Omega Lift 40500 Users Manual M0

2015-02-05

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Operating Instructions Manual

Hydraulic Clutch Jack
Model: 40500

Capacity: 500 lb.

SFA Companies

http://www.omegalift.com
Read this manual and follow all the Safety Rules and Operating Instructions before using this product.
Printed in China
40500-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 Omega 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

The Omega 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 )

Min.
Height

Max.
Height

Spline
Dia.

Shaft
Dia.

Volume of
Hyd. Oil

Net
Weight

40500

500 lb.

44 1/2" x 22 1/2"

16 1/2"

42"

1-3/4" & 2"

6.6 OZ/ 195 mL

145 lb.

Adapter Shaft

Horizontal Position
Spline Sleeve

Tilt Adjustment Bolt
Pump Handle

Head Plate
Release Pin
Lifting Arm

Front Caster

Release Valve Knob
Rear Caster
Figure 1 - Model 40500 Components
2

OPERATION

BEFORE USE

Removing a Clutch
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.
4. Remove the clutch mounting bolts and back the jack
and clutch away from the ﬂywheel.

1. Verify that the product and the application are
compatible, if in doubt call Omega Technical Service
(888) 332-6419.
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
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.

! 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.
2. Add or remove one piece of the clutch at a time.

• 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.

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.

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.
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.

Three attaching bolts retained
on ﬂywheel before securing
the adapter to ﬂywheel.
Flywheel
Flywheel Adapter

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

Flywheel

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.

Quick Release Pin
Head Plate
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
When not in use, store the jack with lifting arm fully
lowered.

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.

TROUBLESHOOTING
Symptom

Possible Causes

Corrective Action

Jack will not lift load

• Release valve not tightly closed
• Overload condition

• Ensure release valve tightly closed
• Remedy overload condition

Jack will lift, but not maintain
pressure

• Release valve not tightly closed
• Overload condition
• Hydraulic unit malfunction

• Ensure release valve tightly closed
• Remedy overload condition
• Contact Omega Tech. Service

Jack will not lower after
unloading

• Reservoir overﬁlled

• Ensure load is removed, then drain
ﬂuid to proper level
• Clean and lubricate moving parts

Poor lift performance

• Fluid level low
• Air trapped in system

• Ensure proper ﬂuid level
• With ram fully retracted, remove
oil ﬁller plug to let pressurized air
escape, then reinstall oil ﬁller plug

Jack will not lift to full
extension

• Fluid level low

• Ensure proper ﬂuid level

• Linkage binding

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.
E-Mail: sales@omegalift.com Tel: (888) 332-6419 Fax: (816) 891-6599 Website: http://www.omegalift.com

(Optional )

Figure 5 - Replacement Parts Illustration for Model 40500
6

Replacement Parts List for Model 40500

Item Part No.

Description

N/A

Top nut

5905-00100-100

Qty.

Item Part No.

Description

Qty.

N/A

Lift Arm Axle

Filler Plug

5701-00006-000

Grease Fitting

N/A

Reservoir

N/A

Lift Arm

N/A

Piston Rod

N/A

Snap Ring

N/A

Ram Bearing

N/A

Lift Arm Axle

N/A

Cylinder

N/A

Bolt

N/A

Screw

N/A

Spline Adapter Seat

N/A

Base

N/A

Parallel Link Axle

4200-01006-000

Handle Sleeve Seat

G410-00001-000 Adapter Shaft

4200-01002-000

Pump Cylinder

G410-10000-000 Spline Sleeve, 2”

4200-01401-000

Pump Piston

G410-80000-000 Spline Sleeve, 1-3/4”

5405-07027-000

N/A

4200-01300-000

Handle Sleeve

G410-20000-000 Spline Adapter

N/A

Retaining Pin

G410-90009-K04 Release Pin

4500-02000-000

Handle Assembly

40501

BL80-20002-000

Handle Grip

Flywheel Adapter
Assembly

N/A

Screw

42000S-102

Seal Kit (Hyd Unit)

N/A

Spring

N/A

Screw

N/A

Safety Valve Screw

Filler Plug

Seal

U-cup

O-ring

Back-up Ring

Bolt

(*) Seal Kit Contents:
Item Description

Qty.

N/A

Safety Spring

N/A

Needle

G410-90009-K02 Release Valve Assy.

N/A

Seal

Back-up Ring

U-cup

Copper Gasket

O-ring

Seal

O-ring

Steel Ball

O-ring

Oil Seal

Filter

G410-70000-000 Hydraulic unit

N/A

Lock Washer

5102-12035-000

Bolt

G410-90009-K01 Caster Assembly

N/A

Snap Ring

N/A

Chassis

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
sales@omegalift.com

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