Clarke CHV 12B, 7610901 User guide

WARNING: Read these instructions before using the bender

12 TONNE HYDRAULIC PIPE BENDER

MODEL NO: CHV12B

PART NO: 7610901

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC1219 - ISS 1

INTRODUCTION

Thank you for purchasing this CLARKE 12 Tonne Pipe Bender which is designed
for bending STEEL PIPE ONLY, either galvanised or black finish.

IMPORTANT: This tool is NOT designed to bend thin wall tube - for example
copper pipe.

This bender is able to be used in both horizontal and vertical positions.

Before attempting to use the pipe bender 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 product giving you long and satisfactory service.

TECHNICAL SPECIFICATIONS

Capacity 12 Tonne

Pump oil capacity 500 ml

Net Weight 36 kg

Dimensions D x W x H 610 x 160 x 530 mm

Length of Handle 550 mm

No of strokes to full extension 157

Range of bending

0-90

o

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.

2

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

SAFETY PRECAUTIONS

• Due to the weight of the pipe bender the help of an assistant may be
beneficial during unpacking or when moving it around.

• ALWAYS operate on a suitably strong bench with adequate light.

• ALWAYS check for signs of cracked welds or any other structural damage
before starting work. Do not operate if any of these conditions exist. Have
repairs made only by a CLARKE service centre.

• NEVER tamper with the hydraulic components. The safety valve is calibrated
and sealed at the factory; - do not attempt to change the setting.

• Use only the recommended CLARKE hydraulic oil.

• The components of this pipe bender are designed to withstand the rated
capacity. Do not substitute any other components or exceed the rated
capacity.

• ALWAYS ensure the workpiece is secure before applying pressure.

• ALWAYS clean up any spillage of hydraulic oil immediately as this can be
dangerous in a workshop environment.

• Do not allow anyone who is unfamiliar with hydraulic tools to use the pipe
bender unless they are under direct supervision.

• ALWAYS ensure the work piece is properly positioned.

• ALWAYS 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.

• Failure to heed these warnings may result in damage to the equipment, or
serious personal injury.

3

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

UNPACKING

Ensure the product suffered no damage during transit and that all items are
present. Should any loss or damage become apparent, please contact your
CLARKE dealer immediately. The following items are supplied.

• 1 x Frame

• 6 x Bending Dies:

1 x ½

1 x ¾” (20 mm)

1 x 1” (25 mm)

” (15 mm)

1 x 1¼

1 x 1½ “(40 mm)

1 x 2” (50 mm)

• 1 x Handle

• 2 x Rollers c/w roller pins & 4 x R-clips (all supplied fitted)

” (32 mm)

METHOD OF USE

The pipe bender is provided with six bending dies in order that the following
sizes of British Standard Pipe, (to BS1387), may be bent to any angle up to 90
degrees.

1. Consult the following chart to ensure the correct die for the corresponding
pipe is used. If the wrong die is used, the quality of bend will be severely

compromised.

Die to be

used

15 mm 1/2” 16.2 0.65 15.0 0.59 21.4 0.84

20 mm 3/4” 21.7 0.85 20.5 0.81 26.9 1.06

25 mm 1” 27.4 1.08 25.8 1.02 33.8 1.375

32 mm 1-1/4” 36.1 1.42 34.5 1.36 42.5 1.68

40 mm 1-1/2” 42.0 1.65 40.4 1.59 48.4 1.9

50 mm 2” 53.1 2.09 51.3 2.02 60.3 2.375

Nominal

pipe size

Inside Diameter (Bore) Outside Diameter

Medium Heavy Medium/Heavy

mm inch mm inch mm inch

4

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

2. Install the rollers on their support pins at one of the hole positions according
to the extent of the bend required. The tighter the bend, the closer the
rollers will be to the centre of the pipe bender.

3. Secure the roller pins in position
using the R-clips.

4. Choose your die, based on the
chart and set it in position on the
ram.

5. Use the tip of the handle to open
the hydraulic valve by turning it
anticlockwise. (The ram will retract
under spring tension).

• If using for the first time, purge any air
from the ram by opening the
hydraulic valve (turning anti­clockwise) inserting the handle into
the actuating lever and pumping
several full strokes to eliminate any
air bubbles.

