724 Robbins Road
Grand Haven, Michigan 49417
616-842-7110 Phone 800-937-3253
616-842-0859 Fax 800-846-3253
Web: www.dakecorp.com
E-mail: customerservice@dakecorp.com
technicalsupport@dakecorp.com
Dura Press Models
FORCE 40, 70 & 100
Dual voltage machines for 220 / 440 volts
Use and Maintenance Manual
Model No: _________________
Serial No: _________________
Force 40 70 100 Ton
1
Model
84935
FORCE
40 40 35" 8" 19" 37" 68 ipm 7 ipm 63" x 27" 88"
FORCE
70 70 35" 8" 19" 37" 42 ipm 4 ipm 63" x 27" 88"
FORCE
100
Max
Ton
100 41" 10" 19" 39" 52 ipm 3 ipm 75" x 33" 90"
Width
between
uprights
Width
between
table
channels
Max.
Ram
travel
Max.
Ram
to
table
Ram
rapid
advance
Ram
pressing
speed
Base
(W x D) Height Weight
Maximum operating pressure for all models 280 bars
Sound pressure maximum 78,6 db
For the safety of the operator/owner it is your responsibility to review the follow warnings
and safety labels located in this manual and on the machine. It is the responsibility of the
operator/owner to understand these labels. If there are any questions regarding these labels
call Dake at 1-800-937-3253.
Below is a diagram of where the safety labels are required.
880
lbs.
1100
lbs.
2200
lbs.
Part number
76462
Part number
84487
Part
number
Part number
300168
Part
number
84399
If at any time these safety stickers need to be replaced or are missing lock out the machine and
contact Dake immediately.
Force 40 70 100 Ton
2
The operator and owner must read and understand all of the following warnings. It is the
responsibility of the employer to check that the following warnings have been understood
by the operator and maintenance personnel.
WARNING!!!!
Operator must never place hands in the area of the ram during pressing operations.
Do not use this press for pulling.
A machine not subject to maintenance and periodic structural inspection is a danger for
the operator and the persons working near by.
It is strictly 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, machine must be
locked out according to local and state laws.
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 strictly forbidden to press, cut, draw and do anything else with pieces whose
dimensions or physical nature may explode or produce splinters.
DEFINITIONS
In this manual “right side”, “left side”, forwards, backwards, top and bottom refer to the operator
situated in front of the press with the power unit to there right.
Press Identification
The press is fitted with a rating plate fixed in a visible manner on the front as shown in Fig. 1
item 1 on next page. The Dake part number and serial number on the front name plate shown in
Fig. 1 item 2.
Force 40 70 100 Ton
3
Item 1
Item 2
Fig. 1
Unpacking
The machine has shrink wrap on it and any accessories, spare part may be
Packed in cardboard boxes and positioned on top of the work table.
To remove the packing, cut the plastic wrap, taking care not to damage the
Machine or any part of it. Remove the accessories from the top of the work
table, check the contents correspond to the order and to the accompanying
documentation. Remove the lag bolts that hold the press to the skid.
Disposing of the packaging
Fig. 3
The packing will have to be disposed of be the purchaser in compliance with the current
regulations.
Claims shall not be accepted in the event of the goods not being in conformity with order or
with the accompanying documents if they are not notified within five days of the date of
receiving the goods.
Handling and transport and positioning
For handling the machine it is necessary to use special lifting equipment whose maximum lifting
capacity must be no lower than the total weight of the press which can be found on page 2 of this
manual.
Loading and unloading the machine
Use lifting straps are to be used to position as shown below in Fig 4.
WARNING!!!
Be sure the maximum capacity of each strap is greater than the total weight of the press.
Force 40 70 100 Ton
4
Do not make sudden movements when transporting the machine.
The manufacturer is not responsible for damage to the machine while loading or unloading the
press.
Pick up
here
Pick up
here
Fig. 4
Positioning the press
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 the other machines in the workplace.
Do not position on unstable or unleveled floor.
Below in fig. 4 is the allowable distance from the wall, other machines or other objects.
Fig. 4
Commissioning and Starting
Electrical connection
This machine is dual voltage 220 3 phase / 440 3 phase. The amp rating on these machines are
6.8 amps on 220 volt 3 phase and 3.4 amp on 220 volt 3 phase.
WARNING!!!
