Clarke CHT637 Operating & Maintenance Instructions

INSTRUCTIONS GC01/12 AIR OPERATED CLUTCH & BRAKE BLEEDING KIT MODEL NO: CHT637 Part No: 1801637

INTRODUCTION Thank you for purchasing this CLARKE Clutch & Brake Bleeding Kit. 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 product giving you long and satisfactory service. 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.

CONTENTS Introduction ............................................................................................ 2 Guarantee .............................................................................................. 2 Parts & Service ....................................................................................... 2 Table of Contents ................................................................................... 3 Technical Specification......................................................................... 3 General Safety Precautions .................................................................. 4 Equipment Components ....................................................................... 6 Principle of Operation ........................................................................... 7 Operation ............................................................................................... 7 Troubleshooting .................................................................................... 11 Maintenance........................................................................................ 11 Parts Lists and Diagrams ..................................................................... 12 TECHNICAL SPECIFICATION Feature pec ifi ca it on S Ex rt actor lF uid Capac ti y es rtiL 2 Typical A ri Consump it on cfm @ 100 p is (w ti h 3/8" hose) 8 Wor ik ng A ri Pre ss ure 0-170 p is 7 zis e A ri Inlet /4" 1 Bo ltt e Capac ti y Re llif e rtiL 1 Dimen is ons (L x W x H) mm 150 x 120 x 275 r( eservo )ri 50 x 250 x 355 (ex rt acto ,)r 2 Weight illif ng un )ti 0.5 kg r( e .6 kg (ex rt acto ,)r 1 Please note that the details and specifications contained herein, are correct at the time of going to print. However, CLARKE International reserve the right to change specifications at any time without prior notice.

GENERAL SAFETY PRECAUTIONS Warning: As with all equipment, there are certain hazards involved with its operation and use. Exercising caution will reduce the risk of personal injury. WORK AREA 1. Keep the work area clean and well lit. Floors should always be kept clear. Cluttered or dark areas invite accidents. 2. Keep children and bystanders away while operating machines and using tools. Distractions can cause loss of control. PERSONAL SAFETY 1. ALWAYS stay alert, watch what you are doing and use common sense when operating this product. Do not use the product while you are tired or under the influence of medication, drugs or alcohol. A moment of inattention can result in personal injury. 2. Do not over-reach. Keep your proper footing and balance at all times when positioning the product. 3. Brake fluid is highly corrosive. It is advisable to always wear gloves and approved safety glasses at all times and always prevent contact with painted surfaces. 4. ALWAYS store this product out of reach of children and do not allow persons unfamiliar with these instructions to operate it. 5. ALWAYS thoroughly familiarise yourself with this product & its operation, and always read and understand the instructions and warnings in this manual before using the equipment. GENERAL EQUIPMENT USE AND CARE 1. ALWAYS maintain the product with care and keep it clean for best / safest performance. 2. NEVER use this product if any part is damaged. Have it inspected and repaired by your local Clarke dealer. 3. NEVER modify or tamper with this product in any way. Use it only for the purpose for which it is designed. 4. NEVER use the unit to extract or store flammable liquids, toxic or corrosive chemicals or hold any fluids at very high temperatures 5. ALWAYS consult and follow the vehicle manufacturers recommended procedures when working on any hydraulic system.

6. ALWAYS drain, wash and clean the unit immediately after each use. 7. ALWAYS ensure the extractor is in a level position. 8. NEVER drop, throw or mishandle this unit. 9. NEVER attempt to pressurise this unit. It is designed for vacuum use only. 10. ALWAYS make sure that the bleeding kit is in perfect condition before use with no cracks which would result in oil leaks. 11. If fluid is spilt, the area must be cleaned completely and sand or sawdust scattered on the area to absorb the fluid and then cleaned up. You should also alert people in the vicinity to the possible danger of slipping. 12. ALWAYS comply with all local authority regulations when disposing of any type of used oil. 13. ALWAYS have the unit repaired by your local CLARKE dealer, using only identical replacement parts. This will ensure the safety of the unit is maintained. The use of non standard parts could be hazardous. Your CLARKE Bleeding Kit has been designed to give long and trouble free service. If, however, having followed the instructions in this booklet carefully, you encounter problems, take the unit to your local CLARKE dealer.

