DAKE Force 100 3-Phase Dura Press Instruction Manual

DAKE Force 100 3-Phase Dura Press

SAFEGUARDING THE POINT OF OPERATION

ANSI B11.2 – Hydraulic Power Presses -Safety Requirements for Construction, Care, and Use
It is important that Dake press users have a clear understanding of their responsibility involving the care and use of their Dake hydraulic press, including point-of-operation safe guards. Dake strongly recommends that Dake press users obtain a copy of the current American National Standard Institute (ANSI) B11.2 standard, for a more complete understanding of their responsibilities.

ANSI B11.2 states the following, relative to point of operation safeguarding:
“Normally, only the employer (press user) can determine the requirements of the press productions system components, including the dies and methods for feeding. Therefore, the employer is ultimately responsible to designate and provide the point-of-operation safeguarding system.”
The standard also discusses additional responsibilities of the employer. Some of the key responsibilities are:

• The employer is responsible for the safety, use, and care of the hydraulic power press production system.
• The employer is responsible to consider the sources of hazards for all tasks to be implemented on the hydraulic power press production system.
• The employer is required to eliminate, or control identified hazards in the scope of their work activity.
• The employer is responsible for the training of personnel, caring for, inspecting, maintaining, and operating hydraulic press production systems to ensure their competence.
• The employer is responsible to provide and ensure that point-of-operation safeguarding is used, checked, maintained, and where applicable, adjusted on every production operation performed on a press production system.
  A complete and current copy of the ANSI B.11.2 standard can be obtained by contacting the following:

Specifications

3-Phase

| 220V/440V,

3-Phase

| 220V/440V,

3-Phase

Width between

uprights

| 35”| 35”| 41”
Width between table

channels

| 8”| 8”| 10”
Min. ram to table| 7”| 7-1/4”| 7-7/8”
Max. ram to table| 32”| 32”| 35”
Ram Travel| 19”| 19”| 19”
Height| 88”| 88”| 90”
Base| 63” x 37”| 63” x 27”| 75” x 33”
Weight| 1,210 lbs| 1,595 lbs| 2,950 lbs
Ram advance speed| 68 ipm| 42 ipm| 52 ipm
Pressing speed| 7 ipm| 4 ipm| 3 ipm

In the space provided record the serial number and model number of the machine. This information is only found on the black and gold Dake tag shown below. If contacting Dake this information must be provided to assist in identifying the specific machine.

SAFETY

This is the safety alert symbol. When you see this symbol on your press be alert to the potential for personal injury.

• Keeps safety labels in good condition and replace missing or damaged labels. If labels are needed send a request to Dake.
  Follow recommended precautions and safe operating practices. It is important that the operator understand all safety instruction listed below in order to prevent damage to themselves, others, or the machine.

• Employer is responsible to perform a hazard/PPE assessment before work activity.

Label Location

Additional Warnings:

• Operator must never place hands in the area of the ram during pressing operations.
• Do not use the press for pulling
• A machine not subject to maintenance and periodical structural inspection is a danger for the operator and all persons working nearby.
• It is forbidden to tamper with, modify, or elaborate parts of the machine that alter its regular operation.
• During the phases of maintenance requiring guards to be removed the machine must be locked out according to local and state laws. Guards must be replaced after maintenance is complete.
• This press is designed for one operator.
• All work requiring the piece to be pressed to be supported by the operator is forbidden.
• It is forbidden to press pieces whose dimensions or physical nature may explode or produce splinters.

SET UP

Handling & Transport

• Total weight of the press plus packing materials is shown on the adhesive tabs places on the packing and on the accompanying documents.

• Loading and unloading is to be done with lifting straps.

• Ensure the machines weight is not over the maximum capacity of the straps and that the straps are in good condition.

• It is forbidden for things and/or persons to stand close to the machine, loading area, unloading area, and means of transport during the loading and unloading operations.

• Do not make any sudden movements with the transportation device with the press lifted.

• Pay close attention during all handling processes that the press, in particular the hydraulic power unit does not receive damage.

• Observe the in-house provisions concerning lifting and handling.

• It is forbidden to approach or pass under the press while it is lifted.

