Clarke HD 50, HD 100, HD 150, HD 200, 7612260 User guide

HEAVY DUTY CRANE

HEAVY DUTY CRANE

HDC RANGE

HDC RANGE

OPERATING & MAINTENANCE

G & MAINTENANCE

INSTRUCTIONS

0599

SPECIFICATIONS

cont...

No. Description Part No.No. Description Part No.

MAXIMUM SAFE WORKING LOADS (kg)

HDC50 HDC100 HDC150 HDC200

1 500 1000 1500 2000
2 400 800 1200 1500
3 250 500 800 1000
4 150 300 500 600

SPARE PARTS & SERVICE

For Spare Parts and Servicing, please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS - 020 8558 6696 : SERVICE - 020 8556 4443

PARTS & SERVICE FAX - 020 8558 3622

79 Extension jib/jib link pin R2108
81 Connecting rod R2110
82 Connecting rod R2111
83 Connecting rod R2112
84 Connecting rod R2113
87 Compression cylinder R2125
88 Rod guide bush R2126
89 Oil reservoir R2127
90 Cylinder head R2128
91 Rod R2129
93 DE 500 pump-cylinder R2131
94 Pump body R2132
95 Pumping element R2133
96 Plug R2134
97 Rear plug R2135
98 Compression valve spring R2136

99 Seal kit R2137
100 Pump body R2138
101 Seal Kit R2139
102 Pump-cylinder R2140
103 Pump body R2141
104 Compression cylinder R2142
105 Rod guide bush R2143
106 Oil reservoir R2144
107 Cylinder head R2145
108 Rod R2146
109 Oil filtering spring R2147
110 De pumping element R2148
111 Front plug R2149
112 Rear plug R2150
113 Cylinder R2151
114 Seal kit R2152
115 Pump-cylinder R2153
116 Rod guide bush R2154
117 Rod R2155

118 Seal kit R2156
119 Mast R2157XX
120 Right strut R2158XX
121 Left strut R2159XX
122 Base R2160XX
123 Pivoting wheel kit R2161
124 Mast R2163XX
125 Right strut R2164XX
126 Left strut R2165XX
127 Base R2166XX
128 Main jib R2167XX
129 Telescopic extension jib R2168
130 Hook 1500 kg. Capacity R2169
131 Fixed wheel kit R2171
133 Pivoting wheel - 25166 R2174
134 Mast R2175XX
135 Right strut R2176XX
136 Left strut R2177XX
137 Base R2178XX
138 Main jib R2179XX
139 Hook with 2000 kg. Cap. R2180
140 Fixed wheel kit R2181
141 Pivoting wheel - 25175 R2184
142 Locking ring nut R2204
143 Copper washer R2205
144 Screw M12 R2206
145 Screw M12 R2207
146 Locking ring nut R2208
147 Screw M16 x 90 R2210
148 Screw M18 x 90 R2212
149 Nut M18 R2213
150 Screw M16 x 45 R2214
151 Screw M18 x 110 R2215
152 Screw M18 x 45 R2216

PARTS E-MAIL - [e-mail]

SERVICE E-MAIL - [e-mail]

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PARTS LIST

No. Description Part No.

No. Description Part No.

Thank you for purchasing this CLARKE Strong Arm Hydraulic Crane.
Before attempting to use the crane please read this leaflet thoroughly and follow

the instructions carefully, in doing so you will ensure the safety of yourself and that
of others around you, and you can look forward to the crane giving you long and
satisfactory service.

1 Retaining ring A0185
2 Plain washer A0346
3 Retaining ring A0444
4 Retaining ring B4045
5 Retaining ring C0159
6 Aluminium washer 14 x 18 C0625
7 Copper washer 14 x 20 C0630
8 Nut M12 R0046

9 Retaining ring R0049
10 Retaining ring R0068
11 Retaining ring R0103
12 Sphere 1/4" R0128
13 Mast R2000XX
14 Right strut R2001XX
15 Left strut R2002XX
16 Base R2003XX
17 Main Jib R2004XX
18 Telescopic extension jib R2005
19 Hook with 500 kg. Cap. R2006
21 Pump lever R2008
23 Lever/mast link pin R2010
24 Lever/conn. rod link pin R2011
25 Conn. rod/pump link pin R2012
26 Hook/extension jib link pin R2013
27 Link pin R2014
28 Cylinder rod link pin R2015
29 Pump/mast link pin R2016
30 Extension jib/jib link pin R2017
31 Short handle R2019
32 Hook with 1000 kg. Cap. R2020
33 Hook extension jib link pin R2021
34 Hand grip R2024
35 1000 pump-cylinder R2025
36 Long handle R2028
37 Retaining pin - split type R2029
38 Screw R2030

