Clarke CSA 20F, 7614055 User guide

WARNING: Read these instructions before using the press

20 TONNE HYDRAULIC PRESS

MODEL NO: CSA20F

PART NO: 7614055

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC1120 - REV 5

INTRODUCTION

Thank you for purchasing this CLARKE 20 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.

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SAFETY PRECAUTIONS

• Due to the weight of the press, the help of an assistant will be beneficial
during assembly or when moving the press around.

• Always operate the press on a suitably strong bench with adequate light.

• Before starting work, check for signs of cracked welds, loose or missing bolts,
or any other structural damage. Do not operate if any of these conditions
exist. Have repairs made only by authorised service centre.

• Before work, always ensure that hydraulic hoses and couplings are
completely sound.

• Never tamper with the press components. 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 capacity.
Do not substitute any other components or exceed the rated capacity of the
press.

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

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

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

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

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

• Always 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. In the case of
varied applications, it is your responsibility to 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.

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

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UNPACKING

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

INVENTORY

• 1 x Frame

• 2 x Base Supports

• 4 x Stay Bars

• 1 x Ram

• 1 x Ram Baseplate

• 1 x Pump

• 1 x Pump Handle

• 1 x Hose Assembly (attached to frame)

• 1 x Pressure Gauge

• 1 x Press Bed (Frame)

• 2 x Bed Support Pins with 4 x retaining spring clips

• 2 x Bed blocks (V-blocks)

• 1 x Instruction Manual

• 1 x Fixing Kit (containing bolts, flat washer, spring washers & nuts,
compression springs & hydraulic fittings).

TOOLS REQUIRED

• Open spanners (10, 12, 17, 19, 22, 27 & 29 mm) or an adjustable wrench

• PTFE tape

ACCESSORIES

• A mandrel set (including storage bracket and pressure plate) is not supplied
with the press but is available from your dealer as Clarke part no 7615062.

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ASSEMBLY

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. With the help of an assistant,
attach the feet to the frame using
the nuts, bolts and washers.

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

3. Lift the frame assembly upright
and manoeuvre it to its intended
location in the workshop.

4. With the help of an assistant, install
the ram support carriage into the
upper frame section by
assembling the baseplate, the
two axles and the four sprung
locking bolts/springs as shown in
Fig 2.

5. Tighten the locking bolts loosely so
that the carriage can still move to
and fro along the frame.

6. The hydraulic hoses must be
correctly installed within the
frame. Check that both the hoses
pass through any supporting rings
and that the T-connector sits
upright when the connecting
parts are fitted to the frame.

IMPORTANT: At the hose connection
to the pump, and at the T-connector
connection to the pressure gauge,
additional large ‘O’ rings are
supplied, purely for transit purposes and require removing by the end user

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prior to making the connections, ensuring the joint has only the smaller ‘O’
ring seated in the recess of the male component.

7. Fit the pressure gauge to the
connecting nut. Check the
gauge is upright before tightening
the nut with a spanner.

8. Make a small hole in the pressure
gauge safety bung with a short
pin or nail before use.

• Do not use a long nail as you may
damage the internal components
of the gauge.

9. Lower the ram through the hole in
the moving carriage and secure
in position using the locking collar.

10. Connect the hydraulic hose to the
ram cylinder, sealing the joint with
PTFE tape if required, and tighten
using two open spanners.

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11. Bolt the hydraulic pump into
position on the side of the frame
using the fixing bolts, nuts and
washers.

12. Ensuring that the hydraulic hose
passes through the retaining loop
on the frame, unfasten the
protective hose cap and screw
the hose onto the threaded
connection of the hydraulic
pump.

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

14. 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 spring clips.

15. Lift the bed frame into position on
the pins.

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

ADDING A MANDREL SET

A mandrel set (including storage
bracket and pressure plate) is not
supplied with the press but is
available as Clarke part no 7615062.

1. Bolt the mandrel storage bracket
to the side of the frame using the
bolts supplied.

2. Store the mandrels (including the
adaptor) in their positions on the
storage bracket.

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PREPARATION FOR USE

1. Insert the pump handle into the
pump actuating lever.

2. Purge any air from the system by
opening the release valve
(turning the control knob anti­clockwise) and pumping several
full strokes to eliminate any air
bubbles. Close the valve using the
control knob.

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 held
by the spring clips.

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

1. Position the ram as required by
sliding the carriage along the
cross-beam. Lock it in a static
position with the four sprung
locking bolts.

• Always position the ram directly
above the workpiece.