No Desc ir p it on No esc ir p it on D A COVER HOU IS NG I IR INLET VALVE A B PUSH BUTTON J LEED CONNECTOR B C MUFFLER K IL NG BOTTLE UTOMA IT C RE LIF A D TANK L RAIN VALVE D E ADAPTER FOR EXTRACT TUBE M E LIF L VALVE R F BLEED TUBE N ECURING CLAMP S G FLUID INLET PLUG O E LIF L NOZZLE R H LUID EXTRACT TUBE F EQUIPMENT COMPONENTS

PRINCIPAL OF OPERATION The Clarke clutch & brake bleeding kit is designed for one-man operation. It is used to drain brake fluid from a hydraulic system such as the clutch or brake systems on an vehicle. It can also be used to extract a variety of fluids from reservoirs including the master cylinders or those for power steering fluid. It uses a normal workshop compressed air supply between 70 to 170 psi (4.8- 11.6 bar), to create a vacuum in the tank. The vacuum can be connected by attaching the adapter to the fluid inlet plug located on the top of the unit. The automatic refill bottle is designed for use with a standard bottle of brake fluid, to maintain an adequate fluid level in the master cylinder while the hydraulic system is bled. The bleeder air inlet will shut off automatically when the hydraulic fluid reaches the maximum level. OPERATING INSTRUCTIONS IMPORTANT: In addition to this manual, always follow the manufacturers recommended procedures when servicing each vehicle. REMOVING OLD HYDRAULIC FLUID FROM THE MASTER CYLINDER 1. Park the vehicle securely on level ground with the engine off. 2. Clean the outside of the master cylinder and master cylinder cap to prevent dirt entering the master cylinder when the cap is removed. 3. Remove the cap from the master cylinder reservoir. 4. Connect compressed air supply to the Air Inlet Valve (I). I

5. Connect the Extract Tube (H) to the Fluid Inlet Plug (G) using the adaptor (E) . 6. Insert the free end of the Extract Tube (H) into the master cylinder on the vehicle. 7. Turn the air valve (I) on, if no air flows through the unit then press the Push Button (B) to create the vacuum. (Allow a few seconds for vacuum to build in the bleeder tank before suction occurs). 8. While extracting the old fluid, agitate the fluid to dislodge and remove any sludge that has accumulated on the bottom and walls of the master cylinder. 9. When all fluid has been removed, turn off the bleeder and refill the master cylinder with the vehicle manufacturers recommended replacement hydraulic fluid. VACUUM BLEEDING HYDRAULIC LINES AND SLAVE CYLINDERS Prior to bleeding, ensure that the master cylinder is full of the vehicle manufacturers recommended replacement hydraulic fluid. The automatic refill unit should be used to maintain the level of new fluid in the master cylinder during the bleeding process. This will prevent air from being sucked into the master cylinder, hydraulic lines and slave cylinders. 1. Park the vehicle securely on level ground with the engine off, for safe access to the brake bleed screws located on each wheel brake cylinder or to the clutch slave cylinder as required. H B I H G E

2. Make sure all the bleed screws are clean. 3. Connect compressed air supply to the Air Valve (I). 4. Connect the adaptor (E) of the Bleed Tube (F) to the Fluid Inlet Plug (G). Note: Consult the vehicle manufacturers guidelines for the vacuum bleeding procedure and any specific wheel bleeding sequence. 5. Slip the Bleed Connector (J) located on the opposite end of the Bleed Tube (F), over the bleed screw nipple on the vehicle. 6. Fill the refill unit with fresh hydraulic fluid and secure it to the master cylinder with the nozzle (O) immersed below the level of the old fluid. Open the refill valve (M). J F G E I

7. Turn the air valve (I) on, if no air flows through the unit then press the Push Button (B) to create the vacuum. Allow a few seconds for vacuum to build in the bleeder tank before suction occurs. 8. Using a wrench, loosen/open the bleed screw slightly, until you can see fluid draining through the Bleed Tube and into the Tank (D). Note: During the bleeding process, as hydraulic fluid is being drawn through the bleed screw, air may also be sucked into the bleed tube from around the bleed screw threads. This can give the impression that air is bleeding from the lines, however it is normal and does not affect operation. To prevent or reduce this kind of air leak, coat the bleed screw threads with silicon grease before bleeding. 9. Keep the bleed screw open until new fluid is visibly flowing through the Bleed Tube (F) (typically 20 to 30 seconds). 10. Close the bleed screw firmly, without over tightening, prior to removing the Bleed Tube from the vehicle and shutting off the unit. 11.Close the refill valve and remove the refill unit. Note: It is important to ensure that the Bleed Tube connector remains connected to the bleed screw, and the unit is still holding a vacuum while the bleed screw is closed. This prevents air from being sucked back into the brake or clutch slave cylinder from around the bleed screw threads before the bleed screw is tightened and sealed. Note: If the automatic refilling bottle is not used, be sure to periodically check the level and top up the fluid in the master cylinder. F B D I

