Clarke CSA 12F, 7613020 User guide

WARNING: Read these instructions before using the machine

12 TONNE HYDRAULIC PRESS

MODEL NO: CSA12F

PART NO: 7613020

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0220 - rev 4

INTRODUCTION

Thank you for purchasing this CLARKE 12 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.

TECHNICAL SPECIFICATIONS

Capacity 12 tonne

Operating
pressure

Ram stroke 184mm

Ram diameter 42mm

Net weight 85kg

Dimensions

A) 80mm

B) 515mm

C) 945mm

D) 205mm

E) 185mm

F) 695mm

G) 500mm

H) 1662mm

L) 152mm

10000psi

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SAFETY PRECAUTIONS

• The components of this press are specially designed to withstand the rated
capacity. Do not substitute bolts, pins, or any other components.

• During assembly or if the press is moved, always call for the help of an
assistant, do not manhandle single-handedly.

• Ensure the press is bolted down onto a solid, flat surface.

• Ensure the press is located on firm level ground with adequate light.

• Before applying a load, ensure all press bed support pins are fully engaged.

• Ensure that hydraulic hoses and couplings are completely sound.

• Before use, always ensure the workpiece is firmly secure and stable.

• Always clean spills of hydraulic oil immediately as this can be dangerous in a
workshop environment.

• Do not exceed the rated capacity of the press.

• Do not allow any person who is inexperienced in the use of hydraulic presses,
to use the press unless they are under direct supervision.

• Do not work directly in front of the press when it is in use.

• Never tamper with the press. The safety valve is calibrated and sealed at the
factory; do not attempt to change the setting.

• Use only the recommended hydraulic oil.

• Always apply the load under the centre of the ram. Offset loads can
damage the ram or ram mount and may cause the work piece to eject.

• Before use, check for signs of cracked welds, bent bed pins, loose or missing
bolts, or any other structural damage. Do not operate if any of these are
found. Have repairs made only by authorised service centre.

• Remove any load from press bed before attempting to adjust bed height.

• Press only on a work piece 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 splinter or be ejected from the press. Due to varied
applications, it is your responsibility to always use adequate guards, wear
eye protection and protective clothing when operating this press.

• Keep hands and fingers away from parts that may pinch and shift.

• Do not use extension tubes on the pump handle. Excessive effort can cause
damage and/or accidents.

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ASSEMBLY

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.

IMPORTANT: Due to the weight of the press components, we recommend
that you get assistance during assembly.

IMPORTANT: We strongly recommend that the press be firmly secured to a
firm and level floor using expansion bolts (not supplied). Holes are provided
in the base supports for this purpose.

IMPORTANT: Do not locate your press where it will be open to the elements,
as severe weather conditions will damage the hydraulic parts.

1. Attach the feet and the bottom
cross member to the side
supports, using the nuts, bolts and
washers.

2. Add the stay bars to each side
and bolt into place.

3. Bolt one of the cross beams to the
side supports, Attach the ram
baseplate to the cross beam,
securing it with the socket
headed bolt.

4. Add the other cross beam by
sliding it along the ram baseplate
from one end.

5. Assemble loosely before
tightening all the bolts at each
end with both spring and flat washers. Position the ram baseplate centrally
and lock in position.

6. With the help of an assistant, lift the frame assembly upright and
manoeuvre it to its intended location in the workshop.

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7. With the upper ring already
screwed home onto the ram
body as supplied, lower the ram
through the hole in the base plate
and secure in position using the
locking collar.

8. Insert the bed support pins into
the holes in the side support at a
height of your choosing. Then
lower the bed frame onto the
pins.

9. Screw the pressure gauge to the
connecting nut on top of the ram
cylinder. Seal the thread with PTFE
tape, ensuring it is tight when the
gauge is facing the front of the
press.

10. Pass the hydraulic hose through
the gap between the two cross
beams. Unfasten the protective
hose caps and screw the hose
onto the threaded connection of
the hydraulic ram.

