7615201 CLARKE | Alldatasheet
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WARNING: Read these instructions before using the press OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS DL0123 - Rev2
30 TONNE HYDRAULIC PRESS
MODEL NO: CSA30FPB PART NO: 7615201
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com INTRODUCTION Thank you for purchasing this CLARKE 30 Tonne Hydraulic Press. Before attempting to operate the machine, it is essential that you read this manual thoroughly and carefully follow all instructions given. In doing so you will ensure the safety of yourself and that of others around you, and you can also look forward to the press giving you long and satisfactory service. GUARANTEE This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt as proof of purchase. This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for the purpose for which it was intended. Faulty goods should be returned to their place of purchase, no product can be returned to us without prior permission. This guarantee does not effect your statutory rights. SAFETY SYMBOLS The above safety symbols appear on the product. Hazard;-shattered workpiece Hazard:- crushed hands Wear Safety Shoes Wear safety glasses Read instruction manual before use Wear protective gloves
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SAFETY PRECAUTIONS
- Due to the weight of the press, lifting equipment and the help of an assistant will be required during installation. Secure the press to a firm level floor using suitable anchor bolts (not supplied). Before starting work, check for cracked welds, loose or missing bolts, a damaged screen (if fitted), or any structural damage. Do not operate if any of these conditions exist. Have repairs made only by your service centre. Before work, always ensure that hydraulic hoses and couplings are completely sound. NEVER tamper with the press components or modify them. The safety valve is calibrated and sealed at the factory; do not attempt to change the setting. Use only the recommended hydraulic oil. The components of this press are designed to withstand the rated load. Do not substitute any other components or exceed the rated load of the press. Before applying pressure, ensure the workpiece is firmly secure and stable. ALWA YS clean up spills of hydraulic oil immediately as this can be dangerous in a workshop environment. DO NOT let any person who is unfamiliar with hydraulic presses use the press unless they are under direct supervision. Keep children and unauthorised personnel away from the work area. ALWA YS position the (optional) safety screen directly front of the workpiece. ALWA YS apply the load under the centre of the ram. Offset loads can damage the ram and may cause the work piece to be ejected. ALWA YS ensure the work piece is properly supported by the press bed. When using accessories such as pressing plates, be certain they are centered below the ram and are in full contact with the bed. Parts being pressed may shatter or be ejected from the press. Always use adequate guards, and wear eye protection and protective clothing when using this press.
- Keep hands and fingers away from parts that may pinch or shift. NEVER use extension tubes to increase the length of the pump handle. Excessive effort can cause damage and/or accidents. Wear approved impact safety goggles and heavy duty work gloves. Failure to heed these warnings may result in damage to the equipment, or serious personal injury.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com UNPACKING & INVENTORY Ensure the press and its components suffered no damage during transit and that all components are present. Should any loss or damage become apparent, please contact your CLARKE dealer immediately. The following items should be present in their packaging. A Frame with pump assembly J Pressure Gauge B Base Supports K Pressing Bed C Stay Bars L Bed Support Pins D Oil reservoir M Retaining Butterfly Clips EP u m p a s s e m b l y N Bed Blocks F Pump Handle P Foot Pedal Connecting Bars G Foot Pedal Fixing Kit (bolts, nuts, washers) H Ram cylinder 1.5L bottle of hydraulic oil
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com ASSEMBLY TOOLS REQUIRED W r e n c h / s o c k e t s e t P T F E t a p e H e x k e y s e t LOCATING THE PRESS The press must be firmly secured to a firm and level floor using expansion bolts (not supplied). Holes are provided in the feet for this purpose. Do not locate your press where it will be open to the elements, as severe weather conditions will damage the hydraulic parts. ASSEMBLY PROCEDURE 1. With the help of an assistant, attach the base supports to the frame using the nuts, bolts and washers. 2. Add the stay bars to each side and bolt into place. 3. With the help of an assistant if required, lift the frame assembly upright and manoeuvre it to its intended location in the workshop. 4. Install the ram by passing it through the top carriage and securing with the retaining collar. 5. Fit the carriage positioning handle to the front of the carriage using the hex bolts as shown. WARNING: DUE TO THE WEIGHT OF THE PRESS, LIFTING EQUIPMENT OR THE HELP OF AN ASSISTANT WILL BE REQUIRED DURING INSTALLATION.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 6. Remove the travel plug and install the pressure gauge. 