Hydraulic
Clutch Jack
Operating Instructions & Parts Manual
Model Number
Atd-7404
Capacity
500 Lb.
160 Enterprise Drive, Wentzville MO 63385
Atd Tools Inc.
Printed in China
ATD7404-M0 05/07
Save these instructions. For your safety, read, understand, and follow the information provided with and on
this jack. The owner and operator of this equipment shall have an understanding of this jack and safe operating
procedures before attempting to use. The owner and operator shall be aware that use and repair of this product
may require special skills and knowledge. Instructions and safety information shall be conveyed in the operator's
native language before use of this jack is authorized. If any doubt exists as to the safe and proper use of this jack,
remove from service immediately. Inspect before each use. Do not use if broken, bent, cracked, or damaged parts
(including labels) are noted. Any jack that appears damaged in any way, operates abnormally or is missing parts,
shall be removed from service immediately. If the jack has been or suspected to have been subjected to a shock
load (a load dropped suddenly, unexpectedly upon it), immediately discontinue use until jack has been checked by
an Atd Tools authorized service center. It is recommended that an annual inspection be done by qualified personnel.
Labels and Operator's Manuals are available from manufacturer.
PRODUCT DESCRIPTION
Atd Tools Hydraulic Clutch Jack is designed for clutch/ flywheel removal and installation. Intended use: to remove,
install and transport (in lowest position) both 14" and 15-1/2" clutches and flywheels. The two most common spline
sizes, 1-3/4" and 2" diameter, are included with this product. The head plate enables clutch to be positioned in either
horizontal position for clearing underneath vehicle or vertical position for installation and removal. The spline sleeve
rotates 360 degrees, turns side to side and vertically tilts for precise clutch alignment.
DO NOT USE FOR ANY PURPOSE OTHER THAN THOSE USES OUTLINED ABOVE !
SPECIFICATIONS
Model Capacity Jack Size (L x W x H)
Atd-7404 500 lb. 44 1/2" x 22 1/2" x 16" 16 1/2" 42" 1-3/4" & 2" 1"
Pump Handle
Release Pin
Lifting Arm
Min.
Height
Adapter Shaft
Spline Sleeve
Head Plate
Max.
Height
Spline
Dia.
Shaft
Dia.
Volume of
Hyd. Oil
6.6 OZ/ 195 mL
Horizonta
l Position
Tilt Adjustment Bolt
Net
Weight
145 lb.
Release Valve Knob
Rear Caster
Front Caster
Figure 1 - Model Atd7404 Components
2
BEFORE USE
1. Verify that the product and the application are
compatible, if in doubt call Atd Tools Technical
Service (636)327-9050.
2. Before using this product, read the operator's manual
completely and familiarize yourself thoroughly with
the product, its components and recognize the
potential hazards associated with its use.
3. Open the release valve by turning the release valve
knob counter-clockwise (no more than 1/2 full turn).
4. With lifting arm fully lowered, locate and remove the
oil filler plug. Pump handle 6 to 8 full strokes. Ensure
the oil level is within ~3/16" from the inner cylinder
as viewed from the oil filler hole. Reinstall the oil filler
plug. Close release valve by turning it clockwise until
firm resistance is felt.
5. Check to ensure that jack rolls freely, that the pump
and release valve operate smoothly. Raise and lower
the unloaded jack throughout the advertised lift range
before putting into service.
6. Replace worn or damaged parts and assemblies
with Factory Authorized Replacement Parts only.
Lubricate as instructed in Maintenance Section.
! WARNING
• Study, understand, and follow all printed materials
provided with/on this device before use.
•
Do not exceed rated capacity.
•
Use only on hard, level, seamless surface.
•
Do not allow any part of your body under the lift
arm or load while the jack is supporting a load.
•
Use only the factory supplied adapters as a
means of contacting the load. Never use any
other part of the jack as a lifting surface.
•
Use of this jack is limited to the removal,
installation and transportation of clutch/flywheel.
•
Adequately support the vehicle before starting
repairs.
•
Failure to heed these markings may result in
personal injury and/or property damage.
OPERATION
Removing a Clutch
1. Select the correct size spline sleeve. Place the
spline on the adapter shaft, then attach the assembly
to the head plate with release pin & retaining pin
provided.
2. Close the release valve by tightening the release
valve knob. Pump the handle to raise the lifting arm
and align the spline sleeve with the clutch.
3. Tilt the head plate with the tilt adjustment bolt to align
it with the clutch bore. Slide the spline sleeve into
the clutch.
4. Remove the clutch mounting bolts and back the jack
and clutch away from the flywheel.
! WARNING
Be sure all tools and personnel are clear before
lowering load.
Transporting the Clutch while on Jack
Be sure the adapter shaft is in the vertical position and
the jack is fully lowered before transporting, as shown
in Figure 2.
