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Clarke
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CSA 50FP
User guide
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Clarke CSA 50FP, 7615202 User guide

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50 TONNE HYDRAULIC PRESS
MODEL NO: CSA50FP
PART NO: 7615202
OPERATION & MAINTENANCE
INSTRUCTIONS
WARNING: Read these instructions before using the press
GC0319 - ISS 4
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INTRODUCTION

Thank you for purchasing this CLARKE 50 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

Read instruction manual before use
Wear Safety Shoes Hazard;-shattered
Hazard:- crushed hand
The above safety symbols appear on the product.
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Wear safety glasses
workpiece
s
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SAFETY PRECAUTIONS

1. Due to the weight of the press, lifting equipment and the help of an assistant will be required during installation. Fix the press to the floor using suitable anchor bolts.
2. Before starting work, check for signs of cracked welds, loose or missing bolts, damaged screen, or any other damage. Do not use if any of these conditions exist. Have repairs made only by authorised service centre.
3. Before work, always ensure that hydraulic hoses and couplings are completely sound.
4. Never tamper with the press components or modify them. The safety valve is set and sealed at the factory; do not attempt to adjust the setting.
5. Use only the recommended hydraulic oil.
6. 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.
7. Before applying pressure, ensure the workpiece is firmly secure and stable.
8. Always clean up spills of hydraulic oil immediately as this can be dangerous in a workshop environment.
9. Do not allow any person who is unfamiliar with hydraulic presses, to use the press unless they are under direct supervision.
10. Keep children and unauthorised personnel away from the work area.
11. Always position the safety screen directly front of the workpiece.
12. 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.
13. Always ensure the work piece is properly supported by the press bed.
14. When using accessories such as pressing plates, be certain they are centered below the ram and are in full contact with the bed.
15. 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.
16. Keep hands and fingers away from parts that may pinch or shift.
17. Never use extension tubes to increase the length of the pump handle. Excessive effort can cause damage and/or accidents.
18. Wear ANSI approved impact safety goggles and heavy duty work gloves.
19. Failure to heed these warnings may result in damage to the equipment, or serious personal injury.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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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 packages.
A
1 x Frame with ram and carriage
G
4 x Bed Support Pins
attached & lifting winch connected
B
2 x Base Supports
C
4 x Stay Bars
D 1 x Pump (with hose attached) &
H
8 x Pin retaining spring clips
I
2 x Bed blocks (V-blocks)
1 x Protective Screen assembly
pump cover
E 1 x Pressure Gauge 2 x Screen mounting brackets
F 1 x Pump Handle 1 x Fixing Kit (nuts/bolts/washers
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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 Keys

ASSEMBLY PROCEDURE

IMPORTANT: 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.
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 base supports to the frame using the nuts, bolts and washers.
2. Add the stay bars to each side and bolt into place.
3. Using suitable lifting equipment if required, lift the frame assembly upright and manoeuvre it to its intended location in the workshop.
4. Bolt the hydraulic pump into position on the side of the frame using the fixing bolts and washers.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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5. Unfasten the protective hose cap (not shown here) and screw the hose onto the connector block.
• We recommend sealing the
thread with PTFE tape. Take care not to let any oil escape while connecting the hose.
6. Fit the pressure gauge to the union nut on the inside of the frame. Check the gauge face is upright before tightening the union nut.
7. The air bleed tube is connected to the ram at one end. Connect the free end to the pump, using an open wrench and sealing the thread with PTFE tape (not supplied).
• The winch is supplied
disconnected from the frame but connected to the lifting cable ready for use. The handle will be pointing towards the middle of the packing crate during transit.
8. Fit the winch as shown with the handle facing away from the press before securing it to the frame with the mounting bracket, nuts, bolts and washers.
9. Bolt the protective screen brackets to the pressing bedplate.
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10. Bolt the connecting bars to the operating arm of the pump. Bolt them together as a pair fitting the short spacers in both positions as shown.
11. Bolt the foot pedal to the frame using the long bolt, long spacer, nut and washers.
12. Fit the protective screen assembly to the brackets and ensure it can be set in one of the available positions using the latches on each side.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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PREPARATION FOR USE

PURGING THE HYDRAULIC SYSTEM

1. Open the release valve by turning anti-clockwise.
2. Pump the handle or foot pedal several full strokes to eliminate any air bubbles from the system.
3. Close the release valve, turning clockwise.
4. Air can subsequently be bled from the system at any time using the bleed valve on the side of the pump.
5. Turn anti-clockwise to release and listen for air escaping before re­tightening.
6. Top up the hydraulic oil to the lower level of the filler plug with CLARKE hydraulic oil, Part No.
3050830.

POSITIONING THE PRESSING BED

1. Use the winch to raise the pressing bed into a suitable position.
• The arrows on the winch
indicate the direction of movement.
• The pressing bed should be as
close as possible to the ram when the workpiece is mounted on it.
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2. When satisfied that the bed is at the correct height insert the locking pins into their positions and secure with the spring clips.

POSITIONING THE RAM

1. Slide the carriage along the cross­beam.
2. Lock it in position with the four sprung locking bolts.
• Always position the ram
directly above the workpiece.

