In the tool and die industry, a “try-out press” is the heartbeat of the shop. For our long-term customer Ram Die, their 1,350-ton Danly stamping press is essential for proving out the complex dies they build for their own clients. When the slide adjust failed and the counterbalances began severely leaking, they called HEL, Inc. to get their production schedule back on track.
The Challenge: The Complexity of the “Underdrive” Design
Most stamping presses have their drive gears located on the “crown” (the top). However, this Danly is an underdrive press, meaning all the gears and mechanical components are located at the bottom.
Underdrive presses are engineered for facilities with low ceilings, but they present unique challenges for repair:
- Accessibility: Components that are usually easy to reach are buried in a pit or integrated into the base.
- The Connecting Rod Dilemma: On a standard press, you can simply pull the slide adjust screw. In this underdrive setup, the connecting rod and screw are one unit. Pulling the rod would have required cutting a hole in the roof—an expensive and invasive option we wanted to avoid.
The Solution: Strategic Sourcing and Precision Machining
Ram Die knew the slide adjust nut had failed, but once HEL, Inc. technicians arrived on-site, our inspection revealed a secondary critical issue: the counterbalance cylinders were leaking severely.
1. Sourcing the “Blank Bore” Nut
To save the customer money and ensure maximum reliability, we worked closely with the Original Equipment Manufacturer (OEM). We ordered a custom casting of the slide adjust nut with a blank bore. Because we couldn’t remove the rod from the press, we measured and precision-machined the threads of the new nut to perfectly fit the existing screw on-site.
2. Modernizing the Counterbalances
While waiting eight weeks for the custom OEM casting to arrive, we prepared for the counterbalance rebuild. During the week-long on-site repair, we chose to upgrade the machine’s technology:
- Old Tech: Original leather seals.
- 2026 Standard: We installed modern urethane seals, which offer significantly longer life cycles and better performance under the heavy loads of a 1,350-ton press.
Why Every Detail Matters
As we’ve noted in our previous posts on counterbalances, these components are critical. If the counterbalances aren’t functioning, the underdrive system has to work twice as hard to lift the ram and the die, leading to the exact type of slide adjust failure Ram Die experienced.
The Result: Reliable Die Try-Outs
By opting for an OEM part and performing precision machining on-site, HEL, Inc. avoided a costly facility teardown and restored the Danly to factory-grade precision. Ram Die is now back to doing what they do best: building and testing world-class dies.
Is your specialized equipment showing signs of wear?
Whether it’s a standard straight-side or a complex underdrive press, the experts at HEL, Inc. have the rigging and machining prowess to handle it.
- Schedule Your 2026 Press Inspection
- Contact HEL, Inc. for Emergency Heavy Equipment Repair.
