50 Ton Ram
Table of Contents Holedall Concept 1 Specifications 2 1¼" through 4" Standard and Long Holedall Swaged Couplings 3 1¼" through 4" Standard and Long Flanged Holedall Swaged Couplings using Collar with Jack Screws 4 Swaging RST Stems with GAS Ferrules 5 Cam and Groove Holedall Couplings 6 Boss Ground Joint Holedall Couplings 7 Converting from Swaging to Internal Expansion 8 Internal Expansion of Steel and Stainless Steel Couplings 9 Internal Expansion of H520 Couplings 10 Parts List and Attachments
0 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 draw type progressive swage. This 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.
50 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.
50 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.
Section 1 50 Ton Ram Specifications Dixon Valve & Coupling Company 800 High Street • Chestertown, MD 21620 ph: 800•355•1991 fax: 800•283•4966 www.dixonvalve.
50 Ton Ram Instruction Manual Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Section 1 Part No.
50 Ton Ram Instruction Manual Specifications: Net Weight Crated Weight Dimensions Crated Dimension Pump Motor Motor Control Safety Valves Control Valve Gauge Reservoir Oil Delivery Note: 630 lbs., basic equipment only 780 lbs. 53" long x 18" wide x 19" high 76" long x 40" wide x 48" high Power Team PE554 1-1/8 H.P.
50 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 gauge and hand held remote.
Section 2 50 Ton Ram Operating Instructions for 1¼" through 4" Standard & Long Holedall Swaged Couplings and 5" & 6" Standard Holedall Swaged Couplings Dixon Valve & Coupling Company 800 High Street • Chestertown, MD 21620 ph: 800•355•1991 fax: 800•283•4966 www.dixonvalve.
50 Ton Ram Instruction Manual 1a Install the 6" main pusher (MPUSH600) 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 1¼" - 5" couplings proceed to Step 1b. For 6" couplings, proceed to Step 2. 1b For 1¼" - 5" couplings insert the appropriate size adapter pusher into the 6" main pusher (MPUSH600). Shown here is the 2" adapter pusher (50TPUSH200) being inserted.
50 Ton Ram Instruction Manual 4 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. 5 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.
50 Ton Ram Instruction Manual 7b Lubricate the I.D. of both die halves with Crisco® (recommended) or high viscosity oil or heavy duty grease. 8 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. 9 Lifting up the hose, insert one die half under the hose.
50 Ton Ram Instruction Manual 11 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. 12a Position a rubber sheet or pad under the die bed.
Section 3 50 Ton Ram Operating Instructions for 1¼" 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.
50 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 6" main pusher (MPUSH600) by sliding it onto the rod cap of the ram cylinder. Make sure that the pusher is all the way on the rod cap.
50 Ton Ram Instruction Manual 3 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. 4 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.
50 Ton Ram Instruction Manual 6a 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: 50TDH6003 1¼" - 3" I.D. hose 50TDH9004 4" I.D. hose Caution! Never use a swaging die as a die holder! 6b Secure the die holders with tie down bars to prevent the die holders from slipping out of the die bed unexpectedly.
50 Ton Ram Instruction Manual 8b 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.
50 Ton Ram Instruction Manual 10b Align the flange face with the pusher. For 4" assemblies, the raised face on the flange will fit into the recess of the Main Pusher (50T-009). For 1-1/4" - 3" assemblies ensure the flange face and the pusher are flush. 11a 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.
50 Ton Ram Instruction Manual 13a 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. 13b 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.
Section 4 50 Ton Ram Operating Instructions for RSTxxxNOS Stems with GASxxxxNOS Ferrules Dixon Valve & Coupling Company 800 High Street • Chestertown, MD 21620 ph: 800•355•1991 fax: 800•283•4966 www.dixonvalve.
50 Ton Ram Instruction Manual 1 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: 50TDH6003 1¼" - 3" I.D. hose 50TDH9004 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.
50 Ton Ram Instruction Manual 5 Lubricate the O.D. of the stem and the I.D. of the hose with Dixon lubricant or equivalent. Insert the end of the fitting into the hose. Assemble the ferrule onto stem by sliding turned over portion of ferrule past notched section of stem collar. Rotate ferrule 90° (1/4 turn). With ferrule and stem engaged, continue installing stem until ferrule reaches the second mark on the hose.
50 Ton Ram Instruction Manual 9 Install appropriate size spacer ring over the threads of the stem so that it contacts the ferrule. The spacer rings are listed as follows: 1½" RST150SPACE 2" RST200SPACE 3" RST300SPACE 10 Insert the stem into the pusher so that the spacer ring just installed contacts the pusher. 1½" 50TPUSH150 2" 50TPUSH200 3" 50TPUSH300 11 Put the directional control lever in the “FORWARD” position. Advance the cylinder forward until the end of the ferrule is near the die opening.
50 Ton Ram Instruction Manual 13 Wipe excess lubricant from hose and ferrule. Bring hose with stem and ferrule back through die bed.
