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20 TONNE HYDRAULIC PRESS
MODEL NO: CSA20FBT
PART NO: 7614058
OPERATION & MAINTENANCE
INSTRUCTIONS
WARNING: Read these instructions before using the press
ORIGINAL INSTRUCTIONS GC1120 - ISS 3
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INTRODUCTION
Thank you for purchasing this CLARKE 20 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.
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 and installation.
• Always operate the press 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 Lower Cross Member
• 2 x Side Posts
• 2 x Upper Cross Members
• 2 x Base Supports
• 4 x Stay Bars
• 1 x Ram
• 1 x Ram Carrier
• 1 x Ram Locking Collar
• 1 x Pump Assembly
• 1 x Pump Handle
• 1 x Hose (attached to pump assembly)
• 1 x Pressure Gauge
• 2 x Pressing Bed Side Frames
• 2 x Bed Support Pins with 4 x Spring Clips
• 2 x Bed Blocks
• 1 x Instruction Manual
• 1 x Fixing Pack
TOOLS REQUIRED
• Wrenches & sockets to suit M10/M12/M16 nuts/bolts or an adjustable
wrench
• Spanners to suit pressure gauge/hydraulic hose connections
• Hexagonal key set
• PTFE tape
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ASSEMBLY
IMPORTANT: Due to the weight of the press components, we recommend
that you get assistance during assembly.
IMPORTANT: The press should 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 harsh weather conditions will damage the hydraulic parts.
1. With the help of an assistant,
attach the base supports to the
side posts using the nuts, bolts and
washers.
2. Add the stay bars to each side
and bolt into place.
3. Bolt one of the upper cross
members into place to connect
the side posts together.
4. Take the second upper cross
member and the ram carrier and
tie the two cross members
together using the ram carrier.
Then bolt the second cross
member to the side posts as
shown.
• The ram carrier can slide along the cross members.
5. Fit and tighten the locking bolts
loosely to stop the ram carrier
from sliding to and fro.
6. Lift the complete press assembly
upright and manoeuvre it to its
intended location in the
workshop.
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7. Bolt the pump assembly to one of
the side posts. Thread the fixing
bolts though the side post from
the inside as shown.
• This will become the right hand
side of the press.
8. Lower the ram through the hole in
the moving ram carrier and
secure in position using the
locking collar.
9. Assemble the pressing bed using
the four spacers and the 140mm
bolts with nuts and washers.
10. Insert the bed support pins into
the holes in the frame side
supports at a height of your
choosing.
11. Lift the pressing bed into position
on the pins.
• Due to the weight of the bed,
we recommend that you get
assistance from another
person.
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12. Connect the hydraulic hose to the
ram cylinder, sealing the joint with
PTFE tape and tighten using two
open ended spanners.
13. The pressure gauge is sealed for
transit and it will be necessary to
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.
14. Bolt the pressure gauge into
position on the hydraulic ram.
• We recommend sealing the
thread with PTFE tape. Take
care not to let any oil escape
while connecting the hose.
15. Top up the hydraulic oil to the
lower level of the filler plug.
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PREPARATION FOR USE
1. Insert the pump handle into the
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 (clockwise).
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 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.
4. Repeat until the bed is at the required height, with the bed supporting pins
secured 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. Loosen the locking bolts and
position the ram as required by
sliding the carriage along the
cross-beam.
2. Lock it in position with the locking
bolts.
• Always position the ram
directly above the workpiece
and do not position it outside
the range indicated by the
maximum travel limit labels.
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POSITIONING THE PRESSING BLOCKS
The pressing blocks can be placed
on the bed to suit the work.
Check all parts are secure and
correctly aligned before using the
press.
OPERATION
1. Place the workpiece on the bed. It must be completely stable and
supported by packing or shims where required. Pressing plates are
supplied, which locate on the bed. Place the workpiece on 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. NEVER USE EXTENSIONS TO THE
PUMPING HANDLE.
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
the control knob 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
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constantly monitor the process, ensuring the ram and work remain
completely in line and there is no risk of slipping.
6. Observe the reading on the pressure gauge and take care not to exceed
the rated working pressure of the press.