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FITTING THE MANDRELS (SUPPLIED SEPARATELY)

Any of the mandrels may be
connected to the end of the ram
using the adaptor supplied.

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

To install a mandrel, the adaptor must
be fitted instead of the pressure cap.
Secure the adaptor by tightening the
grub screw with a suitable hexagonal
key as previous.

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

The mandrel 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 storage bracket when not in
use.

POSITIONING THE 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.

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OPERATION

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.

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

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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.

• 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 THE 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.

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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

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TECHNICAL SPECIFICATIONS

Capacity 20 Tonne

Operating Pressure 69 Mpa

Bursting Pressure 138 Mpa

Ram Travel 189 mm

Ram Shaft Diameter 76 mm

Net Weight 138 kg

Dimensions D x W x H 560 x 800 (exc pump) x 1610

Throat Width 550 mm

Throat Depth (Ram to pressing plate) Platform at highest;- 30 mm

Platform at middle;- 470 mm
Platform at lowest;- 1025 mm

Ram travel per stroke 1.1 mm

No of strokes to full extension 170

Pressure Gauge type Accuracy class 2.5

Length of Handle 620 mm

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FRAME ASSEMBLY PARTS DIAGRAM

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FRAME ASSEMBLY PARTS LIST

PART NO DESCRIPTION PART NO DESCRIPTION

1 Bolt M10 x 110 21 Nut M12

2 Spring 22 Cylinder assembly

3 Roller shaft 23 Spacer ring

4 Bearing 24 Locking collar

5 Ring 25 Pressure gauge

6 Cylinder fixing plate 26 Square section seal

7 Cylinder moving handle 27 Connector

8Spring washer 8mm 28Joint

9 Bolt M8 x 10 29 Hydraulic hose

10 Bolt M10 x 25 30 Gauge connecting nut

11 Washer 10mm 31 O-ring

12 Spring washer 10mm 32 Straight connector

13 Nut M10 33 T-connector

14 Butterfly washer 34 Pump assembly

15 Stay Bar 35 Hydraulic hose

16 Bolt M12 x 25 36 Pressing block

17 Base section 37 Bed frame

18 Frame 38 Bed frame pin

19 Washer 12mm 39 Stay bar

20 Spring washer 12mm 40 Handle

MANDREL SET (CLARKE PART NO 7615062)

PART NO DESCRIPTION PART NO DESCRIPTION

41 Mandrel/Adaptor Bracket 48 25mm Mandrel

42 10mm Mandrel 49 30mm Mandrel

43 12mm Mandrel 50 Pressing Plate

44 16mm Mandrel 51 Bolt M12 x 30

45 18mm Mandrel 52 Flat Washer M12

46 20mm Mandrel 53 Spring Washer M12

47 22mm Mandrel 54 M12 Nut

55 Plain Adaptor

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RAM PARTS DIAGRAM

PART NO DESCRIPTION PART NO DESCRIPTION

R1 Spacing ring R13 Bolt M8x10

R2 Screw M6x6 R14 Guide ring

R3 Y-ring R15 Upper collar

R4 Back ring R16 Toe

R5 O-ring R17 Lower securing collar

R6 Nylon ring R18 Bolt

R7 Piston ring R19 Coupler

R8 O-ring R20 Dust cap

R9 Ring R21 Cylinder

R10 Piston R22 Spring

R11 Screw M6x10 R23 Nut M8

R12 Sealing washer

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PUMP PARTS DIAGRAM

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PUMP PARTS LIST

PART NO DESCRIPTION PART NO DESCRIPTION

P1 Air bleed screw P20 O-ring

P2 O-ring P21 Ball

P3 Hydraulic pump body P22 Copper washer

P4 Screw M12 x 1.25 x 10 P23 Piston body

P5 Ball 9 P24 End cap

P6 Steel spring P25 Yoke assembly

P7 Ball 6 P26 Hinge pin

P8 Screw M8x8 P27 R-clip

P9 Ball 6 P28 Ball

P10 Ball 3 P29 Spring

P11 Spring plate P30 Ball

P12 Safety valve spring P31 Screw M12 x 1.25 x 10

P13 O-ring P32 Angle coupling

P14 Pressure adjusting screw P33 O-ring

P15 Safety valve cap P34 Ring

P16 Limit block P35 O-ring

P17 Spring washer 6 P36 Ring

P18 Bolt M6 x 10 P37 Piston rod

P19 Release valve knob

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DECLARATION OF CONFORMITY

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