7. Fit the gauge through the frame and secure with the nut supplied. We recommend sealing all threads with PTFE tape where hydraulic oil is to be contained. Take care not to let any oil escape while connecting the hoses. 8. Connect the ram hose to the ram cylinder. 9. Bolt the foot pedal to the frame using the long bolt, spacer tube, nut and washers. 10. Insert the bed support pins into the holes in the frame side supports at a height of your choosing. Secure them in position using the butterfly spring clips. 11. Lift the pressing bed into position on the pins. NOTE: Due to the weight of the bed, we recommend that you get assistance from another person.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 12. Fill the oil reservoir with oil from the container supplied, up to the 1.5L mark. PROTECTIVE SCREENS (OPTIONAL) Protective screens (CPS30T part number 7615260) are available from your CLARKE dealer. 1. If the protective screens have been purchased, bolt the mounting brackets supplied to the pressing bed as shown. 2. Fit the protective screen to the pressing bed and ensure it can be set in one of the available positions using the latches on each side.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PREPARATION FOR USE PURGING THE HYDRAULIC SYSTEM 1. Insert the pump handle into the actuating lever. 2. Open the release valve by turning anti-clockwise. 3. Pump several full strokes to eliminate any air bubbles from the system. Use either the handle or the foot pedal. 4. Close the release valve by turning clockwise. POSITIONING THE RAM 1. Slide the carriage along the cross- beam. 2. Lock it in positi on with the four sprung locking bolts. IMPORTANT: Always position the ram directly above the workpiece. POSITIONING THE PRESSING BED IMPORTANT: Due to the weight of the press bed, we recommend that you get assistance from another person when adjusting the bed height. 1. Position the pressi ng bed so that it will be as close as possible to the ram when the workpiece is mounted on it. 2. Raise one side of the bed and insert a bed supporting pin into the next locating hole. 3. Repeat at the other end to level the bed.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 4. Repeat until the bed is at the requir ed height, with the bed supporting pins are secured using the spring butterfly clips. POSITIONING THE PRESSING BLOCKS The bed blocks can be placed on the bed with either the flat face or the V-supports facing upwards. They are prevented from slipping out of position by the retaining pins which drop down within the confines of the bed side members. Check all parts are secure and correctly aligned before using the press. CAUTION: THE BED HEIGHT SHOULD ONLY BE RAISED OR LOWERED ONE HOLE AT A TIME, WORKING ALTERNATELY FROM ONE SIDE AND THEN THE OTHER, FAILURE TO WORK IN THIS WAY MAY CAUSE THE BED TO FALL AND CAUSE INJURY TO THE OPERATOR.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com OPERATION 1. Place the workpiece on the bed. It must be completely stable and supported by packing or shims where required. Pressing plates (bed blocks) are supplied, which locate on the bed. Place the workpiece on these to give it stability. NOTE: Any packing pieces or shims used MUST be capable of withstanding the pressure that will be brought to bear, and MUST be of sufficient size with sufficient surface area, so as to avoid the possibility of slipping or springing out. Mating surfaces MUST be horizontal so that the force being exerted will NOT be at an angle. 2. Close the release valve by turning clockwise until tightly closed. 3. Select either SLOW SPEED or FAST SPEED using the knob on the side of the pump cover. NOTE: Fast speed allows faster movement but greater effort will be required. 4. Pump the handle or foot pedal to bring the ram very lightly into contact with the workpiece. 5. Manoeuvre the workpiece or loosen the locking bolts and slide the ram to one side so that the desired point of contact is directly beneath the centre of the ram. 6. Slowly pump the handle or foot pedal so that the ram begins to exert pressure on the workpiece. 7. Continue to pump the handle and constantly monitor the process, ensuring the ram and work remain completely in line and there is no risk of slipping. KEEP HANDS AND FINGERS AWA Y FROM PARTS THAT MA Y PINCH OR SHIFT CAUTION: DO NOT POINT LOAD SUCH ACCESSORIES AS THEY ARE NOT DESIGNED TO TAKE THE FULL FORCE OF THE RAM IN ONE SPOT. ENSURE THEY ARE ADEQUATELY SUPPORTED.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com 8. Observe the reading on the pressure gauge and take care not to exceed the rated working pressure of the press. NOTE: The scale from 30 metric tonnes upward is highlighted in red, indicating pressure being applied above the rated maximum working pressure. 9. When the pressing task is complete, turn the release valve anticlockwise in small increments to release ram pressure and allow removal of the workpiece. TROUBLESHOOTING Problem Probable Cause Remedy Pump will not work. Dirt on valve seat/worn seals. Bleed pump unit or have unit overhauled with new seals by your dealer. Pump will not produce pressure. Pump feels hesitant under load. Air-lock. Open the release valve and pump the handle a couple of full strokes. Close the release valve. Pump feels hesitant under load. Pump cup seal could be worn out. Have the cup seal replaced by your dealer. Pump will not lower completely. Air-lock. Release air by removing the filler plug.