VEHICLE OPERATIONSCONSTRUCTION SPECIFICATIONS

WORLDWIDE DIE DESIGN ANDW−DX

DATE SECTION

PAGE

W−DX22−50M1SEPT. 2005

DIE HANDLING

PRINTED COPY ISUNCONTROLLED

CASTING DIMENSIONS FOR LIFT PIN LUGS AND SAFETY PAD AREANORTH AMERICA ONLY

BOTH LINERS MUST BE IN LINE AND HELD AT THE PATTERN SHOP.

AT THE PATTERN SHOP AND CAST INTO PLACE AT THE FOUNDRY.CASTING LINERS ARE TO BE PLACED IN THE POLYSTYRENE PATTERNS

SAFETY PAD SIZE

DIE LIFT PINFOR CONVENTIONAL DIES

THIS FACE OF LINER MUST BE .5 TO 1.5mm

PINSIZE

80

63

50

100

50

80

35

A

30

ALL CORNERS AFTER

E

120

150

150

200

BASE IS MACHINED.

60

100

110

120100

70

100

B

50

C

100

90

125

70

D

90

100

125

65

70

80

G

60

H

HAND GRIND & ROUND OFF

R 25 (TYP.)

CASTING WALL

B

BEYOND THE CASTING WALL.

A

"G"MIN.

45

A

50 REF.

TRANSFER DIE LIFT PINTOTAL DIE WEIGHT IN TONS

3 - 10

10 - 40

40 - 80

0 - 3

0 - 10

10 - 30

30 - 50

FOR TRANSFER DIES

DO NOT BREAK SHARP CORNER

D

E MIN.

40

150 MIN.

C

D MIN.

SEE W-DX22-80MFOR CASTING LINERS

PROVIDE 25 R. IN ALLCASTING CORNERS THAT

FOR NUMBER OF SAFETY PADS

SEE W-DX15-50M PAGE 64.

CONTACT LIFTING CABELS.

175

195

225

REQUIRED AND SIZE

PAGE 8

F

SAFETYPAD SIZE

150 X 150

170 X 170

200 X 200

F

25USE "H" DIM. IFTHERE IS NOSAFETY PAD OVERLIFT PIN.

70

10

38 MIN.

R 25

wdx2201m.pdf

VEHICLE OPERATIONSCONSTRUCTION SPECIFICATIONS

WORLDWIDE DIE DESIGN ANDW−DX

DATE SECTION

PAGE

W−DX22−50M6SEPT. 2005

DIE HANDLING

PRINTED COPY ISUNCONTROLLED

EYE BOLT INSERTS IN ROUGH CASTING AREAS

NORTH AMERICA ONLY

USE (4) EYE BOLT INSERTS LOCATED SYMMETRICALLY ABOUT THE CENTER OF MASS TO PROPERLY BALANCE THE CASTING DURING LIFTING. (2) INSERTS MAY BE USED ON LONG NARROW CASTINGS.

LOCATING EYE BOLT INSERTS IN NON-WORKING ROUGH SURFACES 5 mm ABOVE THE CASTING.

SEE W-DX22-80M PAGE 4 FOR EYE BOLT INSERT DIMENSIONS.

DESIGNER TO ADD NOTE TO STOCK LIST SHEET: "CAST-IRON EYE BOLT INSERTS TO BE FURNISHED ANDINSTALLED BY PATTERN SHOP".

DO NOT USE ON STEEL CASTINGS. PROVIDE TAPPED HOLES IN STEEL CASTINGS.

TAPPED EYE BOLT INSERTS PRIOR TO SETTING PATTERN IN SAND".WHEN USING EYE BOLT INSERTS, ADD NOTE ON DRAWING: "FOUNDRY TO PLACE STEEL BOLTS IN ALL

THIS WILL ANCHOR THE INSERT DURING POURING. (SEE SKETCH "A")

CONSIDER TURNOVER WHEN SIZING TAPPED EYE BOLT INSERT. TWO INSERTS MUST CARRY WEIGHT OF ALLOF THE SHOE ADAPTER AND ATTACHED EQUIPMENT, NOT THE COMPLETE ASSEMBLY.

IF DESIGN DOES NOT PERMIT CORED HOLES OR EYE BOLT INSERTS, CONSIDER TAPPING HOLES DIRECTLY

INTO THE CASTING. (SEE W-DX22-2M PAGES 1 AND 2). ANY COMPONENT OVER 30 LBS. MUST AT LEASTHAVE TAPPED HANDLING HOLES.

