Page 1
Section 2
100 Ton Ram Operating Instructions
for
1-1/4" through 4" Standard & Long
Holedall Swaged Couplings
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
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.
1a
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).
Shown here is the 2" adapter pusher (M011-115)
being inserted.
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
Caution!
Never use a swaging die as a die holder!
Step 2
Step 1b
.
.
1b
2
Secure the die holders with tie down bars to prevent
the die holders from slipping out of the die bed
unexpectedly.
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.
1-1/4" through 4" Standard & Long Holedall Swaged Couplings
customer service 800•355•1991
3
1Section 2
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 all the way into the hose until the ring
on the stem comes in contact with the end of the
hose.
4
5
Slide the ferrule over the stem and over the O.D. of
the hose until the turned over portion of the ferrule
rests on the ring of the stem.
Lubricate the outside of the ferrule with Crisco®
(recommended) or high viscosity oil or heavy duty
grease.
6
7a
2 Section 2
1-1/4" through 4" Standard & Long Holedall Swaged Couplings
customer service 800•355•1991
Page 5
100 Ton Ram Instruction Manual
Lubricate the I.D. of both die halves with Crisco®
(recommended) or high viscosity oil or heavy duty
grease.
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.
7b
8
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.
Continue to jog the cylinder until pressure begins to
register on the gauge. Leave the directional control
lever in the “FORWARD” position. Loosen the bolt
on the tie down bar that is holding the die in place.
Move the tie down bar so that the entire flange on
the pusher will clear. Move any other tie down bars
that may interfere with the pusher. When the pusher
contacts the die release the pressure.
Important!
ferrule with the pusher. Make sure the collar (ring)
on the stem is in contact with the ferrule before
proceeding.
Inspect the position of the stem and
9
10
1-1/4" through 4" Standard & Long Holedall Swaged Couplings
customer service 800•355•1991
3Section 2
Page 6
100 Ton Ram Instruction Manual
Move the directional control lever to the “REVERSE”
position and depress the button on the remote.
Retract the cylinder far enough (approximately 1") to
allow a tie down bar be placed so that the die does
not come out of the die holder. Secure the tie down
bar by tightening the bolt. Continue retracting the
cylinder until there is sufficient room for the stem
and ferrule to clear the die bed.
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.
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.
Slowly
slide the hose
11
12a
Wipe excess lubricant from hose and ferrule. Bring
hose with stem and ferrule back through die bed.
12b
4 Section 2
1-1/4" through 4" Standard & Long Holedall Swaged Couplings
customer service 800•355•1991
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