SPECAC. MANUALLY OPERATED HYDRAULIC PRESSES P/N, 15.O11 and 25.O11. Instructions For Use

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1 SPECAC MANUALLY OPERATED HYDRAULIC PRESSES P/N, 15.O11 and 25.O11 Instructions For Use SPECAC Specac Limited, River House, Lagoon Road, St. Mary Cray, Orpington, Kent, BR5 3QX England. Tel: Fax: Telex: SPECAC A Cambridge Electronic Industries Company (~pl

2 CONTENTS Section Packaging and Installation Operation of Press Maintenance and Fault Finding Dismantling and Assembly Preparing Press for Use Specifications Tools for Maintenance Parts List and Diagrams Test Certificate

3 PACKAGING AND INSTALLATION These presses leave the factory in a specially designed waterproof board case which is sealed with vinyl tape. To unpack, cut the tape, remove the top packings, (note that the top is indicated by arrow on the side of the box), and the right hand side packing which is adjacent to the pump block. The press can now be lifted clear from the case, USE A PIECE OF NYLON ROPE, PASSED THROUGH HOLES FOR THE VACUUM TUBING, AS A SLING - DO NOT LIFT BY HANDLE. The press is supplied filled with hydraulic oil and ready for use. The only preparation required is to remove the nyon vent screw 38 from the pump plate 37 of the pump unit. (Please refer to diagram 3 at back of Manual). In certain circumstances it may be necessary to attach the press permanently to a laboratory bench, to enable this to be achieved two holes 0.4" diameter have been provided in the base casting. It is recommended that 0.375" diameter bolts be used for this purpose and that the bench top should be at least 1" thick. 2. OPERATION OF PRESS See diagrams 2 and Raise safety visor, place the work on the lower bolster 5, ensure that it is positioned in the centre of the bolster, lower safety visor. Screw top bolster 23 onto work by means of handle Rotate Release handle 30 clockwise and tighten firmly. 2.3 Pump by means of handle 32 until required load is indicated on Gauge WARNING ENSURE THAT SAFETY VISOR IS DOWN BEFORE PUMPING. Do NOT pump beyond 15 ton mark on the and 25 ton mark on the When Red Ring around piston shows, STOP PUMPING. FAILURE to observe either of these warnings will result in damage to the press mechanism. 2.5 To release load on work rotate release handle 30 anti-clockwise, about one turn. Lower bolster will then return to its original position. 2.6 PRESSURE RELIEF VALVE, P/N , P/N Operating Instructions The pressure relief valve is situated immediately below the load indicating gauge, see diagram 2. The valve may be set so that any load between 0-15 tons or 0-25 tons is the maximum load that can be obtained with that setting. To increase the force, rotate milled head clockwise until the desired load is obtained. When the required maximum load setting is obtained, the press is used in the normal way as described on the instruction panel fitted to the pump block. When the set load is obtained, the relief valve will blow off so that further pumping will not increase the load applied to the ram. To reduce pressure, rotate the milled head anti-clockwise and then open and close pressure relief handle then pump again until the reduced load is obtained. 1

4 MAINTENANCE AND FAULT FINDING Whenever there is a complete failure of the press operation it is recommended to contact Specac immediately. Nevertheless it is appreciated that this may not always be possible or desirable and in this event the following information is provided to enable a skilled mechanic to carry out the necessary repairs and adjustments. FAULT 3.1 LOSS OF PRESSURE CAUSE 1 Oil seals have failed and this will be evident by the excessive oil leakage around piston, cylinder block or pump block. 2 Non return Valve Leaking REMEDY It may only be necessary to re-tighten cylinder and pump securing screws 3 and 29. If oil leak continues it will be necessary to renew seals 8,9, 11, 28,44 or 45. The ball, 51, is not seating correctly due most likely to foreign matter adhering to the seal or ball. By pumping the press without the pressure release screw tightened, foreign matter may be removed from the seating by oil washing through the system. Pump the press about ten times if this does not work, then gauge connector 40 should be loosened and the gauge carefully removed. The connecting piece, 40 should then be removed from the pump block taking care that the valve spring, 50, is retained. Remove spring, 50, and ball, 51, examine ball and if damaged replace with a new one, clean ball and seating and reassemble valve and gauge. If non return valve is still leaking it will be necessary to reseat the ball, this may be achieved by lightly tapping ball into its seating. 3 Release Valve Leaking As with the non return valve the ball, 59, may need cleaning or reseating, the procedure for non return valve should be repeated. 3.2 FAILURE TO ACHIEVE PRESSURE CAUSE 1 Non return Valve, 53, Leaking REMEDY Adopt a similar procedure as described for Non Return Valve behind gauge.

