7615203 CLARKE | Alldatasheet
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WARNING: Read these instructions before using the press OPERATION & MAINTENANCE INSTRUCTIONS ORIGINAL INSTRUCTIONS DL0123 - Rev 2
50 TONNE HYDRAULIC PRESS
MODEL NO: CSA50FPB PART NO: 7615203
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com INTRODUCTION Thank you for purchasing this CLARKE 50 Tonne Hydraulic Press. Before attempting to operate the press, 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. 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. OPERATING FEATURES
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TECHNICAL SPECIFICATIONS SAFETY SYMBOLS The following safety symbols appear on the product. Rated Load 50 To nne (50,000 kg) Operating Pressure 64 Mpa (9200 psi) Ram Travel 265 mm Ram Shaft Diameter 63 mm Net Weight 293 kg Dimensions D x W x H 800 x 1300 x 1960 mm Throat Width 710 mm Throat Depth (Ram to pressing plate) Platform at highest;- 0 mm Platform at lowest;- 950mm No of bed positions 8 @ 140 mm centres Ram travel per stroke 1.72 mm No of strokes to full extension 78 Pressure Gauge type Accuracy class 2.5 Length of Handle 900 mm Oil capacity 1.7 L Oil type (VG13 grade hydraulic oil) Read instruction manual before use Wear safety glasses Wear Safety Shoes Hazard;-shattered workpiece Hazard:- crushed hands Wear protective gloves
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com SAFETY PRECAUTIONS 1. Due to the weight of the press, lif ting equipment and the help of an assistant will be required during installation. Fix the press to the floor using suitable anchor bolts. 2. Before starting work, ch eck for signs of cracked welds, loose or missing bolts, damaged screen, or any other damage. Do not use if any of these conditions exist. Have repairs made only by authorised service centre. 3. Before work, always ensure that hydraulic hoses and couplings are completely sound. 4. NEVER tamper with the press components or modify them. The safety valve is set and sealed at the factory; do not attempt to adjust the setting. 5. Use only the recommended hydraulic oil. 6. The components of this press are desi gned to withstand the rated load. Do not substitute any other components or exceed the rated load of the press. 7. Before applying pressure, ensure the workpiece is firmly secure and stable. 8. ALWA YS clean up spills of hydraulic oil immediately as this can be dangerous in a workshop environment. 9. Do not let any person who is unfamilia r with hydraulic presses use the press unless they are under direct supervision. 10. Keep children and unauthorised personnel away from the work area. 11. ALWA YS position the (optional) safety screen directly front of the workpiece. 12. 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. 13. ALWA YS ensure the work piece is properly supported by the press bed. 14. When using accessories such as pressing plates, be certain they are centered below the ram and are in full contact with the bed. 15. 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. 16. Keep hands and fingers away from parts that may pinch or shift. 17. NEVER use extension tubes to increase the length of the pump handle or foot pedal. Excessive effort can cause damage and/or accidents. 18. Wear ANSI approved impact safety goggles heavy duty work gloves. 19. 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 PREPARATION FOR USE LOCATING THE PRESS Using suitable lifting equipment if required, lift the frame assembly upright and manoeuvre it to its intended location in the workshop. 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 exposed to the elements as harsh weather conditions will damage the hydraulic parts. FITTING THE WINCH During transit, the winch is positioned at 180o to its working position inside the frame and must be correctly mounted. 1. Turn the winch and bracket around and re-fit to the frame with the bolts and washers supplied, noting that the handle will be outside the frame for operation. FITTING THE HANDWHEEL The handwheel which is used to position the ram within the frame is supplied loose and requires fitting. 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 1. Fit the thrust bearing to the end of the axle. 2. Check that the direction of the thrust bearing is with the silver metal side facing outwards. 3. Fit the key into th e slot in the shaft and tap it into place. 4. Install the handwheel onto the shaft, lining up the slot in the wheel with the retaining key. 5. Secure the handwheel with the spring washer, flat washer and cross-headed screw supplied. 6. Remove the travel plug and install the pressure gauge. 7. Fit the gauge through the frame and secure with the connecting nut supplied.