• The scale from 20 metric tonnes upward is highlighted in red, indicating
pressure being applied above the rated maximum working pressure.
7. When the process is complete, turn the release valve control knob
anticlockwise in small increments to release ram pressure and allow
removal of the workpiece.
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.
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 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.
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.
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.
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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.
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TROUBLESHOOTING
Problem Probable Cause Remedy
Pump unit will not work Dirt on valve seat/worn
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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FRAME ASSEMBLY PARTS DIAGRAM
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FRAME ASSEMBLY PARTS LIST
PART NO DESCRIPTION PART NO DESCRIPTION
1 Pressure Gauge 19 Base Foot
2 Nylon Ring 20 Bolt M10 x 20
3 Ram Assembly 21 Bolt M12 x 35
4 Upper Crossbeam 22 Washer 12mm
5 Bolt M8 x 35 23 Spring Washer 12
6 Washer 16mm 24 Nut M12
7 Spring Washer 16 25 Tie Bar
8 Nut M16 26 Support Pins
9 Nut M10 27 Bolt M10 x 140
10 Spring Washer 10 28 Press Bed
11 Washer 10mm 29 Stay bar
12 Side Post 30 Pressing Blocks
13 Bolt M10 x 25 31 Retaining Collar
14 Hydraulic Pump Assembly 32 Ram Carriage
15 Handle 33 Bolt M8 x 25
16 Handle Grip 34 Gauge connecting nut
17 Arm Support 35 Connecting nut
18 Bolt M10 x 30 36 Hose Assembly
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RAM PARTS DIAGRAM
PART NO DESCRIPTION PAR T NO DESCRIPTION
R1 Dust Cap R14 Cylinder
R2 Connection R15 O-Ring
R3 Bolt Screw R16 O-Ring
R4 Ram R17 Piston
R5 Ram Sleeve R18 Back-up Ring
R6 Ram Sleeve Base R19 Y-Seal
R7 M8 Nut R20 Swivel Nut
R8 Spring R21 Bolt M6 x 6
R9 Cap R22 Gauge Connector
R10 Bolt M8 x 12 R23 Seal
R11 Seal R24 Nut
R12 Screw Cover R25 Bolt M20 x 25
R13 Bolt M6 x 12
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PUMP COMPONENT PARTS
PART NO DESCRIPTION PART NO DESCRIPTION
P1 Air bleed screw P9 Ball valve 6
P2 O-ring P10 Ball valve 3
P3 Hydraulic pump unit P11 Spring plate
P4 Grub Screw M12x1.25x10 P12 Spring safety valve
P5 Ball Valve 9 P13 O-ring
P6 Spring P14 Pressure adjusting screw
P7 Ball valve 6 P15 Safety valve cap
P8 Screw M8 x 8 P16 Limit block
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PUMP COMPONENT PARTS (CONT)
PART NO DESCRIPTION PAR T NO DESCRIPTION
P17 Spring washer 6 P28 Ball valve
P18 Bolt M6x10 P29 Spring
P19 Release valve control knob P30 Ball valve
P20 O-ring P31 Screw M12x1.25x10
P21 Ball valve 6 P32 Angle coupling block
P22 Copper washer P33 O-ring
P23 Pump body P34 O-ring
P24 J-ring P35 O-ring
P25 Actuating lever P36 O-ring
P26 Pin P37 Piston rod
P27 R-clip
TECHNICAL SPECIFICATIONS
Rated Load 20 Tonne
Ram Travel (total movement) 250 mm
Ram Shaft Diameter 48 mm
Net Weight 115 kg
Dimensions D x W x H 700 x 723 (exc pump) x 1770 mm
Throat Width 540 mm
Throat Depth (Ram to pressing plate) Platform at highest;- 0 mm
Platform at middle;- 360 mm
Platform at lowest;- 840 mm
Ram travel per stroke 1.04 mm
No of strokes to full extension 230
Pressure Gauge type Oil Filled (Accuracy class 2.5)
Length of Handle 620 mm
Pump Oil Capacity 1000mL (SAE10)
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DECLARATION OF CONFORMITY
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NOTES
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