39 Nut M16 R2031
40 Screw M12 R2032
41 Extension Jib R2033
42 Main jib R2034XX
43 Extension jib/jib link pin R2035
44 Screw M10 R2038
45 Fixed wheel kit R2040
46 Pivoting wheel kit R2041
48 Compression cylinder R2051
49 Rod guide bush R2052
50 Oil reservoir R2053
51 Cylinder head R2054
52 Rod R2055
53 Release handwheel R2056
54 Release handwheel pivot R2057
55 Handwheel return spring R2058
56 Spring cover bush R2059
57 SE pumping element R2060
59 Pawl for relief valve spring R2062
60 Relief valve spring R2063
61 Relief valve screw plug R2064
62 Relief valve plug R2065
63 Inlet valve spring R2066
64 Compression valve spring R2067
66 Oil filtering spring R2069
67 Head locking ring nut R2070
68 Blind plug M14 x 1.5 R2071
69 Vent plug M14 x 1.5 R2072
70 Sphere 3/8" R2073
71 Dowel M6 R2074
73 Fixed wheel kit R2088
74 Jib/mast link pin R2100
75 Pump/mast link pin R2103
76 Cylinder rod/jib link pin R2104
77 Jib/mast link pin R2105
78 Hook/extension jib link pin R2107

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be required
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.

CONTENTS Page

Specifications - Safe Working Loads............................................. 2

Spare Parts & Servicing .................................................................. 2

Safety Precautions ......................................................................... 4

Unpacking & Pre-Assembly ........................................................... 5

Assembly ......................................................................................... 6

Operation ........................................................................................ 7

Maintenance .................................................................................. 7

Specfications - Dimensions ............................................................ 9

Parts Diagrams ...................HDC50....................................... 10 - 11

HDC100..................................... 12 - 13

HDC150..................................... 14 - 15

HDC200..................................... 16 - 17

Parts List .................................................................................. 18 - 19

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SAFETY PRECAUTIONS

HDC200

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.

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

HYDRAULIC RAM

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17

HDC200

PRE-ASSEMBLY

Unpack the components on a clean flat area of hard standing, and ensure that
all parts are present according to the packing list, as follows:

• Base Assembly complete with nuts and bolts for securing the mast, and two
mast support struts, (inserted in the open end of the Base).

NOTE: Castors and fixed wheels are pre-assembled.

• Mast Assembly complete with Hydraulic Ram and pumping handle,

• Jib Assembly with Extension Arm and Hook.

Additionally, a wallet containing:

• This instruction manual • One handle (Tube) • Two handle grips

• Bolt/s with nut/s (for securing mast support struts to the mast - see parts
diagram).

• One plastic Vent Plug for the hydraulic ram.

Visually inspect all components to ensure that no damage was suffered in transit.
Any damage should be reported to your CLARKE dealer immediately.

Fig.1

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5

ASSEMBLY (Numbers Refer to Fig.1)

NOTE:
All pivot pins should be greased during assembly

1. With the Base assembly (22) resting on its wheels, remove the bolts (used for
securing the mast), from the base, and withdraw the two mast support struts
(20 & 21) from the open end of the Base, which, for transit purposes, are wired
in place.

2. Lift the mast, with assistance, and taking all necessary precautions considering
its weight, place it in position on the base. Insert the securing bolts and screw
on the nuts, leaving them loose.

3. Locate each Mast Support Strut in its square housing (23), on the Base assembly,
so that the flat end of the strut lies alongside the mast. Insert the bolt/s (16)
through the holes in the strut, mast and opposite strut, then screw on the nut/
s, (18), leaving it/them finger tight. (Models 1500 & 2000 have two securing
bolts).

NOTE:

Do not be concerned if the holes do not line up initially. It may be necessary to
slacken off the nuts securing the mast to the base slightly, in order for the holes in
the mast to line up, and the bolt to be inserted. This is normal because when all

bolts are fully tightened, the struts are designed to be under stress.

Fully tighten the mast support bolts at the base, and the strut bolt at the mast.