5

25 MIN.

DRAGCOPE

AA

ATHREADS CASTING WEIGHT LIMIT

FOR (2- POINT) LIFT 4'500 lb. 9'200 lb.12'400 lb.22'000 lb.28'000 lb.

M16M20M24M30M36105

658595

55

SKETCH "A"

SIZE

5

25 MIN.

AA

SHOULDER OF EYE BOLTIS TO BOTTOM OUT ON TOP OF INSERT.TOP OF INSERT SURFACEMUST BE SMOOTH WITHNO CASTING FLASH.

A

A

EYE BOLT INSERTSEE W-DX22-80MPAGE 4

BOLT ANCHORED IN THE SAND IN USED TO PREVENT THE INSERT FROM SHIFTINGAS THE METAL IS BEING POURED. BOLT TO BE REMOVED BEFORE SHIPPING CASTING.BOLT THREADS MUST HAVE A LOOSE FIT INTO INSERT TO AVOID FUSING.

EYE BOLT INSERTS ARE TO BE POSITIONED ON A COMMON HEIGHT WITH THE CENTER OF MASS TO PROPERLY BALANCE THE CASTING DURING LIFTING.

VEHICLE OPERATIONSCONSTRUCTION SPECIFICATIONS

WORLDWIDE DIE DESIGN ANDW−DX

DATE SECTION

PAGE

W−DX22−50M7 APRIL 2004

DIE HANDLING

PRINTED COPY ISUNCONTROLLED

NORTH AMERICA ONLY

EYE BOLT INSERTS IN ROUGH CASTING AREAS

DRAW PUNCH

ADAPTOR PLATEINNER RAM

A

A

25 MIN.

X

1/3 'X" MAX.

TAPPED HOLE MUST BE LOCATED TOWARD WORKINGAREA OF PUNCH TO AFFECT OVERBALANCEDCONDITION FOR TURNOVER.

EYE BOLT INSERTSEE W-DX22-80MPAGE 460 REF.

VEHICLE OPERATIONSCONSTRUCTION SPECIFICATIONS

WORLDWIDE DIE DESIGN ANDW−DX

DATE SECTION

PAGE

W−DX22−50M8MAY 2005

DIE HANDLING

PRINTED COPY ISUNCONTROLLED

NORTH AMERICA ONLY

ØC DRILL THRU (2) HOLES MUST BE INLINE

R25

200

FOR 50 AND 63 DIA. LIFT PINLIFT LUG STEEL PLATE CONSTRUCTION

R25 TYP.

200 MIN.

100

55

100

45°

63

PINSIZE

50 170

260 82.55

50.5O

A

Ø65

Ø52

B C

PROVIDE 25 R. IN ALLCORNERS MOST LIKELYTO BE IN CONTACTWITH LIFTING CABLES.

B R25

A

A

DIE SHOE TO BE FASTENED TO THE RISER

TRANSFER DIE LIFT PINFOR TRANSFER DIES

WITH M24 SCREWS AND DOWELS.

WELD ALL AROUND

TOTAL DIE WEIGHT IN TONS

FOR CONVENTIONAL DIESDIE LIFT PIN

3 - 10

10 - 40

177 MIN.

10 - 30

0 - 10

W

W

W

W

VEHICLE OPERATIONSCONSTRUCTION SPECIFICATIONS

WORLDWIDE DIE DESIGN ANDW−DX

DATE SECTION

PAGE

W−DX22−50M9 MAY 2005

DIE HANDLING

PRINTED COPY ISUNCONTROLLED

NORTH AMERICA ONLY

WELD ALL AROUND

235

FOR 80 DIA. LIFT PINLIFT LUG STEEL PLATE CONSTRUCTION

300

82.55

250 MIN.

70

125

R25

125

45°

WITH LIFTING CABLES.TO BE IN CONTACTCORNERS MOST LIKELYPROVIDE 25 R. IN ALL

R25

82.55

DIE SHOE TO BE FASTENED TO THE RISERWITH M24 SCREWS AND DOWELS.

R25

W

W

W

W

Ø82 DRILL THRU (2) HOLES MUST BE INLINE

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CAST BOLLARDNORTH AMERICA ONLY

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ØD1

130

160

200

250

270

360

310

ØD2

240

185

230

205

H MIN.

160

H MIN.

90

ØD1

ØD2

R16

R40

50 WALL

WHEN THERE IS AN ADJACENT FASTINGFLANGE, CAST BEVEL AT 45° TO AVOIDHANGING UP THE WIRE ROPE ON THE DIEDURING TURNOVER.