PROBLEM OLUTION S Ex rt actor un ti w lli not ts a tr when the A ri Va vl e itis on and the si turned to the OPEN po u tt on si pushed down. b Pre ss the blue bu tt on on the cover hou is ng. fI the c il ck sound si heard, si sound but fi not there si a the un ti au .tl f rT y ts anding the un ti body up is de down fi not connected to the lf uid. fI containing lf uid l, ean the body at 45 deg, shake several it me .s Pre ss the bu tt on and fi the "c il ck " sound si eard then everything si norma .l h when to shut o ff automa it ca yll Ex rt actor fa sli level the lf uid in the tank reaches the f" u "ll Close the a ri va vl e to ts op bleeding, hen d si pose of the used lf uid. t si opera it ng but w lli not The ex rt actor un ti emove any more lf uid. r rif m yl Check that the tube si ils pped ou .t ocated and not l Check that the lf uid in is de the ex rt actor has reached the F" u "ll itis on. evel po l Con rif m that a ll the lf uid has been emoved. r TROUBLESHOOTING If you are still having difficulties with this product, contact your CLARKE International Service Department on 020-8988-7400. MAINTENANCE No maintenance is required but always drain, wash and clean the unit after each use. Never clean the unit with aggressive detergents or chemicals. Always store both the main unit and connecting tubes in a dry place which is not exposed to direct sunlight or extremes of temperature. ENVIRONMENTAL PROTECTION One of the most damaging sources of environmental pollution is oil products. Never throw away used hydraulic oil with domestic refuse or flush it down a sink or drain. Collect all the hydraulic oil in a leak proof container and take it to your local waste disposal site. Do not dispose of this product with general household waste. All tools, accessories and packaging should be sorted, taken to a recycling centre and disposed of appropriately.

PARTS LIST - EXTRACTION UNIT No Desc ir p it on Pa tr No No Desc ir p it on a tr No P 1 COVER HOU IS NG HTCHT637001 19 O - RING TCHT63719 H 2 PUSH BUTTON HTCHT63702 20 ARM TCHT63720 H 3 SPRING HTCHT63703 21 SAFETY VALVE HOU IS NG TCHT63721 H 4 VACUUM VALVE HTCHT63704 22 SCREW TCHT63722 H 5 O - RING HTCHT63705 23 FLUID OUTLET VALVE TCHT63723 H 6 O - RING HTCHT63706 24 LEG CAP TCHT63724 H 7 VACUUM BODY HTCHT63707 25 TANK TCHT63725 H 8 MUFFLER INSERT HTCHT63708 26 PACKING TCHT63726 H 9 MUFFLER SHELL HTCHT63709 27 LOCK NUT TCHT63727 H 10 O - RING HTCHT63710 28 O - RING TCHT63728 H 11 O - RING HTCHT63711 29 FLUID INLET HOU IS NG TCHT63729 H 12 SHAFT HTCHT63712 30 O - RING TCHT63730 H 13 O - RING HTCHT63713 31 FLUID INLET COVER TCHT63731 H 14 SPRING HTCHT63714 32 ADAPTOR TCHT63732 H 15 O - RING HTCHT63715 33 AIR VALVE TCHT63733 H 16 PIN HTCHT63716 34 IT NG TIF BRAKE TUBE & TCHT63734 H 17 FLOAT HTCHT63717 35 EXTRACT TUBE TCHT63735 H 18 SAFETY CUP HTCHT63718 36 O - RING TCHT63736 H IMPORTANT: The use of parts other than genuine CLARKE replacement parts may result in safety hazards, decreased performance, and will invalidate your warranty.

PARTS DIAGRAM - EXTRACTION UNIT

PARTS LIST- REFILLING BOTTLE No Desc ir p it on Pa tr No No Desc ir p it on a tr No P 1 BOTTLE HTCHT63737 8 NOZZLE TCHT63744 H 2 IL D HTCHT63738 9 KNOB TCHT63745 H 3 PACKING HTCHT63739 10 WASHER TCHT63746 H 4 VALVE HTCHT63740 11 SCREW TCHT63747 H 5 LOCK NUT HTCHT63741 12 PLATE TCHT63748 H 6 BRACKET HTCHT63742 13 MOUN IT NG BLOCK TCHT63749 H 7 SWIVEL SOCKET HTCHT63743

PARTS DIAGRAM - REFILLING BOTTLE