5 CAUSE 2 Airlock in Pump Assembly REMEDY Pump must be bled of air, first slacken bleed screw, 41, then gently pump handle, 33, expelling air from system. Keep pumping until all air is expelled, that is when a full flow of air free oil issues around screw, 41. With pump handle forward firmly tighten screw, 41. After bleeding pump it may be necessary to bleed also the piston and cylinder assembly. For details of this procedure see Section 5. 3 Filter, 56, Blocked 3.3 PISTON DOES NOT RETURN CAUSE Remove pump block, 26, by first removing screws, 29, and lifting pump clear of base plate 1. Do not damage gasket, 27. Remove circlip, 57, from oil pipe, 55 filter, 56, can then be removed and cleaned by rinsing in an organic solvent such as acetone, petroleum ether or carbontetrachloride and blowing with a compressed air line or bellows to remove stubborn adhered material. Reassemble and test. REMEDY 1 Foreign matter has become lodged To correct both of these it will be necesbetween piston and cylinder sary to remove piston and clean or replace damaged parts. 2 Piston has been pumped beyond the red ring causing damage to return mechanism DISMANTLING AND ASSEMBLY 4.1 PUMP BLOCK Remove pump, 26, from base 1 by first removing screws, 29, taking care not to damage gasket, To remove pump piston, 43, turn crank, 61, so that pin, 64, is horizontal. Gently tap pin through into hole provided in pump block. The shaft, 62, may now be tapped through the pump block bearing, 63, and out of the crank, 61. The crank can then be removed from the piston, 43, and then the piston extracted from its seal. 2 The piston seals, 44 and 45, are retained by seal housing, 46, which is secured to the pump block by 4 screws. Remove these screws and carefully extract the housing from the pump block, taking care not to damage the seals, 44 and 45. After examining and cleaning the seals they may be replaced if not damaged, but if the slightest damage is evident new seals should be used. When replacing the seals take care not to damage them, ensure that the seal cavity and housing are scrupulously clean and that the housing gasket, 47, is in place and the screws, 48, firmly

6 3 To replace pump piston assembly it is first necessary to remove pin, 64, from crank, 61. Clean piston, 43, and insert into seal housing, then locate piston big end over crank pin, 65, so that crank hole is in line with pump shaft bearing, 63. Insert shaft, 62, into pump block and through the crank until hole for pin, 64, is in line with hole in crank. Lightly tap pin, 64, into crank until its end is flush with crank face as shown in diagram 3. Section A.A. 4 To thoroughly overhaul pump all components shown in diagram 3 should be removed from pump block and examined and thoroughly cleaned. To ensure that all cavities and oil ways are clear of foreign matter the block should be soaked in an organic solvent and then the oilways blown clear and dry with a compressed air line or bellows. Reassemble as described in paragraph PISTON AND CYLINDER 1 Remove screws, 14 and 3, taking care not to lose copper sealing washer, 13. The piston, 4, and its assembly can now be pushed out of cylinder block, 2. The top screw, 21, may be used for this purpose. 2 If piston return mechanism is damaged it may be necessary to replace spring, 19, Spring housing, 12, or retaining stud, 16. The whole assembly will now come apart. Examine components and if damaged replace with new components. 3 To reassemble return mechanism first ensure that stud, 16, is firmly secured in piston, 4. Holding piston upside down clamp in a vice with protective jaws, place the spring housing, 12, over the stud, 16. Then replace the spring spacer, 15, followed by the spring, 19, and the spring washer, 18. Replace nut, 17, and tighten down until the washer, 18, is firmly clamping the spring spacer, 15, in this condition the spring has the required tension to return piston. 4 Examine 'O' rings, 9, and replace if damaged or worn. Ensure that groove is clean and free of foreign matter. 5 Piston and Cylinder assembly is now ready to be assembled with cylinder block, 2. Ensure that the piston is clean. 6 Examine 'O' rings, 8 and 11, and replace if damaged. Ensure that grooves and bore are clean. 7 Push piston assembly into bore of cylinder block 2, taking care not to damage 'O' rings in the process, screw, 21, may be used for this purpose. 8 Clean top of base 1 and secure spring housing, 12, to base by means of screws, 14, ensuring that the copper sealing washers, 13, are in good condition, if not replace with new ones, as a faulty washer may cause an oil leak. The screws, 14, must be tightened so as to distort the washer, 13, to form a pressure tight seal. 9 Rotate cylinder block assembly on piston until holes for screws, 3, are in line, replace screws and tighten securely using a socket wrench with a 15" lever. 4.3 ASSEMBLY PUMP BLOCK TO BASE 1 1 Ensure that base of pump block, 26, and the top of the base casting, 1, are thoroughly clean. Pay special attention to the groove for 'O' Ring, 28. Check that 'O' Ring, 28, is in good condition and if damaged replace with a new one, and ensure that the gasket, 27, is in place.

