Dixon Holedall 25 Ton Ram User manual

25 Ton Ram Operating Instructions
Section 2
External Swaging of Standard Holedall
Dixon Valve & Coupling Company
800 High Street •Chestertown, MD 21620
ph: 800•355•1991 fax: 800•283•4966
www.dixonvalve.com

25 Ton Ram Instruction Manual Externally Swaged Holedall
customer service 800•355•1991 1Section 2
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Before you begin, make sure the ram is fully
retracted. Install 25PUSH400 (also referred to
as the pusher hat) onto the main pusher plate.
This is required for all standard Holedall fittings.
Make sure the bolt holes align with the 1/2”
bolts and wing nuts supplied.
Select the proper pusher for the I.D. of the hose.
The pusher should be the same size as the stem.
There are separate pushers required for 1 1/4”
through 3” I.D. hose.
Insert the selected pusher into the 25PUSH400
and secure it with the set screws provided.
For Unirange (1” and below) remove the
25PUSH400 and install the 25PUSH100 as well
as the correct pusher for the size of Unirange
coupling. There is a separate pusher for each
unirange assembly size.
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.
Insert Die Holders into the Die Bed Plate as follows:
a) DH9-004 - Master Die Holder to hold all of
the other die holders.
b) DH9-004-1 - Die Holder for 4” I.D. hoses only.
c) DH6-003 - Die Holder for 1 1/4” - 3” I.D. hose
dies (fits into DH9-004).
d) DH3-001 - Die Holder for 1/4” - 1” I.D. hose
dies (DH6-003 and DH9-004 also required).
Secure the Die Holders with the tie down bars supplied.

25 Ton Ram Instruction Manual Externally Swaged Holedall
customer service 800•355•1991 2Section 2
Assuring that the hose end is cut square, chamfer the
I.D. of the hose 1/8” at a 45° angle (this is to relieve
hose end flare of rubber tube hoses during stem inser-
tion). 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 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.
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 a high viscosity oil or heavy
duty grease.
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25 Ton Ram Instruction Manual Externally Swaged Holedall
customer service 800•355•1991 3Section 2
To complete the swaging process, depress and hold the
“on” switch of the remote control unit (or depress the
foot pedal). Once the ferrule has
entered the die and started to be reduced (approxi-
mately 1/3 of the way), it will no longer need the
operator to keep it seated into the pusher. Continue the
swage until the pusher meets the die, or until the gauge
reads 10,000 PSI.
Insert the hose fitting assembly through the bottom of
the ram (between the die holders) far enough to allow
room to install the die halves into the die holder. After
installing the die halves, push the hose up into the
pusher until the ferrule comes in contact with the
pusher.
“Jog” the ram by quickly depressing and releasing the
“on” button on the remote control switch,
(or by depressing the foot pedal) until the ferrule
enters the opening of the die. Let the ferrule enter the
die slowly, making sure the end of the ferrule does not
hit the top of the die.
Make sure that the stem and ferrule are held securely
against the pusher until the swaging process has
begun.
Lubricate the I.D. of the die halves with Crisco®
(recommended) or a high viscosity oil or heavy duty
grease.
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25 Ton Ram Instruction Manual Externally Swaged Holedall
customer service 800•355•1991 4Section 2
Dixon Valve and Coupling Company recommends that all
hose assemblies be tested as recommended by the Rubber Manufacturers Association.
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.
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25 Ton Ram Instruction Manual Externally Swaged Holedall
customer service 800•355•1991 5Section 2
Typical Setup - 25 Ton Ram, External Swaging