Clarke CFC100 Installation and operation manual

OPERATING & MAINTENANCE
INSTRUCTIONS 1202
1 TONNE FOLDING CRANE
1 TONNE FOLDING CRANE
MODEL No CFC100
PART No 7611005

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Thank you for purchasing this Clarke Hydraulic Crane.
Before attempting to assemble or operate the unit, please read this instruction
manual thoroughly, and follow all directions carefully, by paying particular
attention to the safety precautions. By doing so, You will ensure safe operation
of the unit, and enjoy trouble free service from your Clarke hydraulic crane.
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 effect your statutory rights.
SPECIFICATIONS
Stage 1 Stage 2 Stage 3 Stage4
Lifting Capacity (kg) 1000 750 500 250
Max. Lift Height (mm) 1870 1930 1995 2060
Max.Jib Length (mm) 900 990 1080 1170
Overall Width (mm) 1030
Width Between Legs (mm) 890
Height of Legs (mm) 150
Weight (kg) 79
Part No. 7611005
SPARE PARTS
No Description Qty Part No No Description Qty Part No
1 Main Support post 1 SN10001 37 Ram 1 SN10037
2 Base 1 SN10002 38 Tank Nut 1 SN10038
3 Left Leg 1 SN10003 39 ‘O’Ring 1 SN10039
4 Right Leg 1 SN10004 40 Sealing Gasket 1 SN10040
5 Jib 1 SN10005 41 Reservoir 1 SN10041
6 Jib Extension 1 SN10006 42 Trapezoid Seal Ring1 SN10042
7 Ram Unit 3 Tonne 1 SN10007 43 Vent Plug 1 SN10043
10 Bolt M6 x 30 1 SN10010 44 Screw 1 SN10044
11 Nut M6 1 SN10011 45 Spring Washer 1 SN10045
12 Lock Pin 1 SN10012 46 Stand 1 SN10046
13 ‘R’ Clip 1 SN10013 47 Handle Socket 1 SN10047
14 Handle 1 SN10014 48 Shaft 1 SN10048
15 Bolt M16 x 110 1 SN10015 49 Handle Socket 3 SN10049
16 Washer Ø 16 3 SN10016 51 Plunger Pin 2 SN10051
17 Bolt M16 x 90 1 SN10017 52 Plunger 2 SN10052
19 Washer Ø 8 12SN10019 53 Back Up Ring 2 SN10053
20 Bolt M8 x 20 12 12SN10020 54 ‘O’ Ring 2 SN10054
21 Bolt M16 x 80 1 SN10021 55 Pump Panel 2 SN10055
22 Castor & Fixing 2 SN10022 56 Copper Washer 2 SN10056
23 Bolt M12 x 80 1 SN10023 57 Ball 2 SN10057
24 Hook Assembly 1 SN10024 58 Hyd Press Rel Nut 1 SN10058
25 Nut M16 1 SN10025 59 seal Ring 1 SN10059
26 Pump Handle 1 SN10026 60 Ball 1 SN10060
27 Chain 2 SN10027 61 Supporter 1 SN10061
28 Nut M16 3 SN10028 62 Bush 1 SN10062
29 Valve block 1 SN10029 63 Spring Washer 1 SN10063
30 Copper Washer 1 SN10030 64 Screw 1 SN10064
31 Cylinder 1 SN10031 65 Plunger Link 2 SN10065
32 Retaining Ring 1 SN10032 67 Lock Washer Ø 16 3 SN10067
33 Washer 1 SN10033 68 Lock Washer Ø 12 1 SN10068
34 ‘O’Ring 1 SN10034 69 Flat Washer Ø 12 1 SN10069
35 ‘O’Ring retainer 1 SN10035 70 Nut M8 8 SN10070
36 Ram Seal Washer 1 SN10036 71 Lock & Clip Assy 1 SN10071
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SAFETY PRECAUTIONS
IMPORTANT
Before using your crane, it is in your own interest to read and comply with the
following safety rules.
•NEVER exceed the safe working load capacities as specified on the jib
for each jib extension position.
Stage 1 Stage 2 Stage 3 Stage 4
Lifting capacity (kg) 1000 750 500 250
•Only use the crane on a flat solid level surface, which is capable of
sustaining the weight of the load.
•NEVER stand or work beneath a suspended load.
•Position the load as close to the ground as possible before moving it.
•Do not allow the load to swing or drop suddenly whilst moving or
lowering.
•Use only slings or chains with a capacity equal to , or greater than that of
the crane.
•Do not stand in the path of the jib as loss of load may cause the jib to rise
suddenly.
•If the load capacity decal on the jib becomes worn or illegible, contact
Clarke International Spares Division for a replacement.
•Ensure the crane operator is skilled, and trained in both operation and
safety aspects.
•Inspect the crane before use to ensure it is in good condition. Replace
any damaged or worn parts and ensure all nuts and bolts are tight.