Loading and Unloading a Clutch from the Jack
1. To load or unload a clutch from the jack, be sure the
adapter shaft is in the vertical position, as shown in
Figure 2.
2. Add or remove one piece of the clutch at a time.
Installing a Clutch
1. Raise the clutch into the horizontal position for
installation and tilt the clutch using the tilt adjustment
bolt to align with the flywheel.
2. Put the jack and clutch into position so that the spline
shaft engages the pilot bearing in the flywheel. Install
and tighten the clutch mounting bolts.
Figure 2 - Illustration of Lowest Position with Clutch
Adapter Shaft
Clutch
3
OPERATING with Optional Flywheel Adapter
Note. Flywheel Adapter Assembly is not included with
the unit. To order, refer to replacement parts section.
Install the flywheel adapter
1. Keep jack in lowest position. Remove the release pin,
then remove the spline sleeve and adapter shaft.
2. Install the flywheel adapter assembly, then secure
with the quick release pin.
Adapter Shaft
Flywheel Adapter
Note: Flywheel adapter assembly includes flywheel
adapter, a shorter adapter shaft, and a C-clip (Fig. 3).
Use the shorter adapter shaft on flywheel adapter only.
Removing a Flywheel
1. Remove all the flywheel attaching bolts (flywheel to
crankshaft bolts) except for the three bolts pointed
in Figure 4.
2. Close the release valve knob fully. Pump the handle
to raise the lifting arm and align the flywheel adapter
to the flywheel using the tilt adjustment bolt.
3. Center the flywheel adapter to the flywheel and bolt
the adapter to the flywheel. Leave room to access
the remaining three flywheel attaching bolts retained
on the flywheel.
4. Ensure the releave valve knob of the jack is closed
tightly before removing the last three flywheel
attaching bolts.
5. Remove the jack and flywheel away from the engine
and slowly lower the flywheel by opening the releave
valve knob gradually.
6. Ensure jack is fully lowered before transporting.
Loading and Unloading a Flywheel from the Jack
1. To load or unload a flywheel from the jack, be sure
thejack is in lowest position.
2. While supporting the flywheel, remove the flywheel
from the adapter.
C-clip
Figure 3 - Flywheel adapter assembly components
Three attaching bolts retained
on flywheel before securing
the adapter to flywheel.
Flywheel
Flywheel Adapter
Flywheel
Flywheel Adapter
C-clip
Adapter Shaft
Installing a Flywheel
1. Close release valve knob, pump the handle and
raise the flywheel into position shown in Figure 4 for
installation. Adjust the flywheel using tilt adjustment
bolt to align the flywheel with the crankshaft.
2. Install and tighten the attaching bolts.
Note: Tighten the flywheel attaching bolts gradually.
Each bolt should be tightened to the specified torque
in a crisscross method. Refer to vehicle service manual
for the tightening torque.
Quick Release Pin
Head Plate
Tilt Adjustment Bolt
Figure 4 - Flywheel Adapter Operational Illustration
4
MAINTENANCE
Important: Use only good grade hydraulic jack oil. Avoid
mixing different types of fluid and NEVER use brake
fluid, turbine oil, transmission fluid, motor oil or glycerin.
Improper fluid can cause premature failure of the jack
and the potential for sudden and immediate loss of load.
Mobil DTE 13M or equivalent recommended.
Adding oil
1. With lifting arm fully lowered set jack in its upright,
level position. Locate and remove oil filler plug.
2. Fill with oil until ~3/16" above the inner cylinder as
seen from the oil filler hole. Reinstall oil filler plug.
Changing oil
For best performance and longest life, replace the
complete fluid supply at least once per year.
1. With lifting arm fully lowered, remove oil filler plug.
2. Lay the jack on its side and drain the fluid into a
suitable container.
Note. Dispose of hydraulic fluid in accordance with
local regulations.
3. Fill with oil until ~3/16" above the inner cylinder as
seen from the oil filler hole. Reinstall oil filler plug.
Lubrication
A periodic coating of light lubricating oil to pivot points,
axles and hinges will help to prevent rust and assure
that wheels, casters and pump assemblies move
freely.
Cleaning
Periodically check the pump piston and ram for signs
of rust or corrosion. Clean as needed and wipe with
an oily cloth.
Note: Never use sandpaper or abrasive material on
these surfaces!
Storage
When not in use, store the jack with lifting arm fully
lowered.
TROUBLESHOOTING
Symptom
Jack will not lift load
Jack will lift, but not maintain
pressure
Jack will not lower after
unloading
Poor lift performance
Jack will not lift to full
extension
Possible Causes
• Release valve not tightly closed
• Overload condition
• Release valve not tightly closed
• Overload condition
• Hydraulic unit malfunction
• Reservoir overfilled
• Linkage binding
• Fluid level low
• Air trapped in system
• Fluid level low
Corrective Action
• Ensure release valve tightly closed
• Remedy overload condition
• Ensure release valve tightly closed
• Remedy overload condition
• Contact Atd Tools Tech. Service
• Ensure load is removed, then drain
fluid to proper level
• Clean and lubricate moving parts
• Ensure proper fluid level
• With ram fully retracted, remove
oil filler plug to let pressurized air
escape, then reinstall oil filler plug
• Ensure proper fluid level
5
REPLACEMENT PARTS
Not all components of the jack are replacement items, but are illustrated as a convenient reference of location and
position in the assembly sequence. When ordering parts, give Model number, part number and description below.