Only a certified electrician that follows local and state laws is authorized to perform any
type of electrical connection on this machine. The electrical power supply voltage must be
made in compliance with local and state laws.
Force 40 70 100 Ton
5
For proper operation it is necessary to ensure constant voltage and it must not exceed or be lower
than 5% of the rated value.
Before making any electrical connection confirm voltage rating of the machine. There is a black
plastic box mounted on top of the reservoir.
WARNING!!!
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 in fig. 5. After confirming or changing this to the correct voltage
mount the cover with the two screws. Now, open the electrical panel on the transformer be sure it
is set for the correct output voltage.
Fig. 5
220 Volt connection 440 volt connections
WARNING!!!
Any damage caused by a faulty electrical connection is not covered by warranty.
Filling the pumping unit
To fill the pumping unit, use exclusively the oils indicated in the table on the next page or
equivalent. The environmental conditions must be considered before purchasing oil. To transfer
the oil from the container to the tank use an external filter as shown in Fig. 6 in order to prevent
the introduction of foreign material or liquids at the time of filling.
The amount of oil required for each model is described in the chart below.
40 Ton 10.5 Gallons
70 ton 10.5 Gallons
100 Ton 15.5 Gallons
A - Oil B - Pump C - Filter D - Press Oil
Force 40 70 100 Ton
6
Fig. 6
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 rotation of the pump, fill the reservoir with oil see Fig. 6
1. Unscrew the inspection cap.
2. Identify a reference point on the drive shaft.
3. Power up the motor for Max. 1-2 seconds.
4. Check that the rotation of the shaft coincides with that of the arrow shown on the top of
the unit see Fig 7.
5. Screw down inspection cap.
If the motor rotates in the wrong direction:
See your electrician.
Fig. 7
Any damage caused by wrong electrical connection is not covered by warranty
Force 40 70 100 Ton
7
DTE Oil No.
Gravity 31 26
Maximum Pour
Flash Point
Viscosity @ 100F.
Viscosity @ 130F.
Viscosity @ 210F.
Color 3 Max. 3.5 Max.
Viscosity Index 95 Min. 95 Min.
Also Passes ASTM Rust
Test Yes Yes
Oiliness Additive Yes Yes
Competitive Oils
Equivalent to above
specifications
24
20F. 20F
395F 400F.
145-160 290-310
84.5 144
44 53
DTE Oil No.26
Cities Service Pacemaker Oil
Exxon Co. Nuto H32 Nuto H68
Gulf Oil Co. Harmony No.
Pure Oil Co. Puropale Rx
Shell Oil Tellus Oil No.
Sinclair Oil Duro Oil
Standard Oil Rycon Indl Oil
Sun Oil Co. Sunvis No.
Sunray DX Oil Co. No. 475
Texaco Rando Oil No.
NO. XD 15
43 AW
Anti Wear No.
150
32
AW16
No. 15
706 No. 816
WR
Diamond Roza
L
HD-32
Pacemaker Oil
No. XD30
Harmony No.
54AW
Puropale Rx Anti
Wear No. 300
Tellus Oil No. 68
Duro Oil AW31
Rycon Indl Oil
No. 31
Sunvis No. 754
No. 831 WR
No. 477
Diamond Roza H
Rando Oil No.
HD-68
To obtain best results oil temperature should not exceed 140F. When using DTE No. 26 as an
Alternative for DTE No. 24 there might be a slight variation in the ram speeds.
First starting
After filling the reservoir through the fill cap it is necessary to prime the pump. Check that all the
valves and distributors are in the rest position, at the time of starting do not operate any
movement.
To obtain starting it may be necessary to press the reset button in the electrical panel.
Force 40 70 100 Ton
8
WARNING!!!
This press is exclusively prepared to be used only by one operator.
To prime, jog the start button (electric motor). When the unit emits a dull sound with no jumps
and the sound of the pump is constant. An uneven “tinny” noise indicates there is air in the
pump.
The oil in the reservoir may fall on start up due to:
1. absorption of volume by the cylinder
2. Absorption of volume by the pumping unit.
3. Discharge of air bubbles remaining in the piping.
It is necessary to top off the level of oil bringing it up to the correct height, by checking the level
gauge. The level should be about half way up the stick.
Operation
Before starting any operations make sure there are no other persons in the immediate vicinity of
the machine.