6. Close the hydraulic valve by
turning it clockwise.

7. With the ram in its lowest position
rest your workpiece between the
die and the rollers. Position the
workpiece so that the point of
contact with the die is directly
above the centre of the ram.

8. When satisfied that the workpiece
is correctly positioned and is
completely stable, slowly pump
the handle so that the ram begins
to exert pressure on the workpiece.

9. Continue to pump the handle and
constantly monitor the bending
process.

10. For best results, bend the pipe
progressively. A good technique is
to set the guide rollers wide apart
to begin with, bringing them closer
together as the degree of bend
increases.

5

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

WARNING: NEVER USE EXTENSIONS TO THE RAM PUMPING HANDLE

11. When completed, open the hydraulic valve and the ram will lower,
allowing the work to be removed.

12. To separate the die from the work, a short sharp tap with a hammer and
brass drift should be all that is required. TAKE CARE when removing...NEVER
hammer directly on the edges of the die.

CARE AND MAINTENANCE

This tool requires no maintenance except for keeping it clean.

Always inspect before each use to ensure no welds are cracked or broken
and that the tool is in good general condition. If it is damaged or if in doubt as
to its serviceability, consult your CLARKE dealer immediately.

ALWAYS store in an upright position with the ram in its lowest position
(retracted). DO NOT lay on its side as air could enter the system resulting in
poor performance and the need to bleed before further use.

If the ram fails to operate satisfactorily, it should be bled by turning the release
valve anti-clockwise and pumping the handle several times to expel any air.

If this is not successful, close the
release valve (turn it clockwise), then
remove the filler plug on the cylinder.
Pump the handle several times to
expel all air, then replace the filler
plug.

Owners and/or users should be aware
that repair of this equipment requires
specialised knowledge and facilities
and that any defective parts be
replaced with genuine CLARKE parts.

Ensure that any defective hydraulic components are replaced before using. In
the event of leaking seals, oil can be topped up via the filler plug on the ram.
Oil should be level with the bottom of the hole. If necessary top up with
CLARKE hydraulic oil, Part No. 3050830 (1 litre). This task is carried out with the
ram fully retracted.

If any rust is apparent it must be removed completely and the paint restored.

6

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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.

TROUBLESHOOTING

Problem Probable Cause Remedy

Pump unit will not work Dirt on valve seat/warn

seals

Pump will not produce
pressure
Pump feels hesitant
under load
Pump will not lower
completely

Pump will not deliver
pressure

Pump feels hesitant
under load

Pump will not lower
completely

Air-lock Open the release valve

Reservoir could be over­filled or have low oil level.

Pump cup seal could be
worn out.

Air-lock Release air by removing

Bleed pump unit or have
unit overhauled with new
seals

and remove the oil filler
plug. Pump the handle a
couple of full strokes and
close the release valve.
Replace the filler plug.

Check oil level by
removing the filler plug
and topping up to the
correct level.

Have the cup seal
replaced.

the filler plug

7

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

RAM PARTS DIAGRAM

8

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

RAM PARTS

NO DESCRIPTION NO DESCRIPTION

1 Screw 18 O-ring

2 O-ring 19 Shield ring

3Spring 20Pump core

4 Ball cup 21 Washer

5 Steel ball 22 Hydraulic cylinder

6 Screw cover 23 Pump body

7 Relief valve 24 Seal ring

8 Bush 25 Oil reservoir

9 Steel ball 26 Oil plug

10 Base 27 Sealing ring

11 Pin 28 O-ring

12 Handle 29 Top nut

13 Pin shaft 30 Tubing

14 Connecting bar 31 O-ring

15 Handle sleeve 32 Bowl washer

16 Steel ball 33 Piston

17 Washer

9

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

FRAME ASSEMBLY PARTS

NO DESCRIPTION NO DESCRIPTION

1Frame 91/2” (15mm) bending die

2 12 tonne bottle jack 10 3/4” (20mm) bending die

3 Hex bolt 11 1” (25mm) bending die

4 Roller pin 12 1-1/4” (32mm) bending die

5 Guide roller 13 1-1/2”(40mm) bending die

6 R-clip 14 2” (50mm) bending die

7 Return Spring 15 Jack handle

8 Spring plate

10

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

DECLARATION OF CONFORMITY

11

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]