Clarke CHT637 Installation and operation manual

OPERATING & MAINTENANCE

INSTRUCTIONS GC01/12

AIR OPERATED CLUTCH &

BRAKE BLEEDING KIT

MODEL NO: CHT637

Part No: 1801637

Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]

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.

Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]

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

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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.

Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]

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.

Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]

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.

Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]

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EQUIPMENT COMPONENTS

Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]

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).

Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]

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.

Parts & Service: 020 8988 7400/E-mail:Part[email protected] or [email protected]

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).

Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]

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.

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