depress and hold the button on the remote until the
top of the ferrule (where welded to stem) is even
(flush) with the top of the die. Release the button.
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.
Loosen all of the jackscrews so that they clear the
flange. Loosen the nut on the “T” bolt so that the “T”
bolt moves easily out of its slot. Remove the collar
from between the flange and the ferrule.
11b
12
Section 3
1-1/4" through 4" Standard & Long Flanged Holedall Swaged Couplings using Collar with Jack Screws
customer service 800•355•1991
5
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100 Ton Ram Instruction Manual
Position a rubber sheet or pad under the die bed.
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.
Loosen the bolt(s) on the tie down bar(s) and move
the tie down bar(s) so that they clear one die bed
spacer. Tighten any bolt just loosened. Remove the
die bed spacer one half at a time. Repeat this
process for each die bed spacer to be removed.
Remove only enough die bed spacers to allow the
flange to pass through.
13a
13b
Wipe excess lubricant from hose and ferrule. Bring
hose with stem and ferrule back through die bed.
13c
6 Section 3
1-1/4" through 4" Standard & Long Flanged Holedall Swaged Couplings using Collar with Jack Screws
customer service 800•355•1991
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