POSITIONING THE PRESSING 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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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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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.
• 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 slide the ram to one side so that the desired point of contact is directly beneath the centre of the ram.
6. When satisfied that the workpiece is correctly aligned and is completely stable in that position, slide the protective screen into position before starting any pressing.
• The latches will support the
screen in a selection of positions.
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7. Slowly pump the handle or foot pedal so that the ram begins to exert pressure on the workpiece.
8. Continue to pump the handle and constantly monitor the pressing, ensuring the ram and work remain completely in line with no risk of slipping.
9. Observe the reading on the pressure gauge and take care not to exceed the rated working pressure of the press.
• The scale from 50 metric tonnes upward is highlighted in red, indicating
pressure is being applied above the rated maximum working pressure.
10. When the pressing process is complete, turn the release valve control knob anticlockwise in small increments to release ram pressure and allow removal of the workpiece and lower the protective screen.

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 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 over filled 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 by your Clarke dealer.
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 by your Clarke dealer.
the filler plug.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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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. Clean off any foreign material from the ram carriage. Keep the protective screen clean at all times.
• If the press appears to be damaged in any way, is found to be badly wor n, 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.
• 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 filler plug on the top of the pump after removing the pump cover.
• 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.

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.
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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.
When requesting spare parts, please quote the prefix XXCSA50FP followed by the number on the diagrams/parts lists here.

TECHNICAL SPECIFICATIONS

Rated Load 50 Tonne
Operating Pressure 10,000 psi
Bursting Pressure 20,000 psi
Ram Travel 203 mm
Ram Shaft Diameter 68 mm
Net Weight 298 kg
Dimensions D x W x H 800 x 1325 x 1870 mm
Throat Width 725 mm
Throat Depth (Ram to pressing plate) Platform at highest;- 34 mm
Platform at lowest;- 1014 mm
No of bed positions 8 @ 140 mm centres)
Ram travel per stroke 3 mm
No of strokes to full extension 74
Pressure Gauge type Accuracy class 2.5
Length of Handle 600 mm
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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FRAME ASSEMBLY PARTS DIAGRAM

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FRAME ASSEMBLY PARTS LIST

NO DESCRIPTION NO DESCRIPTION
1 Screw 35 Lock Washer
2Spring 36Nut
3Steel Ball 37Screw
4 Pressing Block 38 Saddle
5Screw 39Spring
6 Nut 40 Connector
7 Lock Washer 41 Ram Assembly
8 Circlip 42 Ram Mounting Plate
9Axle 43Screw
10 Small Cable Roller 44 Elbow Connector
11 Safety Guard 3 45 Frame
12 Safety Guard 4 46 Circlip
13 Safety Guard 47 Bearing
14 Screw 48 Positioning Beam
15 Wire Roller 49 Spring
16 Safety Guard 2 50 Bolt
17 Bush 51 O-Ring
18 Spacer/cable attachment 52 Hydraulic Hose (Ram)
19 Bed Lifting Beam 53 Connecting Block
20 Hand Winch 54 Union Nut (gauge)
21 Nut 55 Screw
22 Washer 56 Nylon Ring
23 Bolt 57 Gauge Fitting
24 Bolt 58 Pressure Gauge
25 Retaining Spring Clip 59 Direct Joint
26 Bed Locating Pin 60 Hydraulic Hose (Pump)
27 Pressing Bed 61 PU Hose
28 Circlip 62 Bolt
29 Safety Guard 2 63 Bush
30 Safety Guard 1 64 Nut
31 Large Wire Roller 65 Connecting Rod
32 Roller Pin 66 Bush
33 Protective Cable Sleeve 67 Spacer Tube
34 Washer 68 Stay Bar
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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NO DESCRIPTION NO DESCRIPTION
69 Base Support 80 Washer
70 Nut 81 Handle Grip
71 Foot Pedal 82 Spring
72 Bolt 83 Winch Mounting Plate
73 Bolt 84 Wire Rope
74 Bolt 85 Wire Rope
75 Pump Assembly 86 Bolt
76 Pump Guard 87 Lock Washer
77 Hex Head Machine Screw 88 Handle for Ram
78 Washer 89 Screw
79 Handle 90 Grid Guard
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PUMP PARTS LIST

NO DESCRIPTION NO DESCRIPTION
P1 Handle Socket P24 Short Release Valve
P2 Big Pump Core P25 Steel Ball
P3 Small Pump Core P26 Ball Seat
P4 PTFE Washer P27 Spring
P5 O-Ring P28 Screw
P6 Retaining Ring P29 O-Ring
P7 O-Ring P30 Safety Valve Screw
P8 Retaining Ring P31 Safety Valve Plastic Cap
P9 Sealing Ring P32 Nylon Ring
P10 Copper Washer P33 Screwed Plug
P11 Hose Connector P34 Copper Washer
P12 Steel Ball P35 Filler Plug
P13 Steel Ball P36 Spring
P14 Pump Assembly P37 Composite Washer
P15 Nut P38 Cotter Pin
P16 Copper Washer P39 R-Clip
P17 Bolt P40 Connecting Rod
P18 Release Valve Seat P41 O-Ring
P19 Steel Ball P42 PTFE Washer
P20 Long Release Valve P43 Copper Washer
P21 Screw P44 Washer
P22 Lock Washer P45 Screw
P23 U-Limit Ring P46 Steel Ball
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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PUMP PARTS DIAGRAM

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RAM PARTS DIAGRAM

NO DESCRIPTION NO DESCRIPTION
R1 Cylinder R13 O-Ring
R2 Pin R14 Washer
R3 Nut R15 Spring
R4 Nylon Block R16 Piston Rod
R5 Grub Screw R17 Copper Washer
R6 Grub Screw R18 Screw
R7 Steel Ball R19 Oil Plunger
R8 Valve Core R20 O-Ring
R9 Piston Cap R21 Round Nut
R10 O-Ring R22 O-Ring
R11 Washer R23 Washer
R12 Nylon Ring R24 Screw
R25 Spring
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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