It is strictly forbidden to pass under the work table.
To operate the cylinder, activate the master switch, and then operate the distributor lever Fig. 8.
Pulling - the lever toward the operator (Pos. 2) the piston rod lowers.
Pushing - the lever from the opposite side to the operator (Pos. 3) the piston rod will go up.
Releasing - the lever will return to the neutral position stopping the ram from moving (Pos. 1).
With the hand wheel positioned on the side of the distributors (Fig. 8 Pos. 4) it is possible to
adjust the operating pressure continually and therefore the pressing force of the cylinder. The
pressure gauge (Fig. 7 Pos. 5) allows displaying the pressure during the working phases.
Adjustment of the maximum pressure must be made starting from the lower value and gradually
increasing to reach the pressure necessary to perform the operation to be carried out.
Dake declines all liability for damage to things and/or persons caused by tampering with
the pressure control valve fitted on the unit.
Force 40 70 100 Ton
9
Fig. 8
Work table height adjustment
To optimize the use of the press it is necessary to set the work table at a convenient height in
relation to the operation to be carried out and to the equipment to be used.
Before proceeding to lift the mobile table, check that:
- The eyebolts fixed to the work table are fully tightened Pos. 01.
- The eyebolt support (nose piece) is properly screwed onto the cylinder ram (Pos. 2)
- The eyebolts fixed to the nose piece are fully tightened.
1. Hook the chains (Pos. 5) to the respective eyebolts and lift the cylinder ram until the
chains are set under tension but, do not lift the table.
2. Check the chain connections to all eyebolts to ensure a safe secure connection.
3. When the connection is safe, lift the table just above the desired table height.
4. Take the split pins (Pos. 6) off the pins then remove the pins.
5. Insert the 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 be sure the position and the assembly of the pins are correct.
8. Unhook the chains and leave them hang in a downward position (Pos. 5).
Pos. 2
Pos. 6
Pos. 3
Pos. 1
Pos. 5
Force 40 70 100 Ton
10
Operating Temperature
After the machine has been put into operation at full rate, check that the oil temperature does not
exceed 140 F.
If the above described conditions are exceeded, check that the fluid used is not too viscous
(replace with more suitable fluid).
Using the unit with temperatures above those indicated above automatically forfeits
warranty.
Maintenance
Routine Maintenance operations 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 with the normal times for maintenance work:
HOURS
50
100
300
500
1000
1500
2000
CHECK OIL
FILTER
YES
YES
YES YES
YES YES
YES YES YES
YES YES
YES YES YES
CHECK
OIL
CHANGE
OIL
CHANGE OIL
FILTER
CHANGE AIR
FILTER
Changing the oil
The oil will have to be changed periodically every 2000 operating hours or at least once a year.
Empty the unit tank by arranging a container of an adequate capacity to contain the quantity of
oil to be removed under the drainage plug at the bottom of the tank.
Remember to tighten the plug before filling the tank.
Disposing of the oil will have to be done in conformity with local and state laws along with
OSHA regulations. Hydraulic oil is considered special waste.
Filters
The filter must be frequently replaced during the first period of operation of the press and then at
regular intervals of time to be defined according to the conditions of use and the environment
where the machine is located.
It is recommended to change the filter after the first 100 hours of operation. After that
approximately every 500-600 hours.
Force 40 70 100 Ton
11
On this unit there are three filters:
- Oil outlet filter
- Oil inlet filter
- Air inlet filter
Replacing the filters will help give the pump, oil and generally all the moving components longer
service life.
Failure to comply with the maintenance table in changing the filter will forfeit the
warranty.
Force 40 70 100 Ton
12
Malfunction Origin Remedy
Cylinder moves
slow
Air in the pump.
