Clarke CFTJ500 Troubleshooting guide

OPERATION AND MAINTENANCE

ORIGINAL INSTRUCTIONS GC12/16

INSTRUCTIONS

TRANSMISSION JACK

MODEL NO: CFTJ500

PART NO: 7612635

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

INTRODUCTION

Thank you for purchasing this CLARKE Transmission Jack, designed for use in

the removal and installation of transmissions and differentials.

Before attempting to use this product, please read this manual 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 your purchase

giving you long and satisfactory service.

GUARANTEE

This 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.

SPECIFICATION

Rated Load 500 kg

Min height of saddle 265 mm

Max height of saddle 645 mm

No of strokes from rest to max height 28

Distance per pump action 14 mm

Dimensions (L x W x H) 761 x 408 x 265 mm

Weight 36.1 kg

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

SAFETY PRECAUTIONS

1. Do not exceed the rated load of the jack.

2. Do not allow personnel to operate the jack unless they have read these

safety precautions.

3. Ensure that the jack is in good working order. Have any damaged parts

repaired or replaced immediately. Use genuine Clarke parts only. The use

of unauthorised parts may be dangerous and will invalidate the

guarantee.

4. Do not operate the jack if damaged.

5. Use the jack in a suitable, well lit work area.

6. Keep the work area clean and tidy and free from unrelated items.

7. Use the jack on level and solid ground, preferably concrete. Avoid soft/

unmade ground as the jack may sink in.

8. Ensure the vehicle is securely and rigidly supported.

9. Check the transmission is centred on the jack saddle.

10. Ensure all non-essential persons keep a safe distance whilst the jack is in

use.

11. Ensure there are no personnel or obstructions under the vehicle

transmission before lowering.

12. Do not stand or work under the load until it secured by suitable means.

13. Ensure when lifting, that the jack and all parts of the load can be clearly

seen.

14. Never climb on, or attempt to ride on the jack.

15. Use the jack for lifting transmissions only, NOT for supporting the weight of

the vehicle.

16. Take care not to trap fingers in the moving parts of the jack.

17. Lower the load as much as possible before moving the jack. Do not

transport loads in an elevated position.

18. Ensure that you can see the saddle and jacking point throughout the

jacking operation in case there is any relative movement.

19. Never tamper with the product or modify it in any way, as this could prove

to be dangerous and will invalidate the guarantee. Only use the product

for the purpose for which it is intended.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

20. Use appropriate safety equipment, such as protective footwear, when

using this jack.

21. When replacing parts, use only those supplied by Clarke International.

Refer to the parts list on page10.

22. Ensure that the jack is properly maintained, and lubricated at all times, and

that no rust or other forms of corrosion is allowed to weaken any part of it.

23. If the jack has been subjected to an abnormal load or shock, it should be

removed from service immediately and fully inspected by qualified

personnel, and passed as serviceable, before being used again.

24. When not in use, store the jack, fully lowered, in a safe, dry, childproof area.

IMPORTANT: ALWAYS ensure that the centre of gravity of the load, is centred

about the head section, before taking the full weight.

SAFETY SYMBOLS

The following safety symbols may be found on the product.

Wear foot protection

LIFTING OPERATIONS AND LIFTING EQUIPMENT REGULATIONS 1998

This jack, depending on use, may fall within the scope of LOLER. It is the

owner’s responsibility to determine whether or not it does and, if so, to comply

with any applicable requirements in LOLER, for having the jack thoroughly

examined.

ENVIRONMENTAL PROTECTION

1. Take care to ensure that if hydraulic oil is spilt that it is cleaned away using

sand or treated with absorbent granules designed for the purpose.

2. Always make every effort to contain any spillage and prevent ingress into

the local water course.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

UNPACKING & ASSEMBLY

Unpack the components on a clean flat area of hard standing and ensure

that all parts are present as listed:

Visually inspect all components to ensure that no damage was suffered in

transit. Any damage should be reported to your CLARKE dealer immediately.

1. Mount the four saddle brackets to

the saddle using the eight bolts

supplied.

2. Insert the operating handle into

the socket.

3. Test the operation of the jack by

tightening the knob clockwise to

close the release valve. Pump the

handle up and down to raise the

saddle. Unscrew the knob to open

the valve and lower the jack.

PURGING AIR BUBBLES

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 via the vent and

the ram action normalised, by raising and lowering the jack a few times while

not under load. If the jack does not reach its full height, the oil level may

require topping up, as described in the Maintenance section.

•1xJack

• 1 x Handle

• 4 x Saddle Brackets

• 1 x Fixings Kit including chain

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

OPERATING INSTRUCTIONS

1. Ensure the vehicle is in a safe state as mentioned in the safety precautions,

ensuring the ground on which the jack is to operate is level and solid.