11. We recommend sealing the thread with PTFE tape. Take care not to let any
oil escape while connecting the hose.

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12. Unscrew the air bleed valve and
check that the pump is filled with
hydraulic oil up to a visible level.

13. If empty, the total capacity is
630ml.

14. Attach the pump support plate to
the right-hand side support using
the fixing bolts, nuts and washers,
ensuring it is level before
tightening the bolts.

15. Bolt the pump to the support
plate using the socket head bolts
from below, then screw the pump
handle into the pump actuating
lever.

16. A set of mandrels complete with
storage bracket is available from
your Clarke dealer. If this is
provided, bolt the mandrel
storage bracket to the side of the
frame using the bolts supplied.

17. If fitted, store the mandrels
(including the adaptor) in their
positions on the bracket.

PUMP/RAM OPERATION

1. Before using the press, purge any
air from the system by opening
the release valve (turning it anti­clockwise) and pumping several
full strokes to eliminate any air
bubbles.

2. Check all parts are secure and
correctly aligned before using the
press.

• The press is now ready for use.

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POSITIONING THE BED

IMPORTANT: Due to the weight of the bed, we recommend that you get
assistance from another person when adjusting the bed height.

1. Position the bed at the desired height, 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 supporting pin into the next locating
hole.

3. Repeat at the other end to level the bed.

4. Repeat until the bed is at the desired height, with the supporting pins fully
‘home’.

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.

POSITIONING THE RAM

The ram can positioned as required
by sliding it along the cross-beam.
Lock it in position with the socket
head adjusting bolt on each side.

• Always position the ram directly
above the workpiece.

FITTING THE MANDRELS OR PRESSURE CAP

Four mandrels are provided, any of
which may be connected to the end
of the ram using the adaptor
supplied.

Alternatively, the basic ram pressure
cap can be fitted as shown. Secure
the pressure cap by tightening the
grub screw with a suitable hex key.

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If one of the mandrels is required, the
adaptor must be fitted instead of the
pressure cap. Secure the adaptor by
tightening the grub screw with a
suitable hex key as previous.

Select your mandrell depending
upon the size of the workpiece
bearing surface.

The mandrell can then be pushed
into the adaptor where the built-in
spring clip will hold it in place.

Store the mandrels in their positions
on the mounting bracket when not in
use.

OPERATION

WARNING: FAILURE TO HEED THE WARNINGS ON PAGE 3 MAY RESULT IN
DAMAGE TO THE EQUIPMENT, OR FAILURE RESULTING IN PROPERTY
DAMAGE, PERSONAL, OR EVEN FATAL INJURY.

1. Place the workpiece on the bed. It must be completely stable and
supported by packing or shims where required. Steel pressing plates are
supplied, which locate on the bed. Place the workpiece on a combination
of these to give it stability.

CAUTION: DO NOT POINT LOAD THESE ACCESSORIES AS THEY ARE NOT
DESIGNED TO TAKE THE FULL FORCE OF THE RAM IN ONE SPOT. ENSURE
THEY ARE ADEQUATELY SUPPORTED.

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.

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2. Close the release valve by turning
it clockwise until tightly closed.

3. Pump the handle to bring the ram
very lightly into contact with the
workpiece.

4. 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.

5. When satisfied that the workpiece
is correctly aligned and is completely stable in that position, slowly pump
the handle so that the ram begins to exert pressure on the workpiece.
Continue to pump the handle whilst standing to the side. Do NOT stand
directly in front of the work, and constantly monitor the process, ensuring
the ram and work remain completely in line and there is no risk of slipping.

6. When the process is complete, turn the release valve anticlockwise in small
increments to release ram pressure and allow removal of the workpiece.

WARNING: NEVER USE EXTENSIONS TO THE RAM PUMPING HANDLE

MAINTENANCE

• 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.

• Any press which 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 and the operating handle in the lowered position to protect the
moving parts.