•When replacing parts, use only parts supplied by Clarke International as
per the parts list on page 10. High tensile bolts are used in the
construction of this crane. NEVER replace them with standard bolts.
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.
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.
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ASSEMBLY
NOTE:
a. During assembly, unless otherwise stated, nuts and bolts should be finger
tight only. They should be fully tightened, once assembly is completed, in
the manner described below.
b. All figures in brackets, refer to the parts list item numbers.
1. Attach the two castors to the Base using the bolts supplied, tighten the
bolts securely.
2. Insert the Left Hand Leg (3) into its housing in the base, line up the holes
and insert the pin (12), securing in place with the ‘R’ clip (13). Repeat the
procedure for the Right Hand Leg (4).
NOTE:
The leg ends should be parallel when legs are correctly assembled.
3. Attach the Main Column (1) to the base using the five nuts, bolts and
washers provided.
4. With assistance, lift the Ram assembly and enter the lower mounting into
its housing on the main support. Locate it using the Bolt (17), and secure
the bolt with washer (16) and nut (28). Rest the ram against the main
column.
5. With assistance, raise the jib (5) and slide it into position on top of the
main column, locate it using the bolt (15), and secure the bolt with washer
(16) and nut (28).
6. Lower the jib and position the ram so that its upper end slides into the housing
on the jib. Line up the holes and locate it using the bolt (21), secure the bolt
with washer (16) and nut (28).
NOTE:
It may be necessary to extend the ram slightly in order for the holes to line up. See
‘Operation’ for details of how to achieve this.
7. Insert the jib extension (6) into the end of the jib and secure in one of the
four positions using the Lock Pin and ‘R’ Clip (71).
8. Attach the hook and chain assembly (24) to the end of the jib extension
using bolt (23) secure with washer (68) and nut (25). Tighten securely.
9. Bolt the Handle (14) onto the main column using the four bolts (20) with
washers (19) and tighten securely.
10. Rock the assembly to ensure that no part is under stress, then tighten all
nuts and bolts, ensuring they are completely secure.
11. To fold the legs, for storage purposes, first manoeuvre the crane to its storage
location, then lower the stabilising foot and secure with bolt (10) and nut
(11).
12. Remove the ‘R’ clips from the leg locking pins then remove the locking
pins. Lift each leg to the vertical position, securing in place, again using the
locking pins. Replace the ‘R’ clips.
PARTS DIAGRAM
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Warning
It is not intended for the crane to be manoeuvred around the workshop
in the storage position. However, if the crane MUST be moved this way,
exercise extreme caution with regard to its stability
PREPARING FOR USE
1. Unfold the legs if necessary by reversing the procedure in paras, 11 and 12
on page 5.
2. With legs unfolded, release the base stabilising foot by unscrewing and re
moving its retaining bolt and rotating it upwards until the bolt can be
relocated, locking it in that position.
3. Select the required Jib Arm Length according to the load to be lifted.
Note: Use the shortest jib length possible to give the greatest safety margin
and extra stability.
OPERATION
1. When removing an engine ensure the vehicle is well supported and se
cure. All ancillary parts must be disconnected, i.e. exhaust system, speedo
cable, electrics etc., and only lifting points recommended by the vehicle
manufacturer should be used.
2. To raise the jib, first locate the slotted end of the pump handle on to the
Hydraulic Pressure Release Nut at the base of the Ram assembly.
Turn the nut clockwise until tight (DO NOT OVERTIGHTEN a firm pressure
only is required), remove the handle and locate it in the pump collar. Pump
the ram to raise the jib to the required height.
3. To lower the jib arm, locate the slotted end of the pump handle on to the
pressure release nut and VERY SLOWLY turn in an anticlockwise direction.
The jib will lower under its own weight. The more the handle is turned...the
faster the rate of descent.
EXERCISE GREAT CARE WHEN LOWERING HEAVY LOADS.
MAINTENANCE
Before Use
Always inspect the crane for visible signs of damage, leaking hydraulic fluid, loose,
worn, missing or broken parts etc.
Note:
If the crane is subjected to any abnormal load or shock, it should be removed
from service immediately and inspected by a local agent or Clarke International
Service Division.
Daily
a) check for tightness of all bolts, and pivoting joints for wear.
b) lubricate wheels and bearings and inspect for cracks or other possible
damage.
c) inspect the hydraulic ram assembly for leaks and wipe with oily rag to
prevent corrosion.
Storage
When not in use, store the crane with the jib in its lowest position so there is no load
on the ram and to prevent corrosion of the ram.
To fill The Hydraulic Pump
With the ram fully retracted (in lowered position), remove vent plug (43), on side
of cylinder (it may be necessary to disconnect ram from jib to access plug.
Top up to level of hole with Clarke hydraulic oil (pt. no. 3050830). Replace the
plug and refit jib as described in the assembly instructions.
SPARE PARTS AND SERVICING
Please contact your nearest dealer, or
CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX [phone]
or e-mail as follows:
PARTS: [email protected]
SERVICE: [email protected]
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