Clarke CSA 30FPB, 7615201 User guide

WARNING: Read these instructions before using the press

30 TONNE HYDRAULIC PRESS

MODEL NO: CSA30FPB

PART NO: 7615201

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC1121 - Rev1

INTRODUCTION

Thank you for purchasing this CLARKE 30 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.

SAFETY SYMBOLS

Hazard;-shattered
workpiece

Wear Safety Shoes Wear safety glasses

Read instruction
manual before use

The above safety symbols appear on the product.

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Hazard:- crushed hands

Wear protective gloves

SAFETY PRECAUTIONS

• Due to the weight of the press, lifting equipment and the help of an assistant
will be required during installation. Secure the press to a firm level floor using
suitable anchor bolts (not supplied).

• Before starting work, check for cracked welds, loose or missing bolts, a
damaged screen (if fitted), or any structural damage. Do not operate if any
of these conditions exist. Have repairs made only by your service centre.

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

• NEVER tamper with the press components or modify them. 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 load. Do
not substitute any other components or exceed the rated load of the press.

• Before applying pressure, 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 let any person who is unfamiliar with hydraulic presses use the press
unless they are under direct supervision.

• Keep children and unauthorised personnel away from the work area.

• ALWAYS position the (optional) safety screen directly front of the workpiece.

• 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. 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.

• Wear approved impact safety goggles and heavy duty work gloves.

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

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UNPACKING & INVENTORY

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.

The following items should be present in their packaging.

A

Frame with pump assembly

B

Base Supports

C

Stay Bars

D

Oil reservoir

E Pump assembly

FPump Handle

J

Pressure Gauge

K

Pressing Bed

L

Bed Support Pins

M

Retaining Butterfly Clips

N

Bed Blocks

P

Foot Pedal Connecting Bars

G Foot Pedal Fixing Kit (bolts, nuts, washers)

H Ram cylinder 1.5L bottle of hydraulic oil

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ASSEMBLY

WARNING: DUE TO THE WEIGHT OF THE PRESS, LIFTING EQUIPMENT OR THE
HELP OF AN ASSISTANT WILL BE REQUIRED DURING INSTALLATION.

TOOLS REQUIRED

• Wrench/socket set

• PTFE tape

• Hex key set

LOCATING THE PRESS

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 open to the elements, as severe
weather conditions will damage the hydraulic parts.

ASSEMBLY PROCEDURE

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

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

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

4. Install the ram by passing it
through the top carriage and
securing with the retaining collar.

5. Fit the carriage positioning handle
to the front of the carriage using
the hex bolts as shown.

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6. Remove the travel plug and install
the pressure gauge.

7. Fit the gauge through the frame
and secure with the nut supplied.

• We recommend sealing all threads
with PTFE tape where hydraulic oil is
to be contained. Take care not to
let any oil escape while connecting
the hoses.

8. Connect the ram hose to the ram
cylinder.

9. Bolt the foot pedal to the frame
using the long bolt, spacer tube,
nut and washers.

10. 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 butterfly spring clips.

11. Lift the pressing bed into position
on the pins.

NOTE: Due to the weight of the

bed, we recommend that
you get assistance from
another person.

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12. Fill the oil reservoir with oil from the
container supplied, up to the 1.5L
mark.

PROTECTIVE SCREENS (OPTIONAL)

• Protective screens (CPS30T part number 7615260) are available from your
CLARKE dealer.

1. If the protective screens have
been purchased, bolt the
mounting brackets supplied to the
pressing bed as shown.

2. Fit the protective screen to the
pressing bed and ensure it can be
set in one of the available
positions using the latches on
each side.

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PREPARATION FOR USE

PURGING THE HYDRAULIC SYSTEM

1. Insert the pump handle into the
actuating lever.

2. Open the release valve by turning
anti-clockwise.

3. Pump several full strokes to
eliminate any air bubbles from the
system. Use either the handle or
the foot pedal.

4. Close the release valve by turning
clockwise.

POSITIONING THE RAM

1. Slide the carriage along the cross­beam.

2. Lock it in position with the four
sprung locking bolts.

IMPORTANT: Always position the ram
directly above the workpiece.

POSITIONING THE PRESSING BED

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

1. Position the pressing 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.

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4. Repeat until the bed is at the required height, with the bed supporting pins
are secured using the spring butterfly 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 PRESSING 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. Pressing plates (bed blocks)
are supplied, which locate on the bed. Place the workpiece on these to
give it stability.