PERIODICALLY

• Check the press frame to make sure all bolts are tight and inspect for
cracked welds, bent, loose or missing parts.

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• Check the hydraulic connections for leaks. Replace or properly repair any
damaged or leaking hydraulic components before using. In the event of
leaking seals, oil can be topped up via the plug on the end of the pump. Oil
should be level with the bottom of the hole. If necessary top up with CLARKE
hydraulic oil, Part No. 3050830. This task is carried out with the ram fully

retracted.

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

DE-COMMISSIONING PRODUCT

Should the product 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

ACCESSORIES

7-piece mandrell (adaptor) kit for CSA12F Press: part no 7615060.

(Also listed as items 14 & 34 -39 on the parts list (pages 12 & 13).

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FRAME ASSEMBLY PARTS DIAGRAM

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PAR TS L IS T S

PART NO DESCRIPTION PART NO DESCRIPTION

1 Pressure Gauge 21 Washer 10mm

2 Nylon Washer 22 Spring Washer 10mm

3 Ram Assembly 23 M10 Nut

4 Upper Collar 24 Bolt M10 x 25

5 Ram Base Plate 25 Pump Assembly

6 Lower Collar 26 Bolt M6 x 16 Hex Hd

7 Hydraulic Hose 27 Washer 6mm

8 Cross beam 28 Bolt M8 x 16

9 Bolt M12 x 35 29 Washer 8 mm

10 Washer 12mm 30 Stay Bar

11 Spring Washer 12mm 31 Foot

12 M12 Nut 32 Pump Support Plate

13 Side Support 33 Connecting Nut

14 Mandrell/Adaptor Bracket 34 15mm Mandrell

15 Bolt M12 x 30 35 25mm Mandrell

16 Heel Blocks 36 40mm Mandrell

17 Press Bed 37 50mm Mandrell

18 Supporting Pins 38 Adaptor Headpiece

19 Bottom Cross Member 39 Pressing Plate

20 Bolt M10 x 30

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RAM PARTS DIAGRAM

PART
NO

R1 Bolt M20 x 25 R10 O-Ring R19 Ram Piston

R2 O-Ring R11 O-Ring 40 x 5.3 R20 Grub Screw M6x10

R3 Connector R12 Sealing Ring R21 Washer

R4 Gauge Coupling R13 O-Ring 45x2.65 R22 Bolt M8 x 12

R5 Dust Cap R14 O-ring 46.5 x 1.5 R23 Threaded End

R6 Connector Nut R15 Distance Piece R24 Cap Piece

R7 Bolt M8 x 30 R16 Spring R25 Upper Ring

R8 Cylinder R17 Nut M8 R26 Locking Collar

R9 Circlip R18 O-Ring 29.5x3.55

DESCRIPTION

PART
NO

DESCRIPTION

PAR T
NO

DESCRIPTION

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PUMP PARTS DIAGRAM

PART
NO

P01 Pump Housing P14 Release Knob P27 Hand Grip

P02 Pin P15 Sealing Washer P28 Connecting Hose

P03 Bleed Screw P16 Sealing Washer P29 Hose Connection

P04 Cylinder Body P17 Piston Ring P30 Dust Cover

P05 O-Ring P18 Piston P31 Steel ball

P06 End Housing P19 Sealing Ring P32 Seat

P07 O-ring P20 O-Ring P33 Spring

P08 Bolt P21 Operating Rod P34 O-Ring

P09 O-ring P22 Operating Yoke P35 Relief Valve Body

P10 Steel Ball P23 Locating Pin P36 Plastic Cap

P11 Steel Ball P24 Pivot Pin P37 O-Ring

P12 Spring P25 Circlip P38 O-Ring

P13Valve Bolt P26Operating Handle

DESCRIPTION

PART
NO

DESCRIPTION

PART
NO

DESCRIPTION

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DECLARATION OF CONFORMITY

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