Section 5 50 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.
50 Ton Ram Instruction Manual 1 Install the 6" main pusher (MPUSH600) on cylinder rod cap. Make sure that the pusher is fully installed on the rod cap. 2 Install the 4" pusher (50TPUSH400) into the main pusher. Install the Cam & Groove pusher necessary to do the size and style of coupling to be swaged. Additional pushers may be required. Reference the chart at the end of this section for proper pusher selection.
50 Ton Ram Instruction Manual 4 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.
50 Ton Ram Instruction Manual 8 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. 9 Bring the hose with the stem and ferrule through the die bed.
50 Ton Ram Instruction Manual 11a 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. 11b 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. For style "C" couplings go to step 12.
50 Ton Ram Instruction Manual For “C” style couplings requiring spacer rings: 12a Release both cam arms. 12b Remove the gasket from the coupler. 12c Put the spacer rings between the ferrule and coupler head, making sure that the two ring halves meet over the turned over portion of the ferrule. 12d Insert the proper pusher into the coupler (reference the chart at the end of this section for proper pusher selection).
50 Ton Ram Instruction Manual 12e Check the ferrule engagement with the stem collar. The mark on the ferrule (from Step 6) must be positioned under the cam arm. 12f 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.
50 Ton Ram Instruction Manual 12i 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.
50 Ton Ram Instruction Manual For “E” style couplings: 13a Check the ferrule for proper alignment. Ensure that the mark on the ferrule (from Step 6) is in the center of the stem collar. 13b 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.
50 Ton Ram Instruction Manual 13e 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.
50 Ton Ram Instruction Manual Pushers and Spacer Rings For Cam & Groove Size Description Part Number 1" Type 'E' Pusher Type 'C' Pusher Spacer Ring * RE100PUSH 100PUSHCGRC 100CGSPACE 1½" Type 'E' Pusher Type 'C' Pusher Spacer Ring * 100PUSHCG15E 100PUSHCG15 (2 pieces) 150CGSPACE 2" Type 'E' Pusher Type 'C' Pusher Spacer Ring * 100PUSHCG2 100PUSHCG2 200CGSPACE 3" Type 'E' Pusher Type 'C' Pusher Spacer Ring * 100PUSHCG3 100PUSHCG2 300CGSPACE 4" Type 'E' Pusher Type 'C' Pusher Spacer Ring *
Section 6 50 Ton Ram Operating Instructions for Boss Ground Joint Holedall Couplings Dixon Valve & Coupling Company 800 High Street • Chestertown, MD 21620 ph: 800•355•1991 fax: 800•283•4966 www.dixonvalve.
50 Ton Ram Instruction Manual 1 Install the 6" main pusher (MPUSH600) by sliding it onto the rod cap of the ram cylinder. Make sure that the pusher is all the way on the rod cap. Install the appropriate adapter pusher (by coupling size) into the main pusher. 2 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 chart.
Ton Ram Instruction Manual 4b Lubricate the I.D. of the hose and the O.D. of the stem (as well as possible) with Dixon Coupling Lubricant or equivalent. Insert the stem all the way until the mark on the hose (from Step 4a) is at the end of the ferrule. 5 Bring the hose with the stem and ferrule through the die bed. Position the wing nut (or spud) as close to the pusher as possible.
50 Ton Ram Instruction Manual 7a Lubricate the outside of the ferrule with Crisco® (recommended) or high viscosity oil or heavy duty grease. 7b Lubricate the I.D. of both die halves with Crisco® (recommended) or high viscosity oil or heavy duty grease. 8a 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.
50 Ton Ram Instruction Manual 9a 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.
50 Ton Ram Instruction Manual 10b Move the directional control lever to the “REVERSE” position and depress the button on the remote. Retract the cylinder until there is sufficient room for the stem and ferrule to clear the die bed. 11a 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.
Section 7 50 Ton Ram Operating Instructions for Converting from Swaging to Internal Expansion Dixon Valve & Coupling Company 800 High Street • Chestertown, MD 21620 ph: 800•355•1991 fax: 800•283•4966 www.dixonvalve.
50 Ton Ram Instruction Manual 1 Remove any swaging pusher from the ram cylinder rod cap. 2 Position a rubber mat under the die bed. Position the tie down bars so that only one die bed spacer is clear. Remove the die bed spacer from die bed. Repeat this process until all die bed spacers have been removed from the die bed. Caution! Die bed spacers are heavy. Remove the die bed spacers one half at a time. 3 Install IX Master Plate onto outside of ram die bed.
Section 8 50 Ton Ram Operating Instructions for Internal Expansion of Carbon Steel & Stainless Steel Couplings Dixon Valve & Coupling Company 800 High Street • Chestertown, MD 21620 ph: 800•355•1991 fax: 800•283•4966 www.dixonvalve.