4. Remove a circlip (9) from the Jib to Mast locating pin (10), and withdraw the
pin from the jib. With assistance, raise the jib to its position on top of the mast,
and insert the pin (10) thereby locating the jib to the mast. Replace the circlip
ensuring it is correctly located

5. Remove the Ram to Jib locating pin (8) from the jib, as above, then lower the
jib so as to line up the hole in the ram with the holes in the jib bracket. Insert
the pin (8), and replace the circlip ensuring it is correctly located.

HDC150

HYDRAULIC RAM

NOTE:

Ensure the ram is central within its housing in the jib when inserting the pin (8). Tap
the jib to one side with a piece of wood if necessary to align.

6. Slide the handle (14) through its holder on the mast, and attach the grips (15).

7. Remove the transit plug (17) from the ram, and replace it with the vent plug
provided. Retain the transit plug.

8. Finally, carry out a check to ensure that all parts are correctly located and
secure, then raise and lower the jib a few times, as described below, WITHOUT
a load being applied.

WARNING

On no account must the crane be used with the Mast Support Struts

removed. They must be correctly in place at all times.

6

15

HDC150

OPERATION (Numbers Refer to Fig.1)

A. Raising the jib

1. IMPORTANT: Ensure the hook is directly above the point of lift, and the point of

lift is directly above the centre of gravity of the load.

2. Close the valve (24) by turning it fully clockwise, and pump the handle (13) to
reach the desired height.

B. Lowering the jib

Turn the valve (24) VERY SLOWLY anticlockwise, and the jib will lower.

NOTE:
The more the valve knob is turned, the faster the rate of descent. Be extremely
careful when lowering heavy loads.

C. Jib Extension

The jib is extended by first raising it to a horizontal position, then removing the ‘R’
clip (6), securing the locating pin (5), and withdrawing the pin.

Reposition the arm extension to the desired length, and replace the pin ensuring
the ‘R’ clip is firmly in place.

NOTES:

a. During 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.

b. Should the jib not reach its full height, the oil level should be checked, as

described in the Maintenance section.

MAINTENANCE

1. 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.

Do not use the crane unless it is perfectly serviceable.

2. A slight dampness on the ram is normal, but where leakage is apparent, the
ram seals must be renewed.

3. Pivot pins should be removed and inspected for wear, deformation, cracks
etc., every 3 months. If serviceable they should be greased and replaced.

If any deformation or cracks are apparent, the pin should be renewed.

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7

4. The crane should be fully inspected annually by a competant person.
a. All pivot pins should be removed, inspected and greased before reinsertion

or replacement.
b. Check for cracks and deformation of components.
c. Check wheels and castors to ensure they move freely without undue wear

to their bores, and that the wheels are not cracked or damaged in any

way.
d. Check the hydraulic ram operation and check oil level. (see below).
e. Remove completely, any rust or corrosion and repaint to prevent further

corrosion.
f. Ensure that all decals and warning notices are in place and perfectly

legible.

5. It may be necessary from time to time to top up the Hydraulic oil level. Proceed
as follows.

a. Lower the jib to its lowest position, and remove the Ram to Jib locating

pin (item 8, Fig1).
b. Rest the ram against the Mast whilst raising and propping the jib.
c. Remove the vent plug (Parts list item 69) from the ram, and using an oil

can, filled with hydraulic oil (see below), slowly top up the oil until it begins

to overflow. When the excess oil has completely drained off, replace the

vent plug.

We recommend that the hydraulic oil is changed after every 100 hours of

operation.

HDC100

HYDRAULIC RAM

NOTE: Top up using Clarke hydraulic oil (part number 3050830).

6. After use, wherever possible, store the crane with the jib in its lowest position.
This not only relieves the hydraulic ram, but also prevents any possibility of
corrosion to the ram.

7. Do not leave the crane in the open, exposed to the elements. Keep under
cover.

8. DO NOT remove the pump Pressure Relief Valve, or attempt to adjust the pump
settings.

HYDRAULIC RAM OIL CAPACITIES

HDC50 - 0.6 litres

HDC100 - 1.0 litres
HDC150 - 2.3 litres

HDC200 - 2.3 litres

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HDC100

DIMENSIONS (mm)

HDC50 HDC100 HDC150 HDC200

A 1610 1740 1850 1995
B 1230 1515 1690 1930
C 1340 1550 1850 1950
D 1040 1250 1400 1500

E 155 160 200 225

F 520 615 420 530
G 725 795 705 815
H 2245 2490 2870 2950

I 2475 2720 3095 3295

L 800 945 860 970

M 880 1065 1000 1000

N 645 740 1000 1100

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HDC50

HDC50

HYDRAULIC RAM

10

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