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com MAINTENANCE ROUTINELY A visual inspection must be made before each use of the press, checking for leaking hydraulic fluid and damaged, loose, or missing parts. Owners and/or users should be aware that repair of this equipment requires specialised knowledge and facilities. It is recommended that a thorough annual inspection of the press be made and that any defective parts be replaced with genuine CLARKE parts. If the press appears to be damaged in any way, is found to be badly worn, or operates abnormally SHOULD BE REMOVED FROM SERVICE until the necessary repairs are made. If the press is not to be used for any length of time, store it with the ram piston withdrawn to protect the surface of the moving parts. PERIODICALLY Check the press to make sure all bolts are tight and inspect for cracked welds, bent, loose or missing parts. Clean any foreign material from the ram carrier. Keep the protective screen (if fitted) clean at all times. Check the hydraulic connections for leaks. Replace or properly repair any damaged or leaking hydraulic components before using. Note any loss of oil and if oil is seen to become foul, replace using CLARKE hydraulic oil, Part No. 3050830. If any rust is apparent on the structure it must be removed completely and the paint restored. DISPOSAL OF UNWANTED MATERIALS One of the most damaging sources of environmental pollution is oil products. Never throw away used oil with domestic refuse or flush it down a sink or drain. Collect any oil in a leak proof container and take it to your local waste disposal site. Should hydraulic components become completely unserviceable and require disposal, draw off the oil into an approved container and dispose of the product and the oil according to local regulations.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TECHNICAL SPECIFICATIONS Capacity 30 Tonne (30,000 kg) Hose Operating Pressure 68 Mpa Ram Travel 215 mm Ram Shaft Diameter 54 mm Net Weight 135 kg Dimensions D x W x H 760 x 560 (exc pump) x 1700 mm Throat Width 510 mm No of bed positions 10 Throat Depth (Ram to pressing plate) Platform at highest;- 0 mm Platform at middle;- 250 mm Platform at lowest;- 940 mm Ram travel per stroke 4.54 mm No of strokes to full extension 31 Pressure Gauge type Accuracy class 2.5 Pressure Gauge range 0-45 tonnes Length of Handle 930 mm Pump oil capacity 1.2 litres Oil type VG13
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com DECLARATION OF CONFORMITY
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com RAM PARTS DIAGRAM NO DESCRIPTION NO DESCRIPTION
1 Spacing ring 13 Bolt M8x10
2 Screw M6x6 14 Guide ring
3 Y-ring 15 Upper collar
4 Back ring 16 Toe
5 O-ring 17 Lower securing collar
6 Nylon ring 18 Bolt
7 Piston ring 19 Coupling
8 O-ring 20 Dust cap
9R i n g 2 1 C y l i n d e r
10 Piston 22 Spring
11 Screw 23 Nut M8
12 Sealing washer
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com GENERAL ASSEMBLY PARTS DIAGRAM
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com GENERAL ASSEMBLY PARTS LIST NO DESCRIPTION NO DESCRIPTION
1 Bolt M10 x 110mm 25 Pressure gauge
2 Spring 26 Sealing ring
3 Roller shaft 27 Gauge connector
4 Bearing 28 Joining piece
5 Circlip 29 Hydraulic hose
6 Cylinder fixing plate 30 Gauge connecting nut
7 Cylinder moving handle 31 O-ring
8 Spring washer 8mm 32 T- connector
9 Bolt M8x10mm 33 Straight connector
10 Bolt M10 x 25mm 34 Pressing block
11 Washer 10mm 35 Bed frame
12 Spring washer 10mm 36 Bed frame pin
13 Nut M10 37 Hydraulic hose
14 Butterfly spring clip 38 Hose fixing sleeve
15 Stay bar 39 Rivet
16 Bolt M12 x 25mm 40 Hose mounting plate
17 Base section 41 Handle
18 Frame 42 Washer 14
19 Washer 12mm 43 Spring washer 14
20 Spring washer 12mm 44 Nut M14
21 Nut M12 45 Tie bar
22 Cylinder assembly 46 Pump peddle
23 Protecting ring 47 Pedal pad
24 Securing collar 48 Screw
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PUMP PARTS DIAGRAM
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PUMP PARTS LIST NO DESCRIPTION NO DESCRIPTION
1 Handle Sleeve 32 Bolt M10 x 70
2 Handle 33 Connecting rod
3H a n d l e S o c k e t 3 4 C a p n u t M 5
4 Nut M14 35 Plastic protective shell
5 Connector 36 Speed regulator valve part
6 Connector pin 37 X-headed screw M5x8
7 Handle socket pin 38 Nut M10
8 Torsion spring bolt A 39 O-ring
9 Torsion spring bolt B 40 End Ring
10 High pressure oil plug 41 Oil pick-up pipe assembly
11 O-ring 5 x 1.8 42 Shaft M6 x 25
12 Hose connector 43 Bush
13 High pressure washer 44 Lock nut M6
14 High pressure oil spring 45 Hoop
15 Steel ball 13.5mm 46 Shaft M10x80
16 Low pressure oil sucking spring 47 Flat washer 6mm
17 Steel ball 9.5mm 48 Spring washer
18 Pump core 49 Inner hex bolt M6 x 16
19 Star O-ring 50 Oil reservoir
20 Pump core back ring 51 Reformed bolt
21 Pump core O-ring 52 Flat washer 14
22 Pump core sleeve 53 Spring washer 14
23 Pump core Y-ring 54 Foot pedal
24 High pressure oil suck ing spring 55 Tension spring
25 Base unit 56 Pressure regulating screw
26 Support rod 57 O-ring
27 Oil return sleeve copper pad 5 8 Pressure regulating spring
28 Return valve stem sleeve 59 Spring base
29 Lock nut M10 60 Steel ball 3mm
30 O-ring 5.7 x 1.9 61 Flat washer 10