7 2 Secure pump block to base casting, 1, by means of screws, 29, ensuring that the two components are tightly secured so as to effect a pressure tight seal. 4.4 TOP BOLSTER ASSEMBLY 1 If the top bolster, 23, or the screw, 21, become damaged they may need to be replaced. This is unlikely as these components are extremely robust. 2 The top bolster, 23, is held in the screw by an 'O' Ring, 22, which allows it to be replaced easily, such as when a heated top platen is used. The bolster just simply pulls free of the screw and the new one is pushed into its place. 3 The screw, 21, may become stiff to turn, this will either be due to the thread becoming damaged or clogged with dirt. Remove the screw, clean and examine. If the thread is damaged it may be possible to remove the burrs by means of a small file. If damage is extensive it will be best to replace with a new screw. 4 When reassembling screw, 21, into top support ensure that threads are clean and smeared with a light oil. 5. PREPARING PRESS FOR USE 5.1 Remove pump plate, 37, and gasket, Remove lower bolster, 5, and slacken bleed screws, 6 and The oil capacity of the press is about 1 pint (0.6 litre). Pour oil into 0.5 inch diameter hole in top of pump block until oil level can be seen about 2" below the top of pump block. 5.4 Prime pump as described in Section 3: Firmly tighten pressure release screw, 30, and continue pumping until oil begins to issue from bleed hole in top of piston. At first the oil will contain air bubbles but continue gently pumping until oil is free of air. 5.6 Top up oil reservoir until oil level is again about 2" below top surface of pump block. 5.7 Pump until piston rises to one inch above the cylinder block, at this height a red ring will appear around piston. DO NOT PUMP BEYOND THIS RED RING. 5.8 Release valve, 30, and piston will slowly return to its lowest position. After new 'O' Rings have been fitted the piston may be a little sticky so it may be necessary to start the piston return by means of the upper screw. Repeat this procedure a few times and it will be found that the piston will then return without assistance. 5.9 Re-bleed the whole system of air by repeating 5.4 and 5.5. Ensure that bleed screws, 6 and 41, are tight and secure Replace pump plate, 37, and its gasket, 39, if press is to be transported replace vent screw, 38.

