Clarke CTBJ5 Troubleshooting guide

OPERATION AND MAINTENANCE

ORIGINAL INSTRUCTIONS GC0720 - REV 2

INSTRUCTIONS

TELESCOPIC BOTTLE JACK

MODEL NO: CTBJ5, 10 & 12

PART NO: 7621037, 7621050 & 7621795

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

INTRODUCTION

Thank you for purchasing this CLARKE Bottle Jack.

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.

Keep these instructions for future reference.

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.

SPECIFICATIONS

CTBJ5 CTBJ10 CTBJ12

Rated Load 5 tonne 10 tonne 12 tonne

Min Height of saddle 220 mm 210 mm 235 mm

Max Height of saddle 495 mm 525 mm 580 mm

Pump oil capacity 475 ml 610 ml 850 ml

Dimensions (L x W x H) mm 130x135x220 175x165x210 190x180x235

Weight 7.8 kg 11.1 kg 15.15 kg

Length of Operating handle 590 mm 590 mm 590 mm

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

SAFETY PRECAUTIONS

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

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

safety precautions.

3. Do not operate the jack if damaged.

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

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

6. Only use the jack on level and solid ground, preferably concrete. Avoid

soft/unmade ground as the jack may sink in.

7. Ensure non-essential persons keep a safe distance whilst the jack is in use.

8. Ensure there are no personnel or obstructions under the vehicle before

lowering.

9. Do not work under the vehicle until it is fully supported by axle stands.

10. Keep hands etc clear of the vehicle until lifting is complete.

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

jacking operation in case there is any relative movement.

12. Always ensure that the jack saddle is centred and stable on the lifting point

before lifting and position the jack to avoid operating it from under the

vehicle.

13. Check the vehicle weight and recommended lifting points by referring to

the vehicle owners manual. Ensure the lifting point is not corroded.

14. Never tamper with the jack or modify it in any way, as this could prove to

be dangerous and will invalidate the guarantee. Only use the jack for the

purpose for which it is intended.

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

using this jack.

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

that no corrosion is allowed to weaken any part of it.

17. 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.

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

19. Always inspect the jack before use. Ensure that all parts are in good

condition and operating smoothly, and that no cracks or distortion is

apparent. If in doubt do not use.

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

20. Never push a vehicle off the jack or start the engine while supported only

by the jack.

21. Do not use if an oil leak is apparent. Consult the Clarke Service

Department.

22. If more than one jack is used in unison, they must all be of the same rating

and be raised at the same speed to reduce the possibility of the load

slipping.

SAFETY SYMBOLS

The following safety symbols may be found on the product.

Read the user manual before use.

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

PRODUCT FEATURES

(CTBJ12 shown)

UNPACKING

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’. In this case the jack may require purging as described on page 7.

If the column does not reach its full height, the ram oil level may require

topping up, as described in the Maintenance section.

1 3 x Handle Tubes

2Ram

3 Screw Extension

4 Oil Filler Plug

5ActuatingLever

6 Release Valve

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

OPERATION

RAISING A VEHICLE

1. Ensure the vehicle is stable and is on firm level ground with the wheels

chocked before positioning the jack so that is directly beneath the lifting

point. DO NOT rely upon the vehicle handbrake alone to prevent vehicle

movement.

2. Ensure the jack is on solid ground. If not, place a suitable piece of solid

wood of sufficient size to provide adequate support beneath the jack.

3. Consult the vehicle owners manual to ascertain the location of suitable

jacking points and position the jack beneath the designated lifting point.

4. Locate the slotted end of the jack handle on to the release valve and turn

fully clockwise to close the valve.

5. Set the screw extension (CTB10 & 12 models) in contact with the lifting

point. Pump the handle and raise the ram so that the jack and lifting point

are in full contact. Before proceeding further, make one final check to

ensure that:

• the jack is completely vertical and stable.

• there are no obstructions to the lift and that the handle can move

freely up and down.

• all personnel are in a safe position.

6. When satisfied, continue to pump the handle and lift the load to the height

required.

7. NEVER allow anyone to get beneath the load until it is firmly supported on

suitable, properly rated axle stands.

LOWERING THE VEHICLE

1. The lowering speed is controlled by the amount you turn the release valve.

With the axle stands removed, check to ensure that there are no personnel

WARNING: ENSURE THE SAFETY PRECAUTIONS ARE STRICTLY FOLLOWED.

NO RESPONSIBILITY CAN BE ACCEPTED FOR INCORRECT USE OF THE

JACK

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

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

DESCENT. BE EXTREMELY CAREFUL WHEN LOWERING HEAVY LOADS.

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

in the immediate vicinity before removing the handle from its housing, and

engaging it with the release valve.

2. Very slowly turn the handle anticlockwise to open the release valve, and

allow the jack to lower the load, under complete control. NEVER, under

any circumstances, jerk the valve open.

MAINTENANCE

IMPORTANT: Only fully qualified personnel should attempt to repair the jack.

INSPECTION

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. Do not use the jack unless it is perfectly serviceable.

• A slight dampness on the ram is normal, but where leakage is found,

the ram seals must be renewed by your Clarke Spares Department.

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

• Check for cracks and deformation of components.

• Check operation and top up the oil level. (see below).

• Remove completely, any rust or corrosion and repaint to prevent

further corrosion.

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

3. After use, 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.

4. Do not leave the jack in the open, exposed to the weather. Keep under

cover. If stored for long periods, inspect before use, clean, and re-oil. For

servicing, contact your CLARKE dealer or CLARKE Service dept.

TOPPING UP THE OIL

It may be necessary from time to time to top up the hydraulic oil level.

Proceed as follows.

1. Turn the release valve counterclockwise and allow the ram to retract to its

lowest position.

• It may be necessary to apply force to the saddle for lowering

without any weight on the jack.

2. With the jack in the level position, remove the filler plug and stand upright.

• The oil should be level with the bottom of the oil filler hole.

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

3. If below this, top up.

4. Do not overfill. Only use the correct type of oil such as Clarke hydraulic oil

(part number 3050830).

5. Replace the filler plug.

6. Check the jack for correct operation and purge any air from the system as

described below.

PURGING AIR FROM THE JACK

1. Turn the release valve counterclockwise one full turn to open.

2. Pump the handle eight full strokes.

3. Turn the release valve clockwise to close the valve.

4. Pump the handle until the ram reaches maximum height and continue to

pump several times to remove trapped air.

5. Turn the release valve counterclockwise one full turn and lower the ram to

its lowest position. Apply pressure if necessary.

6. Turn the release valve clockwise to the closed position and check for

correct operation. It may be necessary to perform the procedure more

than once to evacuate all the air.

TROUBLESHOOTING

Problem Check Solution

Jack will not lift to full

height

Low oil level Check oil level

Jack will not hold load Release valve not closing

Hydraulic oil contaminated

Pump valves not sealing

Cylinder ram binding

Contact Clarke Service

Department

Jack piston will not

lower

Cylinder ram binding

Parts warn

Internal damage

Broken or disconnected

return spring

Lift arm linkage bent or

binding

Contact Clarke Service

Department

Jack feels spongy

when lifting

See Air Purging section See air purging

procedure above

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

PARTS DIAGRAMS

CTBJ5

CTBJ10 & CTBJ12

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

CTBJ5, CTBJ10 & CTBJ12 PARTS LIST

No CTBJ5 CTBJ10/12 No CTBJ5 CTBJ10/12

1 Release valve Release valve 22 Circlip O-ring

2 