Dixon 100 TON RAM User Manual

100 Ton Ram

Table of Contents

Holedall Concept

Specifications

1¼" through 4" Standard and Long Holedall Swaged Couplings

1¼" through 4" Standard and Long Flanged Holedall Swaged Couplings using Collar with Jack Screws

RSTxxxNOS Stems with GASxxxxNOS Ferrules

Cam and Groove Holedall Couplings

Boss Ground Joint Holedall Couplings

Converting from Swaging to Internal Expansion

Internal Expansion of Steel and Stainless Steel couplings

Internal Expansion of H520 couplings

Parts List, Attachments & Sample Forms

100 Ton Ram Instruction Manual

The Concept of the Holedall Coupling

Applied with the Ram

The application of Holedall couplings to hose is best described as a swaging of the coupling to the hose is accomplished by pushing the tubular ferrule (normally made of tubular steel, but also available in brass or stainless steel) through a split die which reduces the ferrule O.D. causing the ferrule to penetrate into the hose wall. This results in a 360° uninterrupted compression band around the hose.

The patented Holedall coupling includes a hose stem and a ferrule. The hose stem is of a conventional serrated design, including a collar which locks the ferrule to the stem. The tubular ferrule will include a top (outboard) row of holes and, depending on style of ferrule, a bottom (inboard) row of holes and a series of serrations (if present, depending upon style) inside. The purpose or design function of the holes and serrations (if present, depending upon style) is as follows:

1. Upon insertion of the stem into the hose, prior to the swage, the top (outboard) row of holes affords positive proof, attained by visual inspection, that the stem portion of the coupling is fully inserted into the hose.

2. The ferrule holes and serrations provide additional holding power to the coupling. This is effected as follows:

The Holedall coupling is applied directly to the raw end of the hose without, in any manner, altering the hose cover. hose wall under the strong compression band of the swaged ferrule tends to be displaced (rubber is not compressible), it is therefore necessary to provide an escape area for this displacement. The ferrule holes provide a portion of this and thus permit a tighter compression band. At the same time, we use this rubber displacement to enhance the holding power of the coupling. The serrations (if present depending upon style) are located under the compression band (swaged area) of the ferrule and act as “teeth” biting into the hose cover.

The hose cover need not be skived or buffed off. However, since the rubber content of the

draw type progressive swage

. This

3. Upon completion of the swage, the holes serve still another function. By visual inspection of the coupling, the holes provide an indication of the adequacy of the swage. Rubber will normally project through the bottom (inboard) row of holes (when present) and at least flow into the holes in the top (outboard) reservoir area. The reservoir area should fill up (except when hose wall thickness is below 5/16").

The contour or swaged form of the Holedall coupling provides additional holding power (coupling retention).

The design of the ram swaging dies effect a swaged form to the Holedall coupling in which it should be noted that the ferrule is not swaged its entire length. With the draw type progressive swage, the Holedall coupling utilizes a planned forward (outboard) cold flow of the rubber content of the hose wall into the reservoir area of the coupling. The hose wall, which is confined between the coupling stem and the tubular ferrule, should (with our type swage) only move forward (outboard). As this occurs, the hose wall tends to slightly thin out in the area of the swage and to become heavier in the forward reservoir area. Thus, when a Holedall coupling is swaged onto a hose much of the same result is accomplished that is effected when one slides a nut onto a section of rigid tubing and then flares the tubing. The nut cannot slide past the flared end of tubing and likewise the Holedall coupling cannot slide past the flared hose end.

The die reduction, which effects the penetration of the ferrule into the hose wall, may vary with hose wall construction. A Holedall coupling may be applied to almost any type of hose construction style with excellent results. The degree of die reduction or subsequent ferrule penetration into the hose wall is dependent upon a number of variable conditions, including the compound nature and thickness of the tube, the compound nature and thickness of the cover stock, and the material and construction design of the reinforcing members. Desirable ferrule penetration into the hose wall is normally approximately 20% of the hose wall thickness, but the construction of the hose wall. In order to effect the proper ferrule penetration into the hose wall and to provide compression band to withstand the hoop stress, it is necessary to increase the gauge or thickness of the ferrule wall. Generally as the hose wall thickens and hose size increases, the ferrule is made with an increased wall thickness.

it will vary

with

Holedall Concept 1

100 Ton Ram Instruction Manual

Listed below are a few guidelines for correct swaging procedures:

1. Always measure (with a diameter tape) the hose free O.D. Both ends of the hose must be measured. Free O.D. is outside diameter before stem is inserted.

2. For hoses having a wall thickness of 5/16" or greater, chamfer hose tube at 45° angle by 1/8" wide. This is done prior to stem insertion and will help eliminate the hose end from flaring when the stem is fully inserted.