R 25

15

30°

R 25

SECTION A-A

A A

USE CAST BOLLARD ON UPPER AND LOWER DIE SHOES AND BINDER RINGS.FOUR CAST BOLLARDS ARE REQUIRED PER DETAIL.CAST BOLLARDS ON THE PUNCH SHOE IS TO BE IN LINE WITH BOLLARD ON DIE SHOE, OR POSITIONED INBOARD FROM THE DIE SHOE. DIMENSIONS FROM BASE OF DIE TO CENTERLINE OF CAST BOLLARD (SECT. A-A) IS MINIMUM CASE ALLOWING ONLY FOR CABLE CLEARANCE. TRY TO CENTRALLY LOCATE CAST BOLLARD ON OUTSIDE WALL IN ELEVATION.DESIGNS MUST INCORPORATE CAST BOLLARD INSIDE OF BOLSTER ON ALL SIDES.DESIGNER TO CONSIDER TURNOVER CONCERNS WHEN USING CAST BOLLARD SEE W-DX22-50M PAGE 13.TOTAL DIE WEIGHT CALCULATIONS ARE BASED ON SAFETY FACTOR OF 6 AND A (2) POINT LIFT.

TOTAL DIEWEIGHT (TONS)

0 TO 10

OVER 10 TO 15

OVER 15 TO 35

OVER 35 TO 80

DIE SIZE R. TO L.

UP TO 96 INCHES

OVER 96" UP TO 108 INCHES

OVER 108" UP TO 144 INCHES

OVER 144 INCHES

30 WALL

CASTING THICKNESSSEE W-DX12-50MPAGES 2 AND 3

PREFERREDOPTIONAL

50

20 80

ØD2

35 MIN.

R50 MIN.

50

FOR END VIEWSEE W-DX22-50MPAGE 12

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50

R 15 TYP.

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CAST BOLLARD

NORTH AMERICA ONLY

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EYE BOLT INSERTSSEE W-DX22-80MPAGE 4

SAFETY PAD AREASEE W-DX15-50MPAGE 64

STORAGE BLOCKWHEN REQ'D.SEE W-DX13-50MPAGE 21

CAST FLOW ARROW ON LIFT LUG WHEN REQ'D.SEE W-DX12-51M PAGE 47

LIFT LUG DIMENSIONSSEE W-DX22-50MPAGE 11

STOP BLOCKSEE W-DX13-80MPAGE 16

SHOULDER GUIDE POSTSEE W-DX13-60MPAGES 4 AND 6

GUIDE POST BUSHINGSEE W-DX13-80MPAGE 8

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DIE HANDLING REQUIREMENTSNORTH AMERICA ONLY

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BEFORE MAKING FINAL DECISION RELATIVE TO LOCATION OF CAST BOLLIARD REVIEW TURNOVER PROCESS FOR UNBALANCED LOAD (SEE W-DX22-50M PAGES 14 THRU 16).

ADD THREADED INSERTS TO SURFACES ADJACENT TO LIFT LUGS TO AID IN TURNOVER PROCESS. BE SURE INSERTS ARE LARGE ENOUGH THAT (2) WILL SUPPORT THE WEIGHT OF THE ENTIRE UPPER OR LOWER ASSEMBLY (SEE W-DX22-50M PAGES 6 AND 7).

LOCATE CAST BOLLARDS IN DOTTED AREA ON THE TOP PLATE SO WIRE ROPE CABLES ARE PARALLEL WITH THE CENTERLINE OR TOWARDS THE OUTSIDE OF CABLE SLOTS IN PLAN VIEW.DESIGN MUST CONSIDER THE LOCATION OF CAST BOLLARD IN RESPECT TO THE ANGLES THAT WIRE CABLES FROM WHEN THE DIE IS TRANSPORTED WITH THE TOP PLATE ATTACHED.A LIFT INVOLVING A COMPLETED DIE SHOULD NEVER REQUIRED THE CABLE TO BEND MORE THEN 30° TO THE LOWER LUG.A SINGLE SHOE, WHICH IS ABOUT HALF THE WEIGHT OF THE COMPLETE DIE, CAN BE HOSTED AT ANGLES UP TO 45°.LOCATE LUGS AS CLOSE TO CENTER OF THE UPPER AND LOWER MASS AS POSSIBLE.IT IS DESIRABLE TO KEEP CAST BOLLARDS IN VERTICAL ALIGNMENT IF POSSIBLE, BUT DON'T SACRIFICE THE BALANCING OF THE SHOE MASS FOR THIS ALIGNMENT.