2. Position the saddle under the

vehicle transmission.

3. Turn the operating valve knob in

Fig 3 clockwise until the valve is

fully closed.

4. Pump the handle to reach the

desired height.

5. Adjust the angle of the saddle to

align with the shape of the

transmission using the adjusting

knobs on the angle setting screws

shown in Fig 4.

6. Adjust the saddle brackets and

use the chain to secure the

transmission onto the saddle as

follows.

7. Screw a wingnut part way up the

chain hook followed by a washer.

Pass the threaded end through the

saddle bracket and attach with a

washer and second wingnut as

shown in Fig 5.

8. Disconnect the transmission from

the vehicle, ensuring its centre of

gravity is centred over the saddle

before the full load is taken.

9. With the load fully secured, turn the operating knob VERY SLOWLY

anticlockwise to lower the saddle.

WARNING: BEFORE LIFTING, ENSURE THE SAFETY PRECAUTIONS ARE

STRICTLY FOLLOWED. NO RESPONSIBILITY CAN BE ACCEPTED FOR

INCORRECT USE OF THE JACK

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

• The more the knob is turned, the greater the rate of descent.

MAINTENANCE

IMPORTANT: Only fully qualified personnel should attempt repairs.

1. Always visually inspect the jack 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 castors for damage. Do not use the jack

unless it is perfectly serviceable.

2. Traces of oil on the ram is normal, but where leakage is apparent, the ram

seals must be renewed by your Clarke dealer.

3. The jack should be fully inspected annually as follows:

• Check for cracks and deformation of components.

• Check castors to ensure they move freely without undue wear to

their bores, and that the wheels are not cracked or damaged.

• Remove any rust or corrosion and repaint to prevent further

corrosion.

• Ensure that all labels and warning notices are in place and legible.

4. Maintain a light coating of grease on the threads of the angle setting

screws.

5. Periodically check the level of oil in the cylinder and top up if low. Proceed

as follows.

• Lower the ram to its lowest position and remove the oil filler plug.

• Using an oil can, slowly top up the oil to the level then replace the

filler screw.

NOTE: Top up using Clarke hydraulic oil (Part Number 3050830).

6. After use, wherever possible, store the jack with the ram 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 jack in the open, exposed to the weather.

WARNING: ALWAYS LOWER IN A SLOW AND CONTROLLED MANNER, AND

ENSURE THAT THERE ARE NO OBSTACLES IN THE PATH OF THE LOAD’S

DESCENT.ALWAYS TRANSPORT THE LOAD IN THE LOWERED POSITION

WITH THE CHAIN SECURELY FASTENED AND ENGAGE THE BRAKES ON

EACH CASTOR WHEN STATIONARY.

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

PARTS LIST & DIAGRAM

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

COMPONENT PARTS

No Description No Description

1 Operating Handle 29 Screw

2 Handle Socket 30 Oil Filler Plug

3 R-Clip 31 Reservoir

4HingePin 32Ram

5 Pivot Pin 33 O-Ring

6 Actuating Link 34 Cup Washer

7Plunger 35Piston

8 O-Ring 36 Piston Shaft

9 Back Ring 37 Split Pin 4x40

10 Umbrella Washer 38 Lower Ring

11 Cylinder 39 O-Ring

12 Pump Washer 40 Upper Ring

13 Connecting Link 41 Circlip

14 3mm Steel Ball 42 Pivot Shaft

15 Spring Seat 43 Circlip

16 Valve Spring 44 Frame

17 Over Pressure Screw 45 Nut M18

18 O-Ring 46 Spring Washer 18dia

19 Safety Valve Cap 47 Castor Wheel

20 6mm Steel Ball 48 Lifting Arm

21 Spring 49 Side Link Plate

22 9mm Steel Ball 50 Circlip 16

23 Tapered Spring 51 Hinge Spindle

24 Airtight Washer 52 Lower Hinge Pin

25 Bolt M12 x 20 53 Roll Pin 4x18

26 Release Valve Knob 54 Moving Trunnion

27 O-Ring 55 Support Plate Hinge Pin

28 Valve Body 56 Washer 12

Parts & Service: 020 8988 7400 / E-mail: Parts@clarkeinternational.com or Service@clarkeinternational.com

RELATED CLARKE PRODUCTS

57 Nut M12 68 Circlip 18

58 Hand Knob 69 Angle Block

59 Threaded Shaft 70 Support Plate

60 Fishplate 71 Saddle Bracket

61 Bush 72 Socket Bolt M10 x6

62 Actuating Pivot 73 Wingnut M6

63 Thrust Bearing 8200 74 Washer 6mm

64 Washer 75 Securing Hook

65 Nut M10 76 Chain

66 Threaded Shaft 77 Chain Hook

67 Pivot 78 Handle Grip

No Description No Description

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