3. Select the correct ferrule from the die and ferrule chart by using the combination of hose I.D. and free O.D. Ferrule must be able to slip over stem and hose without removing (skiving or buffing) hose cover.

4. Select a die (from die and ferrule chart) based upon the free O.D. measured for the end to be swaged to effect a 18% to 24% reduction.

5. For standard length stems and ferrules, swage is complete when the pusher face meets the die face. For long length stems and ferrules, effect as long a swage as possible. (See footnote on next page)

6. Apply a high viscosity lubricant (grease or oil) to ferrule O.D.

and die I.D. before initiating swage.

Crisco works best for most swaging procedures.

7. Inspect (visually) the completed swage of coupling, both external and internal where possible.

Troubleshooting: Listed below are some troubles that may occur and their causes:

Trouble

1. Ferrule cracks

Causes

1. Too small a ferrule size

2. Too small a die selection

2. Hose cover bulge behind ferrule

1. Too small a ferrule size

2. Too small a die selection

3. Hose tube bulge (internal bulge)

1. Too small a ferrule size

2. Too small a die selection

4. Ferrule bulges or collapses at top portion

1. Too small a ferrule size

2. Too small a die selection

3. Length of swage too long

4. Ferrule and stem not in proper position when swage was initiated

5. Buckling or collapsing of coupling stem

1. Too small a ferrule size

2. Too small a die selection

Trouble may occur which is related to the hose design and manufacture. For good coupling application and performance, it is essential that hose manufacturers be concerned with the requirements for good coupling retention. Tensile strength, elasticity, durometer hardness, cold flow characteristics and adhesion of hose components all effect coupling performance.

Holedall Concept2

100 Ton Ram Instruction Manual

Footnote

The normal swage length, for standard length stems and ferrules, is obtained by terminating the swage when the top (outboard) holes completely pass into the lead portion of the die. In other words, when the face of the pusher meets or touches the face of the die, the swage is complete. When using long length stems and ferrules, it may be necessary to terminate the swage sooner. If rubber start s to extrude out of the top (outboard) holes or the top (reservoir area) of the ferrule begins to swell before the normal swage length is effected, stop the swage.

The Ram pressure gauge provides another guide for correct swaging procedures. pressure gauges. These gauges provide a line pressure reading in PSI (Pounds per Square Inch). For example: the 100 Ton Ram includes an electric motor driven hydraulic pump capable of developing 10,000 PSI. The area of the piston head of the ram cylinder is 20.6 square inches. Thus, our maximum ram force is 10,000 x 20.6 or 206,000 pounds, which is equivalent to approximately 100 tons.

All hoses of one size and style should require approximately the same ram force for swaging. However, since the Ram is intended for use with a variety of hoses of varying constructions and hose wall thickness, we therefore cannot provide a chart of recommended pressure gauge readings. Dixon strongly recommends the recording of data such as hose type, I.D. size, O.D. measurement for each end, ferrule used each end, die used each end and pressure (PSI) required to effect the swage on each end. The Ram user, with this database and his/her experience, will consistently produce quality hose assemblies.

All Rams are equipped with

General Guidelines

1. This manual supersedes all previous instructions for the 100 Ton Ram.

2. Operator(s) should wear safety apparel such as safety glasses and steel toe shoes when operating this equipment.

3. The Holedall Coupling System and the procedures in this manual are an engineered system. Skipping or eliminating steps in the procedure, unless directed to do so, can lead to an assembly failure.

4. Do not “mix and match” stems, ferrules and accessories from manufacturers other than Dixon Valve & Coupling Comp any.

5. After assembly is complete, pressure test the assembly in accordance with Rubber Manufacturers Association (RMA) specifications.

6. For questions or assistance, please call Dixon V alve & Coupling Comp any at 1-800-355-1991.

The information contained in this manual applies to couplings engineered and produced by Dixon Valve and Coupling Company for permanent attachment to hoses. It is to be used only as a guide and does not address special, unusual, unique or non-standard coupling applications. If you have any questions regarding any application, please call Dixon at 1-877-963-4966.

Holedall Concept 3

Section 1

100 Ton Ram

Specifications

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

Item

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22

Part No.