Air in the circuit
Damaged cylinder gaskets
Damaged or worn pump
Sequence valve jammed
Delivery oil line clogged or
choked
Bleed the air
Bleed the air
Replace the gaskets
Replace the pump
Recondition seq. valve
Check hydraulic lines
Piston will not
move
Cylinder leaks oil
Piston ram will not
build pressure
Pump Cavitation
Foam forms in the
fluid
Pumps
Pressure relief
valves
Pumps deliver little
or no oil
Pump will not turn
Unstable valves
Valve parts
jammed
Piston moves
irregularly or will
not move
Electric motor will not turn
Piston gaskets completely
Damaged
Blocked distributor
Damaged pump
Head gaskets damaged or worn Replace
Lack of pressure from pump
Pressure control valve set low
Filter Suction clogged
Fluid too viscous
Fluid level too low
Fluid unsuitable
Fittings or joints let air in
Air discharge in the circuit
Worn or damaged Recondition or replace
Operating instability Replace or recondition
Pumps worn or damaged Replace and recondition
Pump joint broken or undone Check or replace
Valve seat damaged
Pressure not constant
Dirty fluid Drain off fluid clean system and
Lack of pressure from the pump
Pressure adjustment valve set
low
The translating cylinder is
damaged
Translating wheels or guides
dirty or blocked
Check motor
Replace
Recondition distributor
Recondition or replace
Recondition pump
Set valve
Clean or replace
Replace
Bring back up to correct level
Replace with suitable fluid
Replace or tighten fittings
Discharge the remaining air from the
system
Replace or recondition
Check pump or pressure relief valve
components refill with clean and filtered
fluid
Recondition the pump
Set the valve
Check and recondition
Clean or replace parts
Excessive wear on
parts
Force 40 70 100 Ton
Oil containing abrasives
Insufficient lubrication
High operating pressure
Foreign bodies in the oil not held
back by the filter
13
Replace the fluid
Poor quality oil
Lowe the setting of the pressure relief
valve
Insufficient filtering, replace the filters
Putting out of service
In the case of not operating for a long period it is necessary to disconnect the press from the
sources of electrical power supply.
Empty the unit of oil and protect it suitably so there is no dust, moisture or other foreign bodies
that can damage the parts of the unit.
Demolition and division of materials
If you are not going to use the machine any more, it is recommended to make it inoperative by
removing the oil contained in the tank and eliminating the 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 be split
up into its homogeneous parts, these parts must be separately disposed of in conformity with
local and state laws along with all OSHA regulations.
Force 40 70 100 Ton
14
Electrical box Parts breakdown
1 2 3
4 5
6 7
Part
Item # Part Name
1 Pump Start button 716542 1
2 Stop button 716539 1
3 Start button 716556 1
4 Emergency button 300351 1
5 Power light 300298 1
6 Main power switch 80554L 1
7 Elect. Box lock 300628 1
7A Door key 80511
8 Female plug 1
N/A Male plug 301547 1
Electrical box w/ all
N/A
N/A
components
Electrical box w/ no
components 300389 1
number Qty.
300387 1
8
Force 40 70 100 Ton
15
Electrical box components parts
1
2
3
4 5 6
Item # Part Name 40 Ton
1 Contactor
2 Transformer 300842
3 Overload 220 volt 302187
3 Overload 440 volt 302189
3A N.O. contact block 302192
4 Relay 72300000
5 Fuse block 300843
5B Fuse 2 amp 77523
6 Terminal block ground
6A Terminal block black
70 Ton 100 Ton
300842 300842
302187 302187
302189 302188
302192 302192
72300000 72300000
300843 300843
77523 77523
Qty
1
1
1
1
1
1
1
3
2
3
Force 40 70 100 Ton
16