50 Ton Ram Instruction Manual (refer to the Converting the 50 Ton Ram from Swaging to Internal Expansion section of the instruction manual) 1 Before you begin, move the directional control lever to the “FORWARD” position, depress the button on the remote and fully extend the ram cylinder. Return the directional control lever to the “NEUTRAL” position. Select the proper Pull Rod.
50 Ton Ram Instruction Manual 4 Slide the adapter(s) over the pull rod and into the recess of the IX Master Plate. While holding the adapter(s) in place with one hand, slide the stem over the pull rod and into the recess of the adapter plate with the connection side of the stem facing the ram. While holding the adapter(s) and stem in place with one hand, screw on (or slide) the IX plug, small end first, onto the pull rod and into the shank of the stem.
50 Ton Ram Instruction Manual 10 Place a rubber sheet or pad under the IX Master plate. Move the directional control lever to the “REVERSE” position. While holding the hose and ferrule firmly against the stem shoulder, engage the ram by depressing the button on the remote. The internal expansion operation is complete when the expansion plug is pulled completely through the stem (see Important! below). Release the button on the remote.
Section 9 50 Ton Ram Operating Instructions for Internal Expansion of H520 Couplings Dixon Valve & Coupling Company 800 High Street • Chestertown, MD 21620 ph: 800•355•1991 fax: 800•283•4966 www.dixonvalve.
50 Ton Ram Instruction Manual (refer to the Converting the 50 Ton Ram from Swaging to Internal Expansion section of the instruction manual) 1 Before you begin, move the directional control lever to the “FORWARD” position, depress the button on the remote and fully extend the ram cylinder. Return the directional control lever to the “NEUTRAL” position. Select the proper pull rod.
50 Ton Ram Instruction Manual 5 Slide the stem over the Pull Rod and into the recess of the Thrust Plate with the connection side of the stem facing the ram. For male stems, insert the hex into the recess of the Thrust Plate. For female stems, insert the first hex into the Thrust Plate so that the second hex will fit into the recess of the Thrust Plate. Note! There is no need to lubricate the plug or stem. The stems are pre-lubricated at the factory.
50 Ton Ram Instruction Manual 9 Slide the hose with the ferrule on over the shank until the ferrule contacts the shoulder of the stem. Make sure you align the ferrule with the second mark from step 8. Make sure the pocket has been maintained. Important! If there is an insufficient pocket for the rubber to displace into, damage may occur to the stem, ferrule, and /or hose.
Section 10 50 Ton Ram List of Parts and Attachments Dixon Valve & Coupling Company 800 High Street • Chestertown, MD 21620 ph: 800•355•1991 fax: 800•283•4966 www.dixonvalve.
50 Ton Ram Instruction Manual 50 Ton Ram Equipment to Swage 1¼" to 6" I.D. Hose Sizes 50TONRAM “Mulcoram” including motor (115 volt) pump, 10,000 PSI hose and gauge.
50 Ton Ram Instruction Manual 50 Ton Ram Equipment to Swage 1" through 4" Cam & Groove MPUSH600 6" Pusher (needed for all sizes) 50TPUSH400 4" Pusher 50TDH9004 Die Holder for 4" die (needed for all sizes) 50TDH6003 Die Holder for 1¼" - 3" dies (fits into 50TDH9004) 100PUSHCG4E Pusher for 4" E 100PUSHCG4C Pusher for 4" C 100PUSHCG3 Pusher for 3" E (fits on 100PUSHCG2) 100PUSHCG2 Pusher for 2" C and E and 3" C (also use with 100PUSHCGRC and RE100PUSH) 100PUSHCG15 Pusher for 1½" C and E (con
50 Ton Ram Instruction Manual Holedall Dies Range Min 3/4 x Max 9/16 2-1/8 x 1-11/16 4-9/16 x 4-5/16 2 x 1-7/8 4-1/2 x 4-1/4 6-15/16 x 6-7/16 7 x 6-1/2 10 x 9-1/2 10 x 9-1/2 12-15/16 x 12-3/8 13 x 12-3/8 16 x 15-1/2 * Dies will be invoiced for full selling price when shipped, credit will be issued when returned for full selling price less rental charge. All freight charges are to be paid by Customer. All dies are to be returned within 30 days.
50 Ton Ram Instruction Manual 50 Ton Ram Equipment to Internally Expand 1” - 6" I.D.
50 Ton Ram Instruction Manual 50 Ton Ram Equipment to Internally Expand “Flow Chief” Food Grade Fittings 001-0067 4" IX Adapter (needed for all sizes from 1¼" to 4") 50T-0073 Master IX Bar Adapter (needed for all sizes) 50T-0072 IX Master Plate (needed for all sizes) (this part is also 6" IX ADAPTER) 25RODLARGE IX Bar for 2" - 4" 25RDLG-A Large Rod (only for 25TONRAM) 25RDLG-B Nut (only for 15 and 25 Ton Rams) 25RODSMALL IX Bar for 1½" 25RDSML-A Small Pull Rod 25RDSML-B Small Pull Rod Ada
