TABLE OF CONTENTS
SECTION
1.
2.
2.1
2.2
3.
3.1
3.2
3.3
4.
4.1
4.2
4.3
4.4
4.5
4.6
5.
5.1
5.2
5.3
5.4
6.
6.1
6.2
6.3
7.
8.
8.1
8.2
8.3
PAGE
GENERAL INFORMATION
SAFETY GUIDELINES
Definitions
Safe Operating Procedure
20 TON PRESS ASSEMBLY
Frame Assembly
Hydraulic Assembly
Electrical Assembly
OPERATION
How the Press Works
Table Adjustment
Cylinder Adjustment
Work Piece Support
Startup
Operating the Press
MAINTENANCE
Oil Level
Oil Change
Pump Repair
Cylinder Seal Replacement
TROUBLESHOOTING
Electrical System
Hydraulic System
Mechanical System
TECHNICAL SPECIFICATIONS
DRAWINGS
20 Ton Shop Press Item # 8217093
Hydraulic System for 20 Ton Press
20 Ton Press Parts List Item #8217093
1
2
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1.
GENERAL INFORMATION
The purpose of this manual is to assist you in operating and maintaining your 20 Ton
Shop Press. For safe, efficient and years of dependable trouble free operation of
your Press requires that you and anyone else using the Press read and understand
all of the safety, operation maintenance and troubleshooting information contained
within this Operator’s Manual.
WARRANTY – PARTS – SERVICE
If you experience any problems and need assistance or parts and repair service
please contact Princess Auto Ltd. At:
Telephone # 1-800-665-8685
Fax # 1-800-265-4212
To obtain prompt, efficient service, always provide the serial number and item
number of your unit. See the parts list for location of the serial number decal. Please
mark the numbers in the space provided for easy reference.
SERIAL #
ITEM #
Printed in Canada
Issue Date: July 2008
10004001
Revision 01
2
2.
SAFETY GUIDELINES
2.1
Definitions
Safety symbols identify important safety messages that alert to the possibility of personal
injury or death. Review them carefully before operating the unit and before performing
maintenance or repairs. Check the rules and regulations at your location and identify
possible hazards. The appropriate signal work for each message has been selected using
the following guidelines:
Danger indicates an immediate and specific hazard, which will result in
severe personal injury or death if the proper precautions are not taken.
Warning indicates a specific hazard or unsafe practice, which could result in
severe personal injury or death if proper precautions are not taken.
Caution indicates potentially hazardous situation, which may result in minor
or moderate injury if proper precautions are not taken.
IMPORTANT SAFETY INSTRUCTIONS
Read and understand operator’s manual and all safety alerts before operating or
maintaining your Hydraulic Press. Be certain that everyone operating this equipment is
familiar with the recommended operating and maintenance procedures and follows all the
safety precautions. Never let children or untrained adults operate the machine.
EXCEEDING RECOMMENDED CAPACITY
The shop press has been designed to safely withstand the load capacities listed in this
Operator’s Manual. To avoid structural damage and/or hydraulic failure, do not exceed the
listed capacity ratings. Failure to comply will void warranty.
RISK OF ELECTRICAL SHOCK
All electrical enclosures, cables, wiring and components must be installed and grounded in
accordance with national and local electrical codes.
RISK OF HOT SURFACES
Contact with hot surfaces, such as engine exhaust components could result in serious burn.
RISK OF FLUID INJECTION
Make sure all hydraulic components are maintained in good condition. Replace kinked,
cracked or otherwise damaged hydraulic components or hoses. Do not check for leaks with
your hands; use wood or cardboard as a backstop instead. Escaping fluid under pressure
can have sufficient force to penetrate the skin causing serious personal injury or even death.
If hydraulic fluid penetrates the skin, seek medical attention immediately. A serious infection
or reaction will develop.
Wear proper eye protection when searching for a high-pressure hydraulic leak. Do
not remove the cap from the hydraulic reservoir while power pack is running. Hot oil under
pressure could result in serious injury.
3
2.2
Safe Operating Procedure
•
Read and understand the Operator’s Manual completely before installing,
adjusting, operating, or maintaining your Hydraulic Shop Press.
•
Do not allow children or un-trained adults to operate your Hydraulic Shop
Press.
