OPERATION &MAINTENANCE INSTRUCTIONS ½ TONNE & 1 TONNE FOLDING CRANE

MODELS CHC500DF & CHC1000DF

PART No. 7610500 AND 7611002

OPERATION &MAINTENANCE

INSTRUCTIONS

0502

Please read these instructions carefully before operating the truck

Thank you for purchasing this CLARKE Strong-Arm Hydraulic Crane.

Before using the device, please read this manual thoroughly and carefully follow all instructions given. This is for your own safety and that of others around you, and is also to help you achieve a long and trouble free service from your new truck.

CLARKE 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 affect your statutory rights.

PARTS & SERVICE TEL: 020 8988 7400 or e-mail as follows:

PARTS: [email protected]

SERVICE: [email protected]

Safety Precautions

WARNING

Failure to comply with these rules and precautions, may result in loss of load, damage to, or failure of the equipment, or even personal injury.

1.

DO NOT exceed the load capacity for each jib position (as marked on the jib). The capacities for each model are shown in tables on the inside front cover.

1

CHC500DF 500

CHC1000DF 1000

2

400

800

3

350

650

4

250

450

Max Lift Ht

2000mm

2450mm

IMPORTANT:

If the load capacity decal becomes worn or illegible, contact Clarke

International Spares Division, on 020 8558 6696 for replacement.

2.

Ensure that the equipment is correctly assembled, and that all the bolts and pins are in place and secure.

3.

Only use chains, slings, hooks etc. with a rated capacity equal to, or greater than that of the load. Check that they are secure and will not slip under load.

4.

Only use the crane on a solid, flat, level surface which is capable of taking the load. Avoid moving the crane over rough surfaces.

5.

Lower the load as much as possible before moving the crane. Do not use the crane to transport loads.

6.

Do not stand under the load, or above the jib. Be aware that if the load slips or falls, the jib may rise suddenly.

7.

Use appropriate safety equipment, such as protective footwear, when using this crane.

8.

Ensure the crane operator is skilled and trained in both operation and safety aspects.

9.

Always inspect the crane before use to ensure it is in good condition, and replace any damaged or worn parts.

10. When replacing parts, use only those supplied by Clarke International. Refer to Parts List.

11. Ensure that the crane is properly maintained, and lubricated at all times, and that no rust or other forms of corrosion is allowed to weaken any part of the crane.

12. If the crane has been subjected to an abnormal load or shock, it should be removed from service immediately and fully inspected by qualified personnel.

Preparation For Use.

Figures in brackets refer to parts list on page 7.

The crane is packed, fully assembled, in the fully folded position. On unpacking check to ensure that no damage occurred during transit, and that all parts are present according to the packing list.

1.

Withdraw the locking pins (Item 21), lower the legs, and lock in position with the same pin, securing with the ‘R’ clip (Item 20).

2.

Release the stabilising foot (Item A), by removing the ‘R’ clip (Item 19), and rotating the foot so that it faces upwards. Secure in position with ‘R’ clip.

3.

Before operating the crane, remove the transit plug from the back of the hydraulic ram unit , and replace with the vent plug supplied. retain the transit plug which should be re-fitted if the crane is stored or transported horizontally.

3.

Test the operation of the crane without a load (refer to ‘Operation’ for raising and lowering the jib). If the ram operation appears ‘spongy’, it is possible that air may have entered the system. Raising the lowering the jib a few times will dispel any air and normalise the ram operation.

If the jib does not reach its full height, the rams hydraulic oil may need topping up, (ref ‘Maintenance’).

Operation

IMPORTANT: Before attempting to lift, ensure the hook is directly above the point of lift, and the point of lift is directly above the centre of gravity on the load.

Select the required jib arm length according to the load to be lifted and access available. Always use the shortest jib length possible to give the greatest safety margin and stability. Lock the jib extension into position with the link pin ( Item 13), and ‘R’ clip (Item 20).

To raise the jib arm, screw the large valve knob (Item B), on the hydraulic ram, fully clockwise to close the control valve. Pump the hydraulic handle slowly to take the weight, check the stability of the load before pumping the jib up to the desired height.

To lower the jib, slowly unscrew the valve knob (item B), the more the valve is released, the faster the load will lower.

Take care when lowering heavy loads

Maintenance

1.

Always inspect the crane before use for visible signs of damage, leaking hydraulic fluid, loose, worn or missing parts.

2. Periodically check the crane for any damage, such as bent, loose or missing bolts and pins. Do not use a damaged crane. The bolts and pins used in the crane are specially designed for use, at the cranes’ rated capacity. If replacements arerequired, contact CLARKE International Spares Department.

Do not use substitute components.

