Operating Instructions Manual
Hydraulic Clutch Jack
Model: 40500
Capacity: 500 lb.
SFA Companies
Read this manual and follow all the Safety Rules and Operating Instructions before using this product.
Printed in China
40500-M0 05/07
OPERATION
BEFORE USE
Removing a Clutch
1. Verify that the product and the application are
compatible, if in doubt call Omega Technical Service
(888) 332-6419.
1. Select the correct size spline sleeve. Place the spline
on the adapter shaft, then attach to the head plate
with the 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.
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.
4. Remove the clutch mounting bolts and back the jack
and clutch away from the flywheel.
! WARNING
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.
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.
6. Replace worn or damaged parts and assemblies
with Factory Authorized Replacement Parts only.
Lubricate as instructed in Maintenance Section.
! WARNING
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.
• Study, understand, and follow all printed materials
provided with/on this device before use.
•
•
•
Do not exceed rated capacity.
2. Add or remove one piece of the clutch at a time.
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.
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.
•
•
•
•
Failure to heed these markings may result in
personal injury and/or property damage.
Adapter Shaft
Clutch
Figure 2 - Illustration of Lowest Position with Clutch
3
OPERATING with Optional Flywheel Adapter
Note. Flywheel Adapter Assembly is not included with
the unit. To order, refer to replacement parts section.
Adapter Shaft
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.
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.
C-clip
Figure 3 - Flywheel adapter assembly components
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.
Three attaching bolts retained
on flywheel before securing
the adapter to flywheel.
Flywheel
Flywheel Adapter
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.
Flywheel
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.
Flywheel Adapter
C-clip
Adapter Shaft
Installing a Flywheel
Quick Release Pin
Head Plate
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.
Tilt Adjustment Bolt
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.
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.
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.
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.
Note: Never use sandpaper or abrasive material on
these surfaces!
Storage
Changing oil
When not in use, store the jack with lifting arm fully
lowered.
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.
TROUBLESHOOTING
Corrective Action
Possible Causes
Symptom
Jack will not lift load
• Ensure release valve tightly closed
• Remedy overload condition
• Release valve not tightly closed
• Overload condition
Jack will lift, but not maintain
pressure
• Ensure release valve tightly closed
• Remedy overload condition
• Release valve not tightly closed
• Overload condition
• Contact Omega Tech. Service
• Hydraulic unit malfunction
Jack will not lower after
unloading
• Ensure load is removed, then drain
fluid to proper level
• Clean and lubricate moving parts
• Reservoir overfilled
• Linkage binding
Poor lift performance
• Ensure proper fluid level
• Fluid level low
• With ram fully retracted, remove
oil filler plug to let pressurized air
escape, then reinstall oil filler plug
• Air trapped in system
Jack will not lift to full
extension
• Ensure proper fluid level
• Fluid level low
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, please give the Model number and parts description. Call
or write for current pricing: SFA Companies 10939 N. Pomona Ave. Kansas City, MO 64153, U.S.A.
(Optional )
Figure 5 - Replacement Parts Illustration for Model 40500
6
Replacement Parts List for Model 40500
Item Part No.
Description
Top nut
Qty.
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
4
5
4
2
1
Item Part No.
N/A
Description
Qty.
1
1
N/A
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
Lift Arm Axle
2
5905-00100-100 Filler Plug
5701-00006-000 Grease Fitting
1
3
N/A
N/A
N/A
N/A
N/A
N/A
Reservoir
Piston Rod
Ram Bearing
Cylinder
Screw
N/A
N/A
N/A
N/A
N/A
N/A
Lift Arm
1
4
Snap Ring
4
5
Lift Arm Axle
Bolt
1
6
1
7
Spline Adapter Seat
Parallel Link Axle
1
8
Base
1
9
4200-01006-000 Handle Sleeve Seat
4200-01002-000 Pump Cylinder
4200-01401-000 Pump Piston
5405-07027-000 Pin
G410-00001-000 Adapter Shaft
G410-10000-000 Spline Sleeve, 2”
G410-80000-000 Spline Sleeve, 1-3/4
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
”
1
N/A
Bolt
2
4200-01300-000 Handle Sleeve
G410-20000-000 Spline Adapter
G410-90009-K04 Release Pin
1
N/A
Retaining Pin
1
40501
Flywheel Adapter
Assembly
-
4500-02000-000 Handle Assembly
BL80-20002-000 Handle Grip
*
42000S-102
Seal Kit (Hyd Unit)
-
N/A
N/A
N/A
N/A
N/A
N/A
Screw
Spring
(*) Seal Kit Contents:
Item Description
Screw
Qty.
1
Safety Valve Screw
Safety Spring
Needle
2
Filler Plug
Seal
A
B
C
D
E
F
1
U-cup
1
O-ring
1
G410-90009-K02 Release Valve Assy.
N/A Filter
G410-70000-000 Hydraulic unit
N/A Lock Washer
Back-up Ring
Seal
1
1
Back-up Ring
U-cup
1
G
H
J
1
Copper Gasket
O-ring
1
5102-12035-000 Bolt
2
G410-90009-K01 Caster Assembly
K
L
Seal
1
O-ring
1
N/A
N/A
Snap Ring
Chassis
M
N
O
P
Q
Steel Ball
Steel Ball
O-ring
1
1
1
O-ring
1
Oil Seal
1
7
ONE YEAR LIMITED WARRANTY
For a period of one (1) year from date of purchase, SFA Companies 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 SFA Companies Warranty Service Department, 10939 N. Pomona Ave., Kansas City, MO 64153.
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) SFA Companies 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.
SFA Companies
10939 N. Pomona Ave. Kansas City, MO 64153
888-332-6419
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