2.6 Exchange valve
Item # Part Name
1 Complete relief valve
O-ring kit spring
N/A
N/A Valve handle
washer
Part #
40 Ton
300178 300178 300178
301393 301393 301393
Part #
70 Ton
Part #
100 Ton Qty
1
1
1
Force 40 70 100 Ton
17
2.5 Distributor section
Part
Item # Part Name
N/A Complete valve assembly 300179
1, 2, 3, 4, 5 Knob lever pin fork powder
scraper 302211
Shaft group cap group main
6, 9, 10
Not shown
7
8
11, 12, 13
Back valve body entry
collector body max valve 302208
body 302210
Relief valve 300852
Cover Body 302209
Gasket Set 300886
number Qty
1
1
1
1
1
1
1
Force 40 70 100 Ton
18
6
Cylinder breakdown
8
7
4
1
2
Item # Part Name
1 Piston Gasket 300609 301195 301189 1
2 Piston 0-ring 300610 301196 301186 1
3 Head guide rings 300647 301197 301187 1
4 Head o-ring 300648 301198 301188 1
5 Head gasket 300649 301199 301185 1
6 Head scraper 300650 301200 301184 1
7 Washer Washer comes with fitting 2
8 Hose fitting top 301390 301390 301390 2
8A Hose fitting bottom 301390 301390 301390 2
Complete cylinder 300698 300642 SS100C00 1
Not
shown
Not
shown
Not
shown
Gauge 300359 300360 1
Hydraulic hose B
port 300382 300382 1
Hydraulic hose A
port 300383 300383 1
3
Part#
40 Ton
Part#
70 Ton
5
Part#
100 Ton
Qty
Force 40 70 100 Ton
19
2.4 Hydraulic pumping unit
Part #
Item # Part Name
1 Complete power unit 300633 300633 79937 1
1 Tank cover 301388 301388 301391 1
2 Electrical cover 300388 300388 300388 1
3 Fill cap 302055 302055 302055 1
4 Air filter 300391 300635 300224 1
5 Drain filter 300392 300392 300223 1
6
7 Back motor bearing 1
*8 Motor rotor 301848 301848 1
*9 Driving shaft 1
8 9 11 Drive shaft assembly 302200 302200
10 Front motor bearing 1
*11 Pump motor 1
12 Blade 302056 302056 1
13 Pumping bearing 1
14 Eccentric 1
15 Roller bearing 1
16 High pressure pump group 301115 301115 301115 2
Outlet filter / on bottom of
N/A
pump 300393 300393 300394 1
40 Ton
Part#
70 Ton
Part #
100 Ton Qty
Force 40 70 100 Ton
20
Hydraulic diagram
Force 40 70 100 Ton
21
Electrical schematic
Force 40 70 100 Ton
22
DURA PRESS
Gauge Conversion
Force 40
Bore 120 mm = 4.73 =
40 Tons = 314 Bar = 4555 PSI
35 Tons = 275 Bar = 3986 PSI
30 Tons = 235 Bar = 3416 PSI
25 Tons = 196 Bar = 2847 PSI
20 Tons = 157 Bar = 2277 PSI
15 Tons = 117 Bar = 1708PSI
10 Tons = 78 Bar = 1138 PSI
5 Tons = 39 Bar = 569 PSI
1 Ton = 7.8 Bar = 114 PSI
Force 40 70 100 Ton
23
DURA PRESS
Gauge Conversion
Force 70
Bore 160 mm = 6.299
70 Tons = 299 Bar = 4493 PSI
65 Tons = 278 Bar = 4172 PSI
60 Tons = 256 Bar = 3851 PSI
55 Tons = 235 Bar = 3530 PSI
50 Tons = 214Bar = 3209 PSI
45 Tons = 192 Bar = 2888 PSI
40 Tons = 171 Bar = 2567 PSI
35 Tons = 150 Bar = 2246 PSI
30 Tons = 128 Bar = 1925 PSI
25 Tons = 110 Bar = 1605 PSI
20 Tons = 88 Bar = 1284 PSI
15 Tons = 66 Bar = 963 PSI
10 Tons = 44 Bar = 642 PSI
5 Tons = 22 Bar = 321 PSI
1 Ton = 4.4 Bar = 64 PSI
Force 40 70 100 Ton
24
DURA PRESS
Gauge Conversion
Force 100
Bore 180 mm = 7.086 =
100 Tons = 350 Bar = 5074 PSI
95 Tons = 332 Bar = 4820 PSI
90 Tons = 315 Bar = 4566 PSI
85 Tons = 297 Bar = 4312 PSI
80 Tons = 280 Bar = 4058 PSI
75 Tons = 262 Bar = 3805 PSI
70 Tons = 245 Bar = 3551 PSI
65 Tons = 227 Bar = 3298 PSI
60 Tons = 210 Bar = 3044 PSI
55 Tons = 192 Bar = 2790 PSI
50 Tons = 175 Bar = 2536 PSI
45 Tons = 157 Bar = 2283 PSI
40 Tons = 135 Bar = 2028 PSI
35 Tons = 122 Bar = 1775 PSI
30 Tons = 105 Bar = 1522 PSI
25 Tons = 87 Bar = 1268 PSI
20 Tons = 70 Bar = 1014 PSI
15 Tons = 52 Bar = 761 PSI
10 Tons = 35 Bar = 507 PSI
5 Tons = 17 Bar = 253 PSI
1 Ton = 3.4 Bar = 50 PSI
Force 40 70 100 Ton
25
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