•
Clear area of people, especially small children before operating Press.
•
Insure the Press is positioned on a flat, level, hard surface; preferably concrete.
Stabilize unit by attaching to the floor.
•
Have a qualified electrician connect power to the Press.
•
Make sure the unit is grounded when connected to electrical power.
•
Maintain a dry and clean working area.
•
Always block and support working piece securely on the table bed.
•
Align working piece with cylinder before using and lock cylinder into position.
•
Always keep hands, clothes or other body parts clear of moving parts.
•
Always use your hands to operate the control lever. Never use another body
part or any extension devices to operate the control lever.
•
Always wear safety glasses, safety shoes, gloves, and hearing protection.
•
Do not use loads beyond rated capacity.
•
Stop motor, remove electric plug from power source and wait for all moving
parts to stop before servicing, maintaining, or adjusting the machine.
•
Keep all electrical wires and connections in good repair.
•
Keep all hydraulic lines, hoses, and fittings in good repair.
•
Do not adjust relief setting of the hydraulic system.
•
Workpiece can shoot out from under ram at a high rate of speed causing injury.
Provide necessary protection to self and others in the vicinity of press
operation.
4
3.
20 TON PRESS ASSEMBLY
The hydraulic press is shipped in a box and requires assembly before it can be used. Parts
are heavy; ensure you have someone to assist you with the assembly. Proper safety
measures must be applied to avoid injury.
1. Select an area that is firm and dry with sufficient space to work around all sides of the
unit.
2. Carefully remove the lid from the box and inspect the contents of the box to ensure all
of the components for your Hydraulic Press model are within.
3. Use the Press drawings and the corresponding bill of materials in the back of the
manual to use as a reference when assembling the press. Compare the Parts list of
materials to the components in the box to see if there are any missing or damaged
components. If there are, please contact your local Princess Auto store or Customer
Service at either:
Telephone # 1-800-665-8685
3.1
Fax # 1-800-265-4212
Frame Assembly
1. Lay out the two Uprights (1) on the floor parallel, with the C-channels facing each
other.
2. Lay one of the Top Beam Frames (28) on top of the two Uprights (1). Ensure that
the three holes on either side of the Top Beam Frame align with the three holes
on the Uprights, insert appropriate hardware, bolt (10), lockwasher (11), nut (12)
to connect the parts as shown in the drawing and Bill of Materials.
3. Turn assembly over and repeat previous procedure with the remaining Top Beam
Frame.
4. Lift assembly to the upright position. Have someone hold the assembly so it does
not tip over. Connect the two Legs (4), and Leg Center (3) to the Uprights. Install
appropriate hardware a shown in drawing. Tighten hardware connecting Legs to
Uprights, bolt (13), lock washer (14) and nut (15).
5. Tighten all fasteners.
6. Install Pins (5) at lowest level and Place Table (2) on pins as shown in drawing.
7. Install Cylinder 4005.5 onto Top Beams. Cylinder must be installed from below
Top Beams, lifted up and rotated 90 degrees so that the upper flange members
of the cylinder are resting on the top of both Top Beam Frames.
8. Center cylinder on Top Beam Frame, ensuring holes on cylinder flange line up
with the holes on both of the Top Beam’s flanges. Install appropriate hardware
and tighten. Ensure Dial gage port is facing the front side of the Press.
9. Fasten Power Pack either Upright using four 5/16 X 1.00” long bolts (17). Fasten
bolts with specified nuts and washers as shown on drawing. Ensure Power Pack
5
is positioned with its tank facing the floor, tighten all fasteners on the Power
Pack.
10. Install Valve (8) to preferred Upright with attached Power Pack. Ensure valve
handle is facing up and outward as depicted in drawing. Fasten Valve to Upright
with two 5/16 X 2.5” long bolts (20). Fasten bolts with appropriate hardware as
shown in the drawing.
3.2
Hydraulic Assembly
1. Use a thread sealant or Teflon tape on the Pressure Gauge male thread when
installing. All other hydraulic fittings do not require any thread sealant or Teflon
Tape.
2. Insert Gauge (9) into Gauge port on Cylinder as depicted in drawing.
3. Install two hydraulic fittings, Elbow #6 ORBM X #6 JICM (24) to the two ports on
the Cylinder. The ORBM side goes on the cylinder. Tighten fittings.