• Before handling the machine, it is necessary to use special lifting equipment whose maximum lifting capacity is greater than the weight of the press. Press weight can be found in the
  “Specifications” section of this manual.

• Lifting straps must be positioned as shown below.
  The manufacturer is no responsible for damage to the machine while loading or unloading the press.
  Placement

• Simple precautions are necessary for correctly positioning the press, always consider the safety aspect not only in relation to the work carried out with the press but also to the dangers originated by another machine in the workplace.

• Do not position on unstable or unlevel floor.

• The press needs to have 36” of clearance on the sides and 42” of clearance in the front and back.

Electrical Connection
Only a certified electrician that follows local and state laws is authorized to perform any type of electrical connection on this press. The electrical power supply voltage must be made in compliance with local and state laws.

• This machine is dual voltage 220V 3-phase / 440V 3-phase. The amp rating for voltages are in the table below.

• For proper operation it is necessary to ensure constant voltage and must not exceed or be lower than 5% of the rated value.
• Before making any electrical connections, confirm the voltage rating of the machine. There is a black plastic box mounted on top of the reservoir with the rated valve.
• Be sure there is no power to the machine before checking the following connections. It may be necessary to lock out the machine for proper power disconnection.
• Remove the two mounting screws that hold this box in place. Under this box you will see one of the following possibilities shown below. After confirming or changing the voltage to the correct voltage mount the cover with the two screws. Now open the electrical panel on the transformer to check if it is set to the correct output voltage.
• Any damage caused by a faulty electrical connection is not cover by warranty.

Filling the Pump Unit
To fill the pumping unit, use exclusively the oils indicated in the table or equivalent. The environmental conditions must be considered before purchasing oil. To transfer the oil from the container to the tank use an external filler to prevent the introduction of foreign material or liquids at the time of filling.

Amount of oil for each press:

Pump Rotation
After making the electrical connections to the press it is necessary to make a visual check on the direction of rotation of the electric motor.
Before checking the direction of the rotation of the pump, fill the reservoir with oil.

1. Unscrew the inspection cap.

2. Identify a reference point on the drive shaft.

3. Power up the motor for a maximum of 1-2 seconds.

4. Check that the rotation of the shaft in moving in the clockwise direction.
   If the motor rotates in the wrong direction contact your electrician.

5. Screw down inspection cap.

Worktable Height Adjustment
To optimize use of the press it is necessary to set the worktable to a different height in relation to the operation to be carried out on the press.
Before lifting the mobile table first check that:

• The eyebolts fixed to the worktable are fully tightened.
• The eyebolt support (nose piece) is properly screws onto the cylinder ram.
• The eyebolts fixed to the nose piece are fully tightened.

1. Hook chains to the respective eyebolts and lift the cylinder ram until the chains are set under tension but, do not lift the table.
2. Check all chain connections to eyebolts to ensure a safe secure connection.
3. If secure, lift the table just above the desired table height.
4. Take the split pins off and then remove the table pins.
5. Insert the table pins to the desired work table height pin location then insert the split pins.
6. Slowly move the table down until it rests on the table pins.
7. Check to ensure the position and assembly of the pins are correct.
8. Unhook chains and leave them to hang in the downwards position.

Priming the Pump
Before starting the machine for the first time it is necessary to prime the pump.

1. Check that all the valves and distributors are in the rest position.
2. Jog the start button (electric motor), when the unit emits a dull sound with no jumps and the sound of the pump is constant.
3. If the sound is uneven or bubbly there is air in the pump still. Repeat step 2 if this occurs.
4. The oil in the reservoir may fall on startup due to:
   • Absorption of volume by the cylinder.
   • Absorption of volume by the pumping unit.
   • Discharge of air bubbles remaining in the piping.
5. It may be necessary to top off the level of the oil to bring it back to the correct height. By checking the level gauge, the level should be about half way up the gauge.

OPERATION

• Before starting any operations, make sure there are no other people in the immediate vicinity of the area.
  It is strictly forbidden to pass under the worktable.
  To operate the cylinder activate the master switch and then operate the distributor level.