3. Lubricate all the moving parts monthly with a general purpose oil or grease as appropriate. Keep a light film of oil on the ram to prevent rust.

4. If the jib does not reach its full height, check the ram hydraulic oil level as follows: a. Raise the jib to the horizontal position and support the end.

b. Remove the ram to jib link pin (item 11).

c. Lower the ram fully by unscrewing the large valve knob (Item B). With the ram in the fully retracted position, the oil should reach the level of the vent plug.

Top up if necessary with Clarke hydraulic oil (part number 3050830).

NOTE: We recommend that the hydraulic oil is changed after every 100 hours of operation.

5. Replace the vent plug and re-attach the ram to the jib.

NOTE: When not in use, the crane should be stored with the jib in its lowest position so there is no load on the ram, and the ram is not xposed to the elements.

If the crane is to be stored, or transported horizontally, the transit plug must be fitted to avoid leakage.

Parts List

Item Description

23

24

25

26

27

28

29

30

17

18

19

20

21

22

10

11

12

13

14

15

16

7

8

9

5

6

3

4

1

2

Mast with Base

Main Jib

Jib Extension

Ram Assembly

Right Leg

Left Leg

Pivoting Wheel Kit

Fixed Roller Kit

Pump Lever

Jib/Mast Link Pin

Ram/Jib Link Pin

Retaining Ring

Extension Jib Link Pin

Hook Assembly

Retaining Ring

Hook Link Pin

Ram/Mast Link Pin

Retaining Ring

‘R’ Clip 4x80mm

‘R’ Clip 3x60mm

Locking Pin

Bolt 18X90mm

Nut 18mm

Con Rod/Ram Link Pin

Retaining Ring

Connecting Rod

Handle/Con Rod Link Pin

Handle/Mast Link Pin

Handle Grip

Vent Plug

CHC 500 DF CHC 1000 DF

Part No.

Part No.

CHC10001

CHC10004

CHC10005

CHC10007

CHC10003

CHC10002

CHC10010

CHC10011

CHC10008

CHC10025

CHC10027

CHC10031

CHC10029

CHC10006

CHC10032

CHC10028

CHC10026

CHC10030

CHC10018

CHC10035

CHC10019

CHC10012

CHC10014

CHC10023

CHC10024

CHC10020

CHC10021

CHC10022

CHC10009

CHR10030

CHC5001

CHC5004

CHC5005

CHC5007

CHC5003

CHC5002

CHC5010

CHC5011

CHC5008

CHC5025

CHC5027

CHC5031

CHC5029

CHC5006

CHC5032

CHC5028

CHC5026

CHC5030

CHC5018

CHC5035

CHC5019

CHC5012

CHC5014

CHC5023

CHC5024

CHC5020

CHC5021

CHC5022

CHC5009

CHR5030

1/2 Tonne & 1 Tonne Folding Crane

Parts List Cont

Item Description

44

45

46

47

38

39

40

41

42

43

48

49

50

31

32

33

34

35

36

37

55

56

57

58

59

51

52

53

54

Ram

Gasket Kit

Ram Guide Bush

Compression Cylinder

Oil Reservoir

Cylinder Head

Locking Ring Nut

Ball ¼”

Handwheel Pivot

Handwheel Return Spring

Spring Cover Bush

Handwheel

Dowel

Transit Plug

Aluminium Washer

Oil Filtering Spring

Delivery Valve Dowel

Compression Valve Spring

Ball 3/8"

Inlet Valve Spring

Relief Valve Plug

Copper Washer

Relief Valve Screw Plug

Relief Valve Spring

Blind Plug

Pump Body

Compression Cyl for Pump

SE Pumping Element

Pawl for Relief Valve Spring

CHC 500 DF CHC 1000 DF

Part No.

Part No.

CHR5031

CHR5032

CHR5033

CHR5034

CHR5035

CHR5036

CHR5037

CHR5038

CHR5039

CHR5040

CHR5041

CHR5042

CHR5043

CHR5044

CHR5045

CHR5046

CHR5047

CHR5048

CHR5049

CHR5050

CHR5051

CHR5032

CHR5053

CHR5054

CHR5055

CHR5056

CHR5057

CHR5058

CHR5059

CHR10031

CHR10032

CHR10033

CHR10034

CHR10035

CHR10036

CHR10037

CHR10038

CHR10039

CHR10040

CHR10041

CHR10042

CHR10043

CHR10044

CHR10045

CHR10046

CHR10047

CHR10048

CHR10049

CHR10050

CHR10051

CHR10052

CHR10053

CHR10054

CHR10055

CHR10056

CHR10067

CHR10058

CHR10059

Hydraulic Ram