4. Install two remaining Elbow #6 ORBM X #6 JICM (24) to the two ports on the
Power Pack. Tighten fittings.
5. Install all four hydraulic fittings, Elbow #8 ORBM X #6 JICM (23) to the four ports
located on the Valve BLB (8). Tighten fittings.
6. Install the two short hydraulic hoses (33) to the hydraulic fittings on the Power
Pack. Install the rigid fitting end of the hose to the Power Pack leaving the swivel
end to be installed on the Valve. Tighten fittings.
7. Install the hose connected to the left side port on the Power Pack to the left side
of the Valve, as shown in the drawing. Install the remaining hose from the right
side of the Power Pack to the right side of the Valve, as shown in the drawing.
Tighten fittings.
8. Install the two long hydraulic hoses (25) to the fittings on the Cylinder. Install the
rigid fitting end on each hose to the cylinder, leaving the swivel to be attached to
the Valve. Tighten fittings.
9. Install the hose connected to the bottom port on the cylinder to the top port fitting
on the front of the Valve. Install the hose on the top port of the cylinder to the
bottom port fitting on the front of the Valve. Tighten fittings.
6
3.3
Electrical Assembly
The 20 Ton Press has a Power Pack that takes a 208-230V, single-phase power source.
The Power Pack does not come with an electrical cord. An electrical cord must be hard
wired into the Power Pack with an appropriate strain coupler connecting the cord to the
Power Pack by a qualified electrician in accordance with the Electrical Code. Have a
qualified electrician connect power to the Press.
4.
OPERATION
4.1
How the Press Works
The press provides force through the action of hydraulic oil flowing into the top port of the
double-acting cylinder. Hydraulic power is provided by the power pack which is a selfcontained pump driven by an electric motor. The directional control valve controls precise
hydraulic flow, which Is located below the power pack.
After turning on the motor, when the operator pushes the handle down, the hydraulic oil is
directed to the top port of the cylinder. The cylinder ram will move downward toward the
press bed to contact the working piece. When the cylinder ram encounters a resistance, the
gage mounted on the cylinder displays a rise in pressure that corresponds to the pushing
force, according to the pressure/force conversion table.
When the vale handle is pulled up, the oil flow is directed to the bottom port of the cylinder
and the ram retracts.
At both ends of the stroke and when the ram encounters a high resistance, the oil pressure
will go up to the relief valve setting of 3800 PSI. At this pressure the relief valve is fully open
and the oil flow is rerouted back to the tank. It is highly recommended not to exceed 3500
PSI that is equivalent to 21.5 tons.
When the cylinder reaches the top or bottom of the maximum stroke, the handle has to be
set to the neutral position IMMEDIATELY. The same is recommended at all times when
pressure reached 3500 PSI. Failure to do so will result in excessive heat that can
permanently damage the power pack. The 20 Ton press has an intermittent duty motor;
therefore the motor should not be on for more than 15 minutes continuously.
Although the Press is very simple to use, the operator must be sure that it is set and
adjusted properly for efficient and safe operation.
4.2
Table Adjustment
The press table has been designed to be easily adjusted to eight different heights, with 4.75
inches spacing to accommodate a wide variety of objects in the unit. The table and work
piece should be set to make contact with the ram after its initial one inch of travel. The job
should be completed after five inches of travel. To adjust the table, proceed as follows:
1.
2.
3.
4.
Grab one of the handles inside the bed and lift.
Remove the pin.
Lift or lower the bed and place the pin to the new hole location under the bed.
Grab the other handle and repeat steps 1-3.
7
5. IMPORTANT: make sure both pins are positioned at the same height and the
bed is against the washer on the pin.
4.3
Cylinder Adjustment
The cylinder can adjust horizontally to seven different positions at 2.50 inch spacing along
the frame to accommodate a variety of shapes on the Press. Ideally the cylinder should be
centered in the frame to allow maximum clearance around all sides. To adjust the cylinder,
proceed as follows:
1. Remove all four bolts that hold the cylinder to the frame. The tabs on the top of
the cylinder will prevent the cylinder from falling.