001-0003 001-0004 001-0008 001-0011 001-0052 001-0053 001-0017 001-0016 001-0005 0010-064 001-0019 31-300 GLSS10000 001-0024 001-0001 0010-154 M012-001 M012-002 M012-003 M012-004 001-0009 001-0010

Description

Tie Rod Tie Rod Hex Nut Hydraulic Pump Hydraulic Pump Support Hydraulic Cylinder Cylinder End Plate Cylinder Backing Plate Cylinder Tie Rod Cylinder Tie Rod Nut Rod Cap Hydraulic Hose with Hydraulic Couplings Hydraulic Quick Connect NPT Plug 0-10,00 P.S.I. Liquid Filled Gauge Gauge Adapter Die Bed Plate Die Retainer Strap 9" Die Carrier 12" Die Carrier 15" Die Carrier 18" Die Carrier

rigid

Steel Wheel ( Steel Wheel (

)

swivel

)

Qty.

3 6 1 1 1 1 1 4 8 1 2 2 1 1 1 6 1 1 1 1 2 2

Section 1

Specifications

100 Ton Ram Instruction Manual

Specifications:

Net Weight 1,900 lbs., basic equipment only Crated Weight 2,100 lbs. Dimensions 60" long x 26" wide x 48" high Crated Dimension 76" long x 40" wide x 48" high Pump Motor Power Team PE554 1-1/8 H.P. Universal Motor;

12,000 RPM; 115V single phase, 60/50 cycle AC (not dual voltage); 25 Amp, lightweight “handle-top” housing

Motor Control “Run-Off-Remote” motor control switch; 25 Amp motor control relay

Cavity mounted in motor housing, hand held remote switch Safety Valves Relief valve set at 10,000 PSI Control Valve Built-in manually operated 4-way control valves with 3/8" NPT port Gauge Calibrated 0-10,000 PSI Reservoir Convenient mounting holes in base Oil Delivery 650 cu. in/min. at 100 PSI

80 cu. in/min. at 1,000 PSI

70 cu. in/min. at 5,000 PSI

55 cu. in/min. at 10,000 PSI

Note

: 2-stage pump provides fast, no load approach speed and then shifts into slow actuation

as the load is applied.

• Ram double acting (Power Team RD10013)

• 13-1/8" stroke

• 103.1 tons of push at 10,000 PSI

• 44.2 tons of pull at 10,000 PSI

Preparations:

Filling the Reservoir Before removing the filler plug, clean the area around the plug.

The pump is a precision built unit, so special care should be taken to preclude

foreign particles from entering the reservoir. With cylinder fully retracted, fill the

tank 1" to 1½" from the top. Replace the filler plug. Approved Hydraulic Power Team 9637 Mobile DTE25 or equivalent. Oils

Available Motor 220-440, etc. Also 1½ H.P. and 3 H.P. Variations

Reservoir 5 gallon or 10 gallon reservoir available Variations

The standard 1-1/8 H.P., 12,000 RPM, 115 volt motor and the 2½ gallon reservoir has proven highly successful. Dixon feels it is the best design, and variations are not desirable.

Specifications

Section 1

100 Ton Ram Instruction Manual

Operating Controls

• F-N-R (Forward-Neutral-Reverse) directional control lever.

The F-N-R lever (shown in the neutral position) controls the

direction of the ram cylinder. To extend the cylinder (forward) in the direction of the die bed, move the lever

toward the pump motor then activate the pump. To retract the cylinder (reverse), move the lever away from the pump motor then activate the pump.

• On-Off-Remote switch, 0 - 10,000 psi pressure gage and hand held remote.

When the toggle switch is placed in the “On” position, the pump motor will run until the toggle switch is placed in the “Off” position. When the toggle switch is placed in the “Remote” position, the hand held remote is activated. To run the pump motor, depress and hold the switch on the remote. To stop the motor, release the switch on the remote. For practical purposes, leave the toggle switch in the “Remote” position. All future references to activating the pump motor should be understood that the hand held remote is being used.

Caution!

Never dead-end the cylinder (fully extended or fully retracted) and leave it with pressure showing on the gage. If the cylinder is dead-ended, always move the lever to the neutral position after stopping the pump. Failure to do so can shorten the life of the cylinder seals.

Section 1

Specifications

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

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.

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

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

1Section 2

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.

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.

2 Section 2

1-1/4" through 4" Standard & Long Holedall Swaged Couplings

customer service 800•355•1991

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.

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

1-1/4" through 4" Standard & Long Holedall Swaged Couplings

customer service 800•355•1991

3Section 2

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

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

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

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.

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.

Step 2

Step 1b

Section 3

1-1/4" through 4" Standard & Long Flanged Holedall Swaged Couplings using Collar with Jack Screws

customer service

800•355•1991

100 Ton Ram Instruction Manual

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.

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.

2 Section 3

1-1/4" through 4" Standard & Long Flanged Holedall Swaged Couplings using Collar with Jack Screws

customer service 800•355•1991

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

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.

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

800•355•1991

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.

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.

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

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