20
ASSEMBLY & USER INSTRUCTIONS ORIGINAL INSTRUCTIONS GC0318 ISS3 1-TONNE FOLDING CRANE MODEL NO: CFC1000B PART NO: 7611011
1-TONNE FOLDING CRANEMODEL NO: CFC1000B
PART NO: 7611011
ASSEMBLY & USER INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0318 ISS3
P
INTRODUCTION
Thank you for purchasing this CLARKE Folding Crane.
Before attempting to operate the product, 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 crane giving you long and satisfactory service.
TECHNICAL SPECIFICATIONSMax Capacity (SWL) 1000 kg (1 Tonne)
Net Weight 68.5 kg
Dimensions (Folded Position) L x D x HDimensions (Unfolded Position) L x D x H
415 x 480 x 1500 mm1525 x 1015 x 1400 mm
Number of pump actions from rest to max height 34
Ram Oil Capacity 0.46L
Oil Grade ISO VG15
Jib Positions Position 1
Lift Capacity 250 kg (0.25 Tonne)
Jib Length Horizontal 1105 mm
Max Lifting Height 2050 mm
Position 2
Lift Capacity 500 kg (0.5 Tonne)
Jib Length Horizontal 1015 mm
Max Lifting Height 1990 mm
Position 3
Lift Capacity 750 kg (0.75 Tonne)
Jib Length Horizontal 925 mm
Max Lifting Height 1930 mm
Position 4
Lift Capacity 1000 kg (1 Tonne)
Jib Length Horizontal 835 mm
Max Lifting Height 1870 mm
2arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
SAFETY PRECAUTIONS
Always read instructions before setting up the equipment and before use. Failure to heed these warnings may result in damage to the equipment, or serious personal injury.
WORKPLACE SAFETY1. Always inspect the crane before use to ensure it is correctly assembled and
in good condition and replace any damaged or worn parts.
2. Only use the crane on a flat, solid, level surface that is capable of bearing the weight of the loaded crane, preferably concrete. Never work on soft/unmade ground as the castors may sink in.
3. Ensure the crane operator is trained in both operation and safety aspects.
4. Do not allow personnel to use the crane unless they have read these safety precautions.
5. Use the crane in a suitable, well lit work area.which is clean and tidy and free from unrelated items.
6. Do not use the crane when you are tired or under the influence of alcohol, drugs or intoxicating medication.
7. Ensure all bystanders keep at a safe distance whilst the crane is in use.
8. Do not over-reach. Keep your proper footing and balance at all times.
9. Safety equipment such as gloves and non-skid safety shoes will reduce personal injuries.
INSPECTION BEFORE USE1. Always visually inspect the crane before use, to ensure that all parts are
correctly located and secure. Check for cracks, deformation or other signs of damage or worn parts and check the castors for damage. Do not use the crane unless it is totally sound.
2. Check castors to ensure they move freely without undue wear to their pivots, and that the wheels are not cracked or damaged.
SAFE OPERATING PRACTICE1. 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.
2. Never exceed the safe working load capacities specified on the jib for each position (as marked on the jib).
3arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
3. Always fully lock the jib and legs into position before lifting.
4. Lower the load as much as possible before moving the crane. Do not use the crane to transport loads over long distances.
5. Do not allow the load to swing or drop suddenly whilst moving or lowering.
6. Do not use this crane to lift people.
7. Do not work under any raised load.
8. Never climb on, or attempt to ride on the crane.
9. Take care not to trap your fingers in the adjustable parts of the crane.
10. Due to the weight of the loaded crane, the help of an assistant will be beneficial when moving the crane around.
11. This is a heavy item. Take care when moving or folding away.
12. Never attempt to move a loaded crane across a floor having cracks, pebbles, or other obstacles which might impede its movement.
13. To move a loaded crane, push it from the operators side. DO NOT move the crane from the handle end and never pull the crane towards yourself.
CARE OF THE CRANE1. Ensure that the crane is properly maintained at all times, and that no
corrosion is allowed to weaken any components.
2. When replacing parts, use only those supplied by Clarke International. Refer to Parts Lists on pages 16-19.
3. 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.
4. Never tamper with the crane or modify it in any way, as this could prove to be dangerous and will invalidate the guarantee. Only use the crane for the purpose for which it is intended.
5. The components of this crane are designed to withstand the rated capacity. Do not substitute any other components or exceed the rated capacity of the crane.
6. If the load capacity decal becomes worn or illegible, contact Clarke Parts and service department, on 0208 988 7400 for replacement.
4arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
UNPACKING & ASSEMBLY
Unpack the components on a clean flat area of hard standing and ensure that all parts are present according to the packing list below. Inspect all components to ensure that no damage was suffered in transit. Any deficiencies should be reported to your CLARKE dealer immediately.:
1 1 x Hydraulic Ram Assembly 9 2 x Small Wheels
2 2 x Locking Pins 10 1 x Hook
3 1 x Handle 11 1 x Jib
4 2 x Side Plates 12 2 x Side Braces
5 2 x Large Wheels 13 1 x Control Handle
6 2 x Caster Assemblies 14 1 x Left Arm
7 1 x Base Frame 15 1 x Right Arm
8 1 x Jib Extension 16 1 x Main Support Post
5arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
ASSEMBLY
TOOLS REQUIREDVarious wrenches of 13,14, 22 & 24 mm will be required or alternatively two adjustable wrenches.
1. Bolt the two larger wheels to the front arms.
• Note that bushes are to be fitted inside each wheel.
2. Fit the casters to the frame using 4 bolts, lock washers and nuts. Loosely fasten the rear 2 bolts & nuts through the slots before sliding the caster into position and adding the other two bolts.
• Assemble with the nuts inside the frame for better appearance/caster clearance.
3. Repeat for both casters.
4. Bolt the two small wheels to the base frame.
• Note that bushes are also fitted inside each wheel.
6arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
5. Bolt the side brackets to each side of the base frame with a single small bolt.
• The 90 mm bolts will be added at the next step.
6. Slide the right arm into the base frame as shown. Line up the holes and secure with a 90 mm bolt, washers and nut, securing the side bracket as you do so.
7. Repeat the procedure for the left arm.
8. Insert the locking pins and secure the pins using the R-clips attached to the small chains.
9. Attach the main support post onto the base frame assembly using two 80 mm bolts with washers and nuts. Leave the nuts & bolts loose until step 10.
WARNING: IT IS ESSENTIAL THAT THE LOCKING PINS ARE IN PLACE BEFORE ATTEMPTING ANY LIFTING TASKS. FAILURE TO INSTALL THESE WOULD RESULT IN THE CRANE TIPPING FORWARD WHEN SUBJECTED TO ANY LOAD.
7arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
10. Add the two side braces, bolting them between the base frame and the main support post. Leave the bolts loose until they are aligned with the hole in the main support post. Once aligned, fully tighten the side braces to the base and the support post.
11. Fix the ram to the main support post using 75 mm bolt, washer and nut.
12. Attach the jib to the top of the main support post using the 100 mm bolt, washer and nut.
13. Connect the top of the ram to the jib as shown using 65 mm bolt, washer and nut.
NOTE: The ram may require partially extending to facilitate assembly.
14. Slide the jib extension into the jib, using the locating pin to secure it in the required position.
8arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
15. Bolt the hook assembly through the hole on the jib extension using the 90 mm bolt, washer, lock washer and nut.
16. Connect the handle to the rear of the main support post using the two remaining bolts and lock washers.
17. Ensure that all weight is spread evenly across all sections, making sure that all castors are on level ground and that the assembly is sitting square and true. Tighten all nuts and bolts.
18. Store the operating handle in the holder on the column.
PURGING THE HYDRAULIC SYSTEMDuring transit or storage, it is possible that an air pocket may have developed within the hydraulic ram and the ram action may therefore appear to be ‘spongy’. As the ram is self bleeding, any air will be dispelled and the ram action normalised by fully raising and lowering the jib a few times.
Should the jib not reach its full height, the oil level should be checked, as described in the Maintenance section.
9arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
OPERATION
RAISING THE JIBIMPORTANT: Make sure that the hook is directly above the point of lift, which in turn is directly above the centre of gravity of the load.
1. Close the operating valve by turning it fully clockwise.
2. Pump the handle until the crane reaches the desired height.
LOWERING THE JIB1. Turn the valve anticlockwise VERY
SLOWLY.
• The speed of lowering is controlled by how much you turn the valve.
EXTENDING THE JIB1. Lift the jib to a horizontal position.
2. Remove the locating pin.
3. Reposition the jib extension to the desired length.
• The hole near the end of the jib extension will match the hole in the jib according to the weight being lifted. These are clearly marked.
4. Replace the locating pin.
5. Store the operating handle in the socket provided when not in use.
WARNING: IT IS ESSENTIAL THAT THE ARM LOCKING PINS ARE IN PLACE BEFORE ATTEMPTING ANY LIFTING TASKS. FAILURE TO INSTALL THESE WOULD RESULT IN THE CRANE TIPPING FORWARD WHEN SUBJECTED TO ANY LOAD.
10arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
STORAGE
1. Remove the bolt and slide the jib extension back to its shortest position. Replace the bolt to secure the jib.
2. Release the control valve to lower the jib assembly to its lowest position.
3. Pull out the ‘R’ clip, which secures the each arm locking pin, then pull out the lock pin.
4. Raise the arm up to its storage position.
5. Replace the arm locking pin through the hole in the frame so that the arm is locked in the up position.
6. Replace the retaining clip to secure the arm locking pin.
7. Store the pump handle in its bracket on the side of the main support post.
8. Once the crane is folded use extreme care when moving it to the storage location.
STORAGE WARNING1. The crane MUST be firmly secured
to a wall or fixed location when not in use.
2. Use a strong strap or chain or suitable restraint to prevent any accidental movement.
3. Test that the crane is firmly secured before leaving it in its storage location.
11arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
MAINTENANCE
GENERAL1. Always store the crane with the jib in its lowest position. This prevents any
possibility of corrosion to the ram.
2. Do not leave the crane in the open or exposed to the elements. Keep under cover.
3. Do not attempt to adjust or tamper with the ram assembly, there are no user-serviceable parts. Contact your Clarke service department for any servicing.
4. Always visually inspect the crane before use, to ensure that all parts are correctly located and secure. Check for hydraulic leaks, signs of damage or worn parts and check the wheels and castors for serviceability.
ANNUALLY1. The crane should be fully inspected annually by a competent person.
2. Each load bearing bolt should be removed and inspected for wear, deformation or cracks. If any are apparent, the bolt should be renewed.
3. Check the hydraulic ram operation and inspect for oil leaks. A slight dampness on the ram is normal, but where leakage is apparent, the ram seals must eventually be renewed and the lost oil be replaced. Consult your Clarke service department.
4. Check castors to ensure they move freely without undue wear to their spindles, and that the wheels are not cracked or damaged.
5. Remove any rust and repaint to prevent further corrosion.
6. Ensure that all decals and warning labels are in place and clearly legible.
HYDRAULIC OILIf any leakage is observed, it may be necessary to top up the hydraulic oil level, as follows.
1. Lower the jib to its lowest position, and remove the bolt that joins the ram to the jib. This will allow the ram to fully retract.
12arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
2. Rest the ram against the main support post and raise and prop up the jib. Use a cable or similar, to ensure the ram does not move.
3. Remove the plug from the side of the ram.
4. Top up the oil until it is level with the hole and replace the plug.
NOTE: Top up using Clarke hydraulic oil (part number 3050830).
• Do not mix different types of oil.
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.
13arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
PARTS DIAGRAM - FRAME ASSEMBLY
14arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
PARTS LIST- FRAME ASSEMBLY
PART NO DESCRIPTION PART NO DESCRIPTION
1 Bolt 19 Bolt
2 Bush 20 Flat Washer
3 Large Wheel 21 Bolt
4 Spring Washer 22 Spring Washer
5 Nut 23 Nut
6 Right Arm 24 Ram Assembly
7 Left Arm 25 Side Brace
8 Small Wheel 26 Main Upright
9 Nut 27 Bolt
10 Spring Washer 28 Spring Washer
11 Bolt 29 Handle Grip
12 Locking Pin 30 Handle Bar
13 R-Clip 31 Jib Arm
14 Frame 32 Bolt
15 Bolt 33 Jib Locating Pin
16 Side Plate 34 Jib Extension
17 Bolt 35 Hook/Chain Assembly
18 Swivel Castor
15arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
PARTS DIAGRAM - RAM ASSEMBLY
16arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
PARTS LIST - RAM ASSEMBLY
PART NO DESCRIPTION PART NO DESCRIPTION
1 O-Ring 25 Socket Head Cap Screw
2 Top Nut 26 Copper Washer
3 Sealing Ring 27 Valve Body
4 Outer Sleeve 28 O-ring
5 Oil Plug 29 Large Cylinder
6 Sealing Ring 30 O-ring
7 Piston Rod 31 Retaining Seal
8 Circlip 32 Big Pump Plunger
9 Sealing Ring 33 Handle Socket
10 Wire Ring 34 Handle
11 Cylinder 35 X-head Pan Head Screw
12 Cylinder Washer 36 Spring Washer
13 6 mm Ball 37 Control Knob
14 Valve Rod 38 Pressure Spring Sleeve
15 Copper Washer 39 Pressure Spring
16 Pump Cylinder 40 Return Valve Stem
17 Dust Ring 41 Safety Cap
18 Small Pump Plunger 42 Plug Screw
19 Hinge Pin 43 Spring
20 R-clip 44 Spring Base
21 Hinge Pin 45 3 mm Ball
22 Connecting Rod 46 Base
23 Washer 47 Seal Repair Kit
24 Spring Washer
17arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
DECLARATION OF CONFORMITY
18arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
P
FURTHER CLARKE PRODUCTS
19arts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