• Pulling the lever towards the operator (Pos. 2) will lower the ram.

• Pushing the lever all the way away from the operator (Pos. 3) will raise the ram.

• Releasing the lever will return it to natural position (Pos. 1) and stop the ram’s movement.

With the hand wheel positioned on the side of the distributors (Pos. 4) it is possible to adjust the operating pressure continually and therefor the pressing force of the cylinder. The pressure gauge (Pos. 5) displays the pressure during working phases.
Adjustment of the maximum pressure must be increased gradually from a lower pressure until the necessary capacity is reached to perform the operation at hand.

Operating Temperature
After the machine has been operating at full rate check that the oil temperature does not exceed 140°F. If it does exceed 140°F check that the oil used is not too viscous and replace with more suitable oil if this is the case.

MAINTENANCE

Routine maintenance operation must be carried out by authorized and trained personnel.
All maintenance or cleaning operations must be done with the machine properly locked out in accordance with OSHA regulations.

• Below is a table the normal times for maintenance work. In addition the work area and press needs to be cleaned and cleared of material.

Operating

Hours

| Check oil filter| Check oil| Change oil| Change oil filter| Change air filter
---|---|---|---|---|---
50| X|  |  |  |
100|  |  |  | X|
300| X| X|  |  |
500|  |  |  | X| X
1000|  | X|  | X| X
1500| X|  |  | X| X
2000|  |  | X| X| X

Changing Oil
The oil will need to be routinely changed every 2000 operating hours or at least once a year. Empty the until tank be arranging a container of adequate capacity to contain the quantity of old oil being removed under the drainage plug at the bottom of the tank.
Remember to tighten the plug before refilling the tank with new clean, filtered oil.

Disposing of the oil will have to be done in conformity with local and state laws along with OSHA regulations. Hydraulic oil is considered a special waste.

Filters
The filter must be frequently replaced during the first period of operating the press and them at regular intervals of time to be defined according to the conditions of use and the environment where the machine is located. After that replacement is needed every 500-600 hours.

TROUBLESHOOTING

Cylinder moves slow

| Air in pump| Bleed the air
Air in circuit| Bleed the air
Damaged cylinder gaskets| Replace cylinder gaskets
Damaged or worn pump| Replace pump
Sequence valve jammed| Recondition sequence valve
Delivery oil line is choked or clogged| Check hydraulic lines

Piston will not move

| Electric motor will not turn| Check motor
Piston gaskets are completely damaged| ****

Replace piston gasket

Blocked distributor| Recondition distributor
Damaged pump| Recondition or replace pump
Cylinder leaks oil| Head gaskets are damaged or worn| Replace head gaskets

Piston ram will not build pressure

| Lack of pressure from pump| Recondition pump
Pressure control valve is set low| Reset valve appropriately

Pump cavitation

| Filter suction is clogged| Clean or replace
Oil is too viscous| Empty and refill with more suitable oil

Foam forms in the hydraulic fluid

| Oil level is too low| Fill oil back up to correct level
Oil is unsuitable for the press| Replace with suitable oil
Fittings or joints letting air in| Tighten or replace fittings
Air is being discharged into circuit| Discharge air from system
Pumps deliver little or no oil| Pump is worn or damaged| Recondition or replace
Pump will not turn| Pump joint is undone or damaged| Check and/or replace

Unstable valves

| Valve seat damage| Recondition or replace
Pressure not constant| Check pump or pressure relief valve
SYMPTOM| CAUSE| SOLUTION
---|---|---
Valve parts jammed| Dirty hydraulic oil| Drain oil from system and replace with new filtered oil

Piston moves irregularly

| Lack of pressure from pump| Recondition pump
Pressure adjustment valve is set low| Reset valve appropriately
Translating cylinder is damaged| Check and/or recondition
Translating wheels or guides are dirty or blocked| Clean and/or replace parts

Excessive wear on parts

| Oil containing abrasives| Drain and replace oil
Insufficient lubrication| Drain and replace with higher quality oil
Too high of operating pressure| Lower the setting of the pressure relief valve
Contaminants in oil not caught by filter| Insufficient filtering. Replace oil and filter

