Clarke CSA 4B, 7613025 User guide

WARNING: Read these instructions before using the product

4 TONNE HYDRAULIC PRESS

MODEL NO: CSA4B

PART NO: 7613025

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL1022 - rev 3

INTRODUCTION

Thank you for purchasing this CLARKE 4 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.

Keep these instructions in a safe place for future reference.

SPECIFICATIONS

Dimensions (D x W x H) 400 x 528 x 685 mm

Rated Load 4 tonne

Throat Width 345 mm

Throat Depth 291 mm

Ram extension piece 1 (length) 82 mm

Ram extension piece 2 (length) 127 mm

Ram travel (total) 121 mm

Ram travel per stroke 3.56 mm

Ram action Single

Mandrell (pressure cap) dia 29 mm

Steel pressing plates type/size Pair (150 x 65 x 20 mm)

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: [email protected] or [email protected]

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.

3

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

ASSEMBLY

The following safety symbols are to be found on the machine.

Read this
instruction
booklet
before use.

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

1. Bolt the bottom cross members to
the side supports using the nuts,
bolts and washers. You may find it
better to insert some of the bolts
pointing away from the press to
avoid obstructing the nuts.

Wear
protective
footwear

Wear eye
protection.

2. Attach the feet to the side
supports using the nuts, bolts and
washers.

3. Bolt the upper crossmembers to
the side supports using the nuts,
bolts and washers.

• Assemble loosely before evenly
tightening all the bolts at each end
with both spring and flat washers.

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

5. Bolt the ram baseplate to the
upper cross beams from below.

6. Insert the ram through the hole in the base plate from above and screw
into position.

4

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

7. Unfasten the protective hose cap
and screw the hose onto the
threaded connection of the
hydraulic ram.

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

8. Unscrew the filler plug/bleed
valve on the end of the cylinder
and check that oil can be seen at
the bottom of the aperture. Top
up if necessary.

9. Screw the pump handle into the
pump actuating lever.

PURGING THE SYSTEM

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. Close the release valve.

3. Vent any residual air by releasing
the bleed valve shown above.
Unscrew by hand to release any
air before re-tightening.

FITTING THE RAM EXTENSIONS

1. Fit the ram extensions and
pressure cap as required.

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

The press is now ready for use.

5

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

OPERATION

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

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. Position the workpiece 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 anti-clockwise in
small increments to release ram pressure and allow removal of the
workpiece.

WARNING: NEVER USE EXTENSIONS TO THE RAM PUMPING HANDLE

6

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

MAINTENANCE

INSPECTION AND STORAGE

1. A visual inspection should be made before each use of the press, checking
for leaking hydraulic fluid and damaged, loose, or missing parts.

2. 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.

3. 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.

4. 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

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

2. 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.

3. 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.

7

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

FRAME ASSEMBLY PARTS

PART NO DESCRIPTION PART NO DESCRIPTION

1 Upper crossmember 11 Washer

2 Pump Handle 12 Lower Crossmember

3 Bolt 13 Pump Assembly Complete

4Nut 14Hose Assembly

5 Flat Washer 15 Ram Assembly Complete

6 Side Support 16 Ram Extension 82mm

7 Pressing Plates 17 Ram Extension 127mm

8 Frame Foot 18 Ram Tip (Cap)

9 Bolt 19 Ram mounting Plate

10 Nut

8

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

RAM & PUMP PARTS

PART NO DESCRIPTION PART NO DESCRIPTION

1 Union Assembly 26 Oil Reservoir

2 O-Ring 27 Oil Filler /Bleed Valve

3Handle Sleeve 28O-Ring

4 Handle 29 Tapered Spring

5Handle Socket 30O-Ring

6 Circlip 31 Reservoir Cover

7 Handle Hinge Pin 32 Screw

8 Lower Hinge Pin 33 O-Ring

9 Plunger 34 Ball

10 Plunger Cover Plug 35 Ball Seat

11 Nylon Gasket 36 Spring

12 O-Ring 37 Adjusting Screw

13 O-Ring 38 Screw

14 Filter Gauze 39 Screw Cover

9

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

PART NO DESCRIPTION PART NO DESCRIPTION

15 Ball 40 Retaining Ring

16 Coupling 41 Piston

17 Dust Proof Cover 42 Nylon Sealing Ring

18 Hydraulic Hose 43 Bowl

19 Seal 44 Retaining Ring

20 Screw 45 Ram Piston

21 Control Knob 46 End Cap

22 Screw 47 Tension Spring

23 Sealing Ring 48 Screw Cap

24 Valve Body 49 Piston Ring

25 Oil Filter 50 Ram Cylinder

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 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 pump seal
replaced.

the filler plug

CLARKE hydraulic oil is available, part no 3050830.

10

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

DECLARATION OF CONFORMITY

11

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