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.

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.

NOTE: 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
loosen the locking bolts and slide
the ram to one side so that the
desired point of contact is directly
beneath the centre of the ram.

6. Slowly pump the handle or foot
pedal so that the ram begins to
exert pressure on the workpiece.

7. Continue to pump the handle
and constantly monitor the
process, ensuring the ram and work remain completely in line and there is
no risk of slipping.

• KEEP HANDS AND FINGERS AWAY FROM PARTS THAT MAY PINCH OR SHIFT

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8. Observe the reading on the pressure gauge and take care not to exceed
the rated working pressure of the press.

NOTE: The scale from 30 metric tonnes upward is highlighted in red,

indicating pressure being applied above the rated maximum
working pressure.

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

TROUBLESHOOTING

Problem Probable Cause Remedy

Pump will not work. Dirt on valve seat/worn

seals.

Pump will not produce
pressure.
Pump feels hesitant
under load.

Pump feels hesitant
under load.

Pump will not lower
completely.

Air-lock. Open the release valve

Pump cup seal could be
worn out.

Air-lock. Release air by removing

Bleed pump unit or have
unit overhauled with new
seals by your dealer.

and pump the handle a
couple of full strokes.
Close the release valve.

Have the cup seal
replaced by your dealer.

the filler plug.

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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.

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TECHNICAL SPECIFICATIONS

Capacity 30 Tonne (30,000 kg)

Hose Operating Pressure 68 Mpa

Ram Travel 215 mm

Ram Shaft Diameter 54 mm

Net Weight 135 kg

Dimensions D x W x H 760 x 560 (exc pump) x 1700 mm

Throat Width 510 mm

No of bed positions 10

Throat Depth (Ram to pressing plate) Platform at highest;- 0 mm

Platform at middle;- 250 mm
Platform at lowest;- 940 mm

Ram travel per stroke 4.54 mm

No of strokes to full extension 31

Pressure Gauge type Accuracy class 2.5

Pressure Gauge range 0-45 tonnes

Length of Handle 930 mm

Pump oil capacity 1.2 litres

Oil type VG13

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DECLARATION OF CONFORMITY

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RAM PARTS DIAGRAM

NO DESCRIPTION NO DESCRIPTION

1 Spacing ring 13 Bolt M8x10

2 Screw M6x6 14 Guide ring

3 Y-ring 15 Upper collar

4Back ring 16Toe

5O-ring 17Lower securing collar

6Nylon ring 18Bolt

7 Piston ring 19 Coupling

8O-ring 20Dust cap

9Ring 21Cylinder

10 Piston 22 Spring

11 Screw 23 Nut M8

12 Sealing washer

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GENERAL ASSEMBLY PARTS DIAGRAM

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GENERAL ASSEMBLY PARTS LIST

NO DESCRIPTION NO DESCRIPTION

1 Bolt M10 x 110mm 25 Pressure gauge

2 Spring 26 Sealing ring

3 Roller shaft 27 Gauge connector

4 Bearing 28 Joining piece

5 Circlip 29 Hydraulic hose

6 Cylinder fixing plate 30 Gauge connecting nut

7 Cylinder moving handle 31 O-ring

8 Spring washer 8mm 32 T- connector

9 Bolt M8x10mm 33 Straight connector

10 Bolt M10 x 25mm 34 Pressing block

11 Washer 10mm 35 Bed frame

12 Spring washer 10mm 36 Bed frame pin

13 Nut M10 37 Hydraulic hose

14 Butterfly spring clip 38 Hose fixing sleeve

15 Stay bar 39 Rivet

16 Bolt M12 x 25mm 40 Hose mounting plate

17 Base section 41 Handle

18 Frame 42 Washer 14

19 Washer 12mm 43 Spring washer 14

20 Spring washer 12mm 44 Nut M14

21 Nut M12 45 Tie bar

22 Cylinder assembly 46 Pump peddle

23 Protecting ring 47 Pedal pad

24 Securing collar 48 Screw

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PUMP PARTS DIAGRAM

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PUMP PARTS LIST

NO DESCRIPTION NO DESCRIPTION

1 Handle Sleeve 32 Bolt M10 x 70

2 Handle 33 Connecting rod

3 Handle Socket 34 Cap nut M5

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 sucking spring 55 Tension spring

25 Base unit 56 Pressure regulating screw

26 Support rod 57 O-ring

27 Oil return sleeve copper pad 58 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

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