PARTS LIST

Electrical Box Components:

Item| Description| 40 Ton| 70 Ton| 100 Ton
---|---|---|---|---
1| Contactor|  |  |
2| Transformer| 300842| 300842| 300842
3| Overload 220-volt| 302187| 302187| 302187
3| Overload 440-volt| 302189| 302189| 302188
3A3| N.O. Contact Block| 302192| 302192| 302192
4| Relay| 7230000| 7230000| 7230000
5| Fuse Block| 300843| 300843| 300843
5B| Fuse 2 Amp| 77523| 77523| 77523
6| Terminal Block Ground|  |  |
6A| Terminal Block Black|  |  |
 | On-Off Switch Body| 302728| 302728| 302728

Cylinder:

 | 5|  | 6|
---|---|---|---|---
Item| Description| 40 Ton| 70 Ton| 100 Ton
1| Piston Gasket| 300609| 301195| 301189
2| Piston O-Ring| 300610| 301196| 301186
3| Head Guide Ring| 300647| 301197| 301187
4| Head O-Ring| 300648| 301198| 301188
5| Head Gasket| 300649| 301199| 301185
6| Head Scraper| 300650| 301200| 301184
7| Washer|  |  |
8| Hose Fitting (Top)| 300890| 300890| 300890
8A| Hose Fitting (Bottom)| 301390| 301390| 301390
 | Gauge| 301721| 301720| 301719
 | Gauge Adapter| 301813| 301813| 301813
 | Hydraulic Hose A| 300383| 300383|
 | Hydraulic Hose B| 300382| 300382|
 | Eye Bolt| 301880| 301880| 301880
 | Nose Piece Bolt| 300793| 300793| 300793
 | Cylinder Bolts w/ Jam Nut| 303795

303797

| 303796

303797

| 301136

303797

 | Cylinder Fitting w/ Seal (B Port)| 302957

301365

| 302957

301365

| 302957

301365

 | Repair Kit| 716791| 716790| 716789
 | Complete Cylinder| 300698| 300642| SS100C00

Hydraulic Pumping Unit:

Item| Description| 40 Ton| 70 Ton| 100 Ton
---|---|---|---|---
1| Complete Power Unit| 300633| 300633| 79937
1| Tank Cover| 301388| 301388| 301391
2| Electrical Cover| 300388| 300388| 300388
3| Fill Cap| 302055| 302055| 302055
4| Air Filter| 300391| 300635| 300224
5| Drain Filter| 300392| 300392| 300392
6|  |  |  |
7| Back Motor Bearing|  |  |
8| Motor Rotor| 301848| 301848|
9| Driving Shaft|  |  |
10| Front Motor Bearing|  |  |
11*| Pump Motor| 302200| 302200|
12| Blade| 302056| 302056|
13| Pumping Bearing|  |  |
14| Eccentric|  |  |
15| Roller Bearing|  |  |
16| High Pressure Pump Group| 301115| 301115| 301115
 | Outlet Filter / bottom of pump| 300393| 300393| 300394
 | Motor Windings with Shell| 301848| 301848|
 | Drive Shaft Assembly (Items: 8, 9, 11)| 302200| 302200|

ORDER INFORMATION

Parts are available for direct purchase from Dake or through a distributor. When placing a parts order, you will need to provide the part number, name of part, and model number. All parts shipped F.O.B. Factory in Grand Haven, MI.

DEACTIVATING THE MACHINE
If the machine is not going to be used for a long period of time it is recommended that you so the following:

1. Disconnect the press from power sources.
2. Empty the unit of oil.
3. Protect it suitable so there is no dust, moisture or other foreign bodies that can damage the machine.

DISMANTLING THE MACHINE
If the machine is not going to be used anymore it is recommended to make it inoperable by removing the oil in the tank and eliminating oil remaining in the cylinder, hydraulic lines, pump body, and valves. When going for demolition the press must be treated as special waste, it must therefore to be split into its homogenous parts. These must be separately disposed of in conformity with local and state laws along with will all OSHA regulations.

References

• Dake Corp | Metalworking Machine Tools
• Metalworking Machine Tools | Dake Corp

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