OTC 1845 User manual

Sheet No.
Issue Date: Rev. E, August 21, 2015
Shop Press
Maximum Capacity: 25 Tons and 55 Tons
SAFETY PRECAUTIONS
© Bosch Automotive Service Solutions Inc.
1 of 2
WARNING: To prevent personal injury;
• Read and carefully follow the operating instructions and safety precautions for the press,
pump, and cylinder. Most problems are caused by incorrect assembly or operation.
• The owner of the press must ensure the press is installed and operated according to
Federal (OSHA), state, and local safety standards.
• A press can exert an extremely high force at a moderate hydraulic pump pressure. If you have
any questions about how much force is exerted at a given pressure, contact the Technical Services
Department.
• This press is designed for shop maintenance applications. For use in other applications, contact
Technical Services.
OPERATION
• Wear eye protection that meets the standards of ANSI Z87.1 and OSHA. Keep hands
away from the work area. The press should be located in an isolated area or shielded
to minimize danger to others. Hydraulic pressure can cause materials to break, possibly
resulting in personal injury.
• It is impossible for the manufacturer to provide practical, all-purpose shielding because
this is a general purpose press used in many different applications. The owner of the
press must supply shielding (such as the 1230PB or 2036PB available through OTC)
 thatispracticalandspecicforaparticularapplication.
• A work piece must be well supported and aligned to prevent slippage and breakage.
• To prevent accidental slippage, do not place work piece on the press bed or apply hydraulic force
until all bolster pins are in place and all tension has been removed from the bolster lift cables.
• Do not stress adapters beyond their capacities. Pushing or pulling adapters used with this press
must have a maximum tonnage rating equal to, or greater than, the maximum tonnage rating of the
press. Otherwise, breakage may occur.
• The user must ensure all safety-related decals are installed, maintained, and replaced when necessary.
BOLSTER ADJUSTMENT: A winch and cable assembly support the bolster when the bolster support
pins are not in place.
• To prevent accidental slippage, all bolster support pins must be in place and all cables
slack before a hydraulic pressing operation is performed.
• Keep hands, feet, legs, etc. out from under the bolster to prevent personal injury.
• To prevent accidental cable breakage, never raise or lower the bolster when under a load.
• When raising or lowering the bolster, place a support pin all the way through the front and back
uprights in the highest hole under the bolster. Ensure the pin does not interfere with the position
of the new bolster. To prevent injury, keep your hands free of the pins once the pins are in place.
• Inspect the entire length of each cable every three months. Replace
any cable that is worn, frayed, or crushed. The cables must run
easily along the pulleys, allowing the pulleys to turn freely.
Form No. 102481
Operating Instructions for:
655 Eisenhower Drive
Owatonna, MN 55060 USA
Phone: [phone]
Tech. Serv.: [phone]
Fax: [phone]
Order Entry: [phone]
Fax: [phone]
International Sales: [phone]
Fax: [phone]
1872
1872-220v
211200
576780
60361
61275
D01008AA
D01009AA
1826
1845
1846A
1847

Figure 1
Figure 2
Figure 3
Pump
Operating Instructions Form No. 102481, Sheet 1 of 2, Back
ASSEMBLY
Remove banding from press and shipping pallet.
Then remove all cartons. Stand press upright. Refer
to the following instructions and parts list provided.
1. Attach the feet to the press frame uprights with
the fasteners noted on the parts list.
2. Remove the lock ring and spring from the winch
shaft. Place winch handle onto shaft. Then
reassemble the lock ring and spring.
3. Using the fasteners noted on the parts list, attach
the pump to the pump mounting bracket. See
Figures 1 through 3.
NOTE: If your pump is a model 4044 or PE172,
remove the handle from the pump to allow
clearance for the shop press winch handle.
4. Cleanthethreadsonthettingsandonthehydraulic
hose. Assemble the hose to the pump. Thread the
other end of the hose into the cylinder.
IMPORTANT: Seal hydraulic connections with
pipesealant.Teontapemayalsobeusedto
seal hydraulic connections, if only ONE layer
of tape is used. Apply the tape carefully to prevent
itfrombeingpinchedbythettingandbrokenoff
inside the pipe end. Loose pieces of tape could
travelthroughthesystem,obstructingtheowof
oilorjammingprecision-tparts.
5. Air can accumulate in the hydraulic system during
initial setup or after prolonged use causing the
cylinder to respond slowly or in an unstable manner.
To remove the air, lay the cylinder on the oor.
Then extend and retract the cylinder several times
without putting a load on the system. Trapped air
will release through the pump reservoir.
6. Position the work bed:
A. Put a small amount of tension on the cable by
cranking the winch up, taking weight off the pins.
This frees the pins in the end of the bolster next
to the winch (or right side of the press). Then pull
out the loose pins.
B. Raise theotherend ofthebolsterbypullingslightly
on the handle until the remaining two pins are free.
C. Crank the winch for either up or down movement
of the work bed. Reassemble the pins.
CAUTION: The winch has a special friction
break for holding the bolster during positioning.
The friction break is NOT designed to hold
during a pressing operation nor will it hold a
workload during position.
Pump
Gauge
Hose
Mounting
Bracket

Sheet No.
Issue Date: Rev. E, August 21, 2015
2 of 2
CYLINDER ATTACHMENT
25 TON PRESS
1. Remove the adjusting screw from the cylinder mounting plate. Slip the two roll pins on the mounting plate
over the back lip on the bottom of the upper bolster.
2. Slide the mounting plate to the right side (winch side) of the press until the front roll pin lines up with the
notch on the front of the upper bolster. Raise the plate until the roll pin clears the lip on the bolster and
slide the mounting plate to the left.
3. Reinstall the adjusting screw in the mounting plate.
4. Disassemble the hose from the cylinder. Plug the cylinder and the end of the hose.
5.Threadthecylinderintothemountingplate.Positionthecylindersothehosettingonthecylinderpoints
to the side of the press where the pump is mounted.
WARNING: To prevent personal injury, the cylinder and mounting plate MUST have maximum
thread engagement to prevent the threads from stripping while the press is under a full load.
6.Re-threadthehosebackintothecylindertting,usingpipesealantorTeontape.
55 TON PRESS
1. Disassemble the hose from the cylinder. Plug the cylinder and the end of the hose.
2.Threadthecylinderintothemountingplate.Positionthecylindersothehosettingonthecylinderpoints
to the side of the press where the pump is mounted. NOTE: The cylinder handle must not interfere with
the winch cable after the cylinder is installed.
WARNING: To help prevent personal injury, the cylinder and mounting plate MUST have maximum
thread engagement to prevent the threads from stripping while the press is under a full load.
3. Due to the weight of the mounting plate and cylinder, the lower bolster can be used with cribbing to raise
the mounting plate and cylinder to the top bolster. CAUTION: The lower bolster should be used in this
manner only during the assembly of the press because raising and lowering the bolster with a load
can cause cable breakage.
4. Build two roller assemblies by installing the adjusting screw, rollers, bushings, and hardware onto the roller
plates.
5. Attach the cylinder/mounting plate assembly to the upper bolster by installing the roller assemblies to the
mounting plate.
6. Lower the bolster assembly and remove cribbing, if used. Insert bolster pins through lower bolster and
uprights at desired height.
7. Re-threadthehosebackintothecylindertting,usingpipesealantorTeontape.
CAUTION: To prevent equipment damage.
• Retract the cylinder when not in use to protect the surface of the piston rod.
• Whenaddingoiltothepumpreservoir,useonlyahigh-gradehydraulicoil.Neverusebrakeuid
or other substitute.
Operating Instructions Form No. 102481