PLAN VIEW OF DIE WITH PLATE

TOP OF PLATE

DIE

THREADED INSERT

CABLE SLOT

CAST BOLLARD

FLOW

SIDE ELEVATION

45°

60°

45°

ALIGN VERTICAL ONLYIF MASS OF SHOE CAN BEBALANCED

IF LOWER SHOE HAS AFLANGE EXTENDING LEFTTO RIGHT, LIMIT LOWERSHOE LOCATION TOHATCHED GREEN AREA.

CENTRALLY LOCATE TOACHIEVE BALANCE WHENSHOE IS HANGING.

LOCATE CAST BOLLARDAS SHOWN OR IN DOTTEDAREA.

FOR CAST BOLLARD OR LIFT PINS

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DIE HANDLING REQUIREMENTSNORTH AMERICA ONLY

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ALL TOP PLATES ARE TO BE DESIGNED WITH CABLE/CHAIN SLOTS AT LOCATIONS TO PREVENT CABLE OR CHAIN FROM INTERFERING WITH CLAMP SLOTS.THE PRIMARY HANDLING PROVISIONS FOR TURNOVER PURPOSES ARE LOCATED ON THE SHOE. DESIGN INTENT IS THAT TOP PLATES, SPACERS, AND RISERS THAT ARE ATTACHED TO THE DIE SHOES ARE REMOVED PRIOR TO SHOE ASSEMBLY TURNOVER. HOWEVER, TOTAL WEIGHT OF EACH DIE ASSEMBLY SHOULD BE CONSIDERED WHEN SLEETING LIFT LUG OR CAST BOLLARD SIZE.CONSIDERATION MUST BE GIVEN TO LIFT LUG LOCATION SO THAT, IN THE FRONT ELEVATION, CABLES/CHAIN ANGLES DO NOT EXCEED 30° WHEN LIFTING COMPLETE DIE ASSEMBLY AND 45% WHEN LIFTING UPPER SHOE ASSEMBLY.

FRONT ELEVATION

45°MAX.

45°MAX.

30°MAX.

30°MAX.

HANDLING OF AN UPPER DIE SHOE

HANDLING OF AN COMPLETE DIE SHOE

COF DIE

CABLE/CHAIN SLOT CLAMP SLOTS

FOR DIES WITH ADAPTOR PLATES

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RIGGING REQUIREMENTS

NORTH AMERICA ONLY

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IF THE BLANK HOLDER PLATE OVERHANGS THE DIE MORE THAN 500mm FROM THE EDGE OF LIFT PIN/BOLLARD, PROVIDE CABLE ROUTING CORES ABOVE LIFT PINS/CAST BOLLARDS IN BLANK HOLDER PLATE.

FOR HANDLING DIE WITH BLANK HOLDER PLATE

BLANK HOLDER PLATE

ADAPTOR PLATE

ROUND OFF ALL (R25 MIN.) CORNERSTHAT COME IN CONTACT WITH WIREROPE OR CHAIN.

500

PROVIDE CABLE/CHAIN SLOTS IN ADAPTOR PLATE WHENPLATE INTERFERENCE. (SEE W-DX15-50M PAGE 44)

ROUTING CORES100 MN. X 153 MIN.

30°MAX.

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DIE HANDLING REQUIREMENTSNORTH AMERICA ONLY

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ALL TOP PLATES ARE TO BE DESIGNED WITH CABLE/CHAIN SLOTS AT LOCATIONS TO PREVENT THE CABLE OR CHAIN FROM INTERFERING WITH FASTENING SLOTS.CAST OR MACHINE CABLE DIVERSION SLOTS IN THE RISER TO PREVENT CABLE OR CHAIN FROM INTERFERE WITH FASTING SLOT ON THE ADAPTOR PLATE.CONSIDERATION MUST BE GIVEN TO LIFT LUG LOCATION SO THAT, IN THE FRONT ELEVATION, CABLES/CHAIN ANGLES DO NOT EXCEED 30° WHEN LIFTING COMPLETE DIE ASSEMBLY AND 45% WHEN LIFTING UPPER SHOE ASSEMBLY.

FOR DIES WITH UPPER RISER

30° MAX.

RISER

25 MIN.

BREAK ALL SHARP EDGES WITH A 25mm RADIUS THAT IS MOST LIKELY TO BE IN CONTACT WITH LIFTING CHAIN.

RAM ADAPTOR PLATE

UPPER DIE SHOE

25 MIN.

CHANNEL WAS MACHINED IN RISER SO CHAIN / CABLE WOULD NOT INTERFERE WITH FASTING SLOT.

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