2. Move the cylinder to desired hole location.
3. Align holes and refasten hardware, tighten all fasteners.
4. Ensure the end cap is fully threaded into the cylinder shaft.
4.4
Work Piece Support
The press is designed to exert a 20 Ton force on anything that is positioned beneath the
ram. With this loading capacity, it is very important that the workpiece is supported securely
on the table base. Use the following procedure when placing supports under the workpiece.
1. Using square or flat pieces of heavy walled tubing or plate as the baseplate. The
plate can be purchased at your local Princess Auto store (part # 3460016).
2. Pay strict attention to the support pieces, making sure that they will not bend,
twist, or collapse when loaded.
3. Support the workpiece equally on at least two opposite sides to prevent twisting.
4. Place all supports perpendicular to the ram direction of travel.
5. Immediately STOP loading if work piece starts to move.
6. Use only Support pieces that can withstand the large force of 20 tons pressing
down.
4.5
Startup
Remove Breather Cap and add hydraulic oil into Power Pack reservoir. Use ISO G32
hydraulic oil. Turn Power Pack on. Air must be removed from the hydraulic system. Turn
power pack on and slowly cycle the cylinder ram up and down twice with the use of the
valve. Top up reservoir with hydraulic oil and cycle another time. Continue this process until
the fluid level in the reservoir remains the same. Make sure there is no foaming of the
hydraulic oil in the reservoir. The Reservoir should have a constant fluid level of up to one
inch below the breather cap or approximately 80% full during normal operation.
8
4.6
Operating the Press
1. Clear the area of bystanders.
2. Set the press Table to the required height.
3. Set the cylinder to the appropriate lateral spacing in the frame.
4. Place good support under the workpiece when it is placed on the press table.
5. When the workpiece is properly positioned, turn on the switch that starts the
electric motor.
6. Move the handle down to start the downward motion of the cylinder ram.
7. Watch the pressure gauge on the top of the cylinder to determine the pressure in
the cylinder.
8. Watch the workpiece carefully as the ram moves downward. Should the
workpiece or supports move or twist in any way, STOP the cylinder immediately.
9. Redo the support setup.
10. When the job is completed retract the ram to its fully retracted position. Always
leave the press with the cylinder ram in its fully retracted position.
5.
MAINTENANCE
5.1
Oil Level
Check every 20 hours of use or every two weeks during intermittent operation. The oil level
should be 1” from the breather cap.
5.2
Oil Change
Dispose of the drained oil in an approved container and according to local environment
protection regulations and bylaws.
Fill the reservoir with fresh hydraulic oil up to 1” below the cap. Approximately 3 quarts of
U.S. or ISO G32 hydraulic oil are required to fill the system. Repeat bleeding if the oil is still
foamy and replenish oil in the tank.
5.3
Pump Repair
The hydraulic pump (power pack) is a non-serviceable component. When it fails, call your
local authorized repair center for replacement and parts. Remember to replace all the oil in
the system to remove contaminants.
5.4
Cylinder Seal Replacement
A seal replacement kit is available for the cylinder. When the seals start to leak, they must
be replaced.
9
6.
TROUBLESHOOTING
In the following troubleshooting section, we have listed many of the problems, causes and
solutions to situations that you might encounter.
If you face a situation that is difficult to solve, even after having read through this
troubleshooting section, please contact our customer service at 1-800-665-8685. Before you
call, please have this Operator’s Manual and serial number of the press ready.
6.1
Electrical System
PROBLEM
Power pack will
not start.
CAUSE
Power not ON.
Motor won’t run.
Pump seized – frozen up.
6.2
SOLUTION
Check master electrical panel.
Turn switch ON.
Check integrity of motor and power
cord.
Replace or repair motor as required.
Check for defective connections.
Check for proper voltage.
Replace or repair component.
Hydraulic System
PROBLEM
No oil flow.
CAUSE
Power pack does not come
ON.
Cylinder does not move.
Air lock in the lines.
No pressure reading on
gauge.
Oil in press.
Oil leaking from cylinder.
Oil leaking from fitting or line.
10
SOLUTION
Check electrical system.
Check oil level. Fill as required.
Defective control valve. Clean, repair
or replace as required.
Loosen fitting to bleed line.
Check pressure gauge. Replace if
defective.