8 6. SPECIFICATIONS Maximum Load Stroke Screw Travel Max. Daylight Min. Daylight Lower Work-Face Dia. Upper Work-Face Dia. P/N tons 1 inch 3.5 inches 6 inches 1.5 inches inches 1.25 inches Kg 2.54 cm 89 mm 152 mm 38 mm 86 mm 32 mm P/N tons 1 inch 3.5 inches 6 inches 1.5 inches inches 1.25 inches Kg 2.54 cm 89 mm 152 mm 38 mm 86 mm 32 mm Distance between Plates Side to Side Front to Rear inches inches mm mm Oil Capacity 1 pint 6 litre Shell Type Tellus TOOLS FOR MAINTENANCE 2 Required Socket Wrench Socket Wrench Socket Wrench Socket Wrench Open End Spanner Box Spanner Screw Driver Pin Punch Hammer A/F A/F A/F A/F A/F A/F dia. 9.5 mm 7.9 mm 4.8 mm 3.2 mm 18 mm 15 mm 5.5 mm Specac supply a Press Tool Kit which contains all of the tools listed above except a hammer, the kit also contains 1 litre of Shell Type Tellus 37 hydraulic oil. The hydraulic oil can also be supplied as individual item from Specac. NOTE: REF. ITEM 7 TOOLS FOR MAINTENANCE THIS IS SUPPLIED AS PART OF OR IF REQUIRED PLEASE ORDER AS TOOL KIT FOR OR IF OIL IS REQUIRED PLEASE ORDER AS P/N (1 LITRE)

9 PARTS LIST P/N Item Base Casting Cylinder Block Cylinder Block Screw Piston Lower Bolster Bleed Screw Bleed Ball Wiper Ring Piston 'O' Ring Piston Upright Bolt 'O' Ring Cylinder Block Spring Housing Copper Sealing Washer Spring Housing Screw Spring Spacer Spring Stud Spring Nut Spring Washer Spring Screw Handle Screw Top Bolster 'O' Ring Top Bolster Top Bolster Oilway Plug Seal Oilway Plug Pump Block Pump Block Gasket Pump Block 'O' Ring Pump Block Screw Pressure Release Handle Pressure Gauge Pump Handle Pump Handle Grip Upright Bolt Upright Bolt Washer Upright Dowel Pump Plate Pump Vent Screw Pump Gasket Upper Gauge Connector Bleed Screw (15.006) Bleed Ball (15.007)

10 P/N Item Pump Piston Pump Piston Seal Pump Piston 'O' Ring Pump Piston Sealing Housing Pump Piston Gasket Pump Piston Screws Gauge Seal Non Return Spring Non Return Valve Ball As 50 As 51 Intake Seal Intake Pipe Intake Filter Intake Circlip Release Screw 'O' Ring Release Ball Crank Pin Circlip Crank Crank Shaft Crank Shaft Bush Crank Fixing Pin Crank Pin Safety Visor Relief Valve Body Relief Valve Seal Relief Valve Poppet Relief Valve Set Knob Relief Valve Ball Relief Valve Spring Relief Valve Poppet 'O' Ring Relief Valve Seating For those not wishing to strip down the Piston and Pump Block Assembly, Specac can supply these two units, built and tested. "DO NOT DISASSEMBLE RELIEF VALVE. IF THIS UNIT MALFUNCTIONS, RETURN COMPLETE VALVE UNIT TO SPECAC FOR REPLACEMENT." SEAL KIT 1 LITRE OF OIL SEAL KIT For For

11 3) 19 18( DIAGRAM 1

12 PuraURFRFI IFF VALVE AS FinEDTO 15011/25011 DIAGRAM 2

13 DIAGRAM 3

14 DETAILS OF PRESSURE RELIEF VALVE ASSY DIAGRAM 4

15 Specac Limited, River House, Lagoon Road, St. Mary Cray, Orpington, Kent, England. BR5 3QX Tel: Fax: Telex: SPECAC SPECAC TEST CERTIFICATE Hydraulic Press (Manual) Product No.: pt Serial No.: /.&.~>/..Q.. Order No.:. Item Check/Test Checked 1. Visual inspection of guard 2. Visual inspection of gauge nuts 3. Visual inspection of HEX bolts 4. Condition of paint 5. Correct function of gauge 6. Check for oil leaks 7. Check piston release 8. Press able to reach 15 tons/2ftfflw tons/sirtsns = Less than 1 ton in 15 minutes 10. Pressure Relief Valve - set to 10 tons J4UIIJ " 2J.011 Tested by: Final Approval By:..C^//.f*(^i^&Z?Z. Date Original to File Completed TAG Label on Press DRG. Nos. Issue 1 3MZ MZ13067

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