Call or write for current pricing: Atd Tools Inc. 160 Enterprise Drive, Wentzville, MO 63385. Tel:(636)327-9050
Fax:(636)327-9044
(Optional )
Figure 3 - Replacement Parts Illustration for Model Atd7404
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Replacement Parts List for Model Atd7404
Item Part No. Description Qty.
1 N/A Top nut 1
2 5905-00100-100 Filler Plug 1
3 N/A Reservoir 1
4 N/A Piston Rod 1
5 N/A Ram Bearing 1
6 N/A Cylinder 1
7 N/A Screw 1
8 N/A Base 1
9 4200-01006-000 Handle Sleeve Seat 1
10 4200-01002-000 Pump Cylinder 1
11 4200-01401-000 Pump Piston 1
12 5405-07027-000 Pin 2
13 4200-01300-000 Handle Sleeve 1
14 N/A Retaining Pin 2
15 4500-02000-000 Handle Assembly 1
16 BL80-20002-000 Handle Grip 1
17 N/A Screw 1
Item Part No. Description Qty.
31 N/A Lift Arm Axle 1
32 5701-00006-000 Grease Fitting 1
33 N/A Lift Arm 1
34 N/A Snap Ring 4
35 N/A Lift Arm Axle 1
36 N/A Bolt 1
37 N/A Spline Adapter Seat 1
38 N/A Parallel Link Axle 1
39 G410-00001-000 Adapter Shaft 1
40 G410-10000-000 Spline Sleeve, 2” 1
41 G410-80000-000 Spline Sleeve, 1
-3/4
” 1
42 N/A Bolt 2
43 G410-20000-000 Spline Adapter 1
44 G410-90009-K04 Release Pin 1
45 ATD7405 Flywheel Adapter
-
Assembly
* 42000S-102 Seal Kit -
18 N/A Spring 1
19 N/A Screw 1
20 N/A Safety Valve Screw 1
21 N/A Safety Spring 1
22 N/A Needle 1
23 G410-90009-K02 Release Valve Assy. 1
24 N/A Filter 1
25 G410-70000-000 Hydraulic unit 1
26 N/A Lock Washer 4
27 5102-12035-000 Bolt 5
28 G410-90009-K01 Caster Assembly 4
29 N/A Snap Ring 2
30 N/A Chassis 1
(*) Seal Kit Contents:
Item Description Qty.
2 Filler Plug 1
A Seal 1
B U-cup 1
C O-ring 1
D Back-up Ring 1
E Seal 1
F Back-up Ring 1
G U-cup 1
H Copper Gasket 1
J O-ring 2
K Seal 1
L O-ring 1
M Steel Ball 1
N Steel Ball 1
O O-ring 1
P O-ring 1
Q Oil Seal 1
7
ONE YEAR LIMITED WARRANTY
For a period of one (1) year from date of purchase, ATD Tools Inc. will repair or replace, at its option, without
charge, any of its products which fails due to a defect in material or workmanship under normal usage. This limited
warranty is a consumer's exclusive remedy.
Performance of any obligation under this warranty may be obtained by returning the warranted product,
freight prepaid, to ATD Tools Inc. Warranty Service Department, 160 Enterprise Drive, Wentzville, MO 63385.
Except where such limitations and exclusions are specifically prohibited by applicable law, (1) THE
CONSUMER'S SOLE AND EXCLUSIVE REMEDY SHALL BE THE REPAIR OR REPLACEMENT OF DEFECTIVE
PRODUCTS AS DESCRIBED ABOVE. (2) ATD Tools Inc. SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL
OR INCIDENTAL DAMAGE OR LOSS WHATSOEVER. (3) ANY IMPLIED WARRANTIES, INCLUDING WITHOUT
LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, SHALL BE LIMITED TO ONE YEAR, OTHERWISE THE REPAIR, REPLACEMENT OR REFUND AS
PROVIDED UNDER THIS EXPRESS LIMITED WARRANTY IS THE EXCLUSIVE REMEDY OF THE CONSUMER,
AND IS PROVIDED IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED. (4) ANY MODIFICATION,
ALTERATION, ABUSE, UNAUTHORIZED SERVICE OR ORNAMENTAL DESIGN VOIDS THIS WARRANTY AND
IS NOT COVERED BY THIS WARRANTY.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not
apply to you. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Atd Tools Inc.
160 Enterprise Drive,
Wentzville MO 63385
636-327-9050
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