Check control valve. Clean, repair or
replace as required.
Check power pack. Replace if
defective.
Check cylinder seals. Oil bypassing in
cylinder. Replace seals.
Replace seals as required.
Loose fitting. Tighten or add sealant
as required.
Defective fitting. Replace.
6.3
Mechanical System
PROBLEM
Cylinder ram
does not move.
CAUSE
Electrical problems.
SOLUTION
Check electrical system.
Hydraulic problems.
Check hydraulic system.
Press overloaded.
Check work piece. Exceeded capacity
of press. Use a larger press.
Check cylinder. Remove defective
part and repair.
Cylinder ram is bent. Replace ram
and seals. Use more care when
applying loads to avoid side loading.
Ram jammed.
Ram binding.
7.
TECHNICAL SPECIFICATIONS
•
Maximum capacity: Push 21.5 Tons
Pull 17.2 Tons
•
Maximum working pressure: 3500 PSI
•
Ram bore: 4.0”
•
Ram stroke: 5.5”
•
Working area (width): 24”
•
Ram to bed distance: 4.5” – 37.75” at 4.75” increments (ram fully retracted)
•
Bed width: 9.0”
•
Ram speed: 25”/min extending, 31”/min retracting
•
Overall Height: 64”
•
Overall Width: 39”
•
Electric motor: 2HP, 3450 RPM, 230 V, 15 A, Intermittent Duty
•
Hydraulic Pump: Double Acting, 3 Quarts Reservoir
•
Volume Flow Rate: 1.29 GPM Open Flow
•
Weight: 400 Lbs
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8. DRAWINGS
8.1
20 Ton Shop Press Item # 8217093
12
8.2
Hydraulic System For 20Ton Press
13
8.3 20 Ton Press Parts List Item # 8217093
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Item No.
Description
10003992 UPRIGHT 20 TON PRESS
10003899 TABLE 20 TON PRESS S/ASSY
10003896 LEG CENTER S/ASSY 20 TON PRESS
10003995 LEG 20 TON PRESS
10004107 PIN 20 TON PRESS
10003427 CYL 4005.5 20 TON PRESS
9213950
POWER PACK 30 TON PRESS
10003233 VALVE BLB W/O RELIEF VALVE
9212259
GAUGE 0-10000 PSI .25 NPTM BACK MOUNT STEM (2.5"DIA)
9537440
BOLT HEX .750-10 UNC X 1.75 LG GR 5 PTD
9853417
WASHER LOCK SPLIT .75
9856667
NUT HEX .750-10 UNC GR 5 PTD
9804394
BOLT HEX .500-13 UNC X 1.50 LG
9853375
WASHER LOCK SPLIT REG .50 PTD
9856634
NUT HEX .500-13 UNC GR 5 PTD
10004101 BOLT HEX FLANGE .375-16 UNC X 1.50 LG
9803545
BOLT HEX .312-18 UNC X 1.00 LG GR 5 PTD
9856600
NUT HEX .312-18 UNC GR 5 PTD
9852377
WASHER PTD .344 ID X .688 OD
9801184
BOLT HEX .312-18 UNC X 2.50 LG GR 5 PTD
9853342
WASHER LOCK SPLIT REG .312 PTD
10003994 TOP BEAM FRAME 20 TON PRESS
10003998-3 ELBOW #8 ORBM X #6 JICM
10003998-4 ELBOW #6 ORBM X #6 JICM
10003998-2 .25 HOSE, 2 WIRE X 49 LG/4000psi /FITTING: JICF-06/JICF-06 SWL
9160235
DECAL WARNING OIL PRESSURE
10004005 DECAL PRESS 20 TON POWERFIST
10004006 DECAL CONVERSION TABLE
9161084
DECAL CAUTION
9160284
DECAL ELECTROCUTION HAZARD
9160813
DECAL PAL SERIAL #
10004102 NUT WING .375-16 UNC
10003998-1 .25 HOSE, 2 WIRE X 21 LG /4000psi /FITTINGS: JICF-06 / JICF-06 SWL
14
Qty
2
1
1
2
2
1
1
1
1
12
12
12
4
4
4
4
4
6
6
2
6
2
4
4
2
1
1
1
1
1
1
4
2