- We recommend sealing threads with PTFE tape where hydraulic oil is to be contained. Take care not to let any oil escape while connecting the hoses.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com PROTECTIVE SCREEN (OPTIONAL) A protective screen CPS50T is available from your CLARKE dealer, part no: 7615262. 1. Bolt the protective screen brackets to the pressing bedplate. 2. Fit the protective screen assembly to the brackets and ensure it can be set in one of the available positions using the latches on each side. PURGING THE HYDRAULIC SYSTEM 1. Open the release valve by turning anti-clockwise. 2. Pump the handle or foot pedal several full strokes to eliminate any air bubbles from the system. 3. Close the release valve, turning clockwise.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com POSITIONING THE PRESSING BED 1. Use the winch to raise the pressing bed into a suitable position. The arrows on the winch indicate the direction of movement. The pressing bed should be as close as possible to the ram when the workpiece is mounted on it. 2. When satisfied that the bed is at the correct height insert the locking pins into their positions and secure with the butterfly clips. POSITIONING THE RAM 1. Position the carriage horizontally along the cross-beam using the adjusting handwheel on the side of the press. Always position the ram directly above the workpiece which should be as close to the centre of the press as possible.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com POSITIONING THE PRESSING BED 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.
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. 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 slide the ram to one side so that the desired point of contact is directly beneath the centre of the ram. 6. When satisfied that the workpiece is correctly aligned and is completely stable in that position, slide the protective screen (if fitted) into position before starting any pressing. The latches will support the screen in a selection of positions. 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 7. Slowly pump the handle or foot pe dal so that the ram begins to exert pressure on the workpiece. 8. Continue to pump the handle an d constantly monitor the pressing, ensuring the ram and work remain completely in line with no risk of slipping. 9. Observe the reading on the pressure gauge and take care not to exceed the rated working pressure of the press. The scale from 50 metric tonnes upward is highlighted in red, indicating pressure is being applied above the rated maximum working pressure. 10. When the pressing task is complete, turn the release valve control knob anticlockwise in small increments to release ram pressure and allow removal of the workpiece and lower the protective screen.
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. When requesting spare parts, please quote the number on the diagrams/parts lists on pages 14-18.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com TROUBLESHOOTING If this does not solve the problem, contact the CLARKE Sevice department on 020 8988 7400. GUARANTEE This product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt which will be required 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 its intended purpose. 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. 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. See “Purging the Hydraulic System” on page 7. 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. Piston will not retract completely. Air-lock. Release air by removing the filler plug.
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com RAM PARTS DIAGRAM NO DESCRIPTION NO DESCRIPTION
1 Elbow connector 12 Ring
2 Ram cylinder 13 Ring
3 Pin 14 O-ring 60.5x2.5
4 Nut 15 Piston
5 Spring 16 Grub screw
6G r u b s c r e w 1 7 W a s h e r
7 Nut 18 Bolt M10 x80
8Y - r i n g 1 9 R a m T o e 9 Back ring 20 O-ring 120x5.3
10 Piston head 21 Mounting Collar
11 O-ring 90.5 x 5.3 22 O-ring 74.5x5.3
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com FRAME ASSEMBLY PARTS LIST NO DESCRIPTION NO DESCRIPTION
1 Bolt M12 x 120 34 Grub screw
2 Spring 35 Pressure gauge
3 Bolt M8 x 12 36 Sealing ring
4 Spring washer 37 Gauge connector
5 Screw adjuster assembly 38 Connector
6 Carriage beam 39 Gauge connecting nut
7 Bearing 6202-2Z 40 T-connector
8 Clip 15 41 Connector
9 Nut M20 42 Bolt M12x20
10 Upper roller 43 Ram bearing plate
11 E-Clip 44 Bolt M12 x 40
12 Washer 45 Straight connector
13 Pivot bolt 46 Long roller
14 Bolt M10 x 25 47 Roller
15 Winch assembly 48 Circlip 20
16 Bolt 49 Pressing block set
17 Winch support bracket 50 Pressing beam
18 Washer 10 51 Butterfly clip
19 Spring Washer 10 52 Pressing beam support pin
20 Nut M10 53 Hydraulic pump assembly
21 Bolt M12 x 30 54 Frame upright
22 Bolt M12 x 35 55 Pedal footpad
23 Support beam 56 Screw
24 Support beam 57 Sleeve
25 Base support section 58 O-ring
26 Short roller shaft 59 Connecting hose
27 Roller cover plate 60 Hose connecting sleeve
28 Roller spool 61 Rivet
29 Roller cover 62 Hose fixing plate
30 Washer 12 63 Washer 14
31 Spring washer 64 Spring washer 14
32 Nut M12 65 Nut M14
33 Ram assembly complete
Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com FRAME ASSEMBLY 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
31 Oil release stem part 62 Flat washer 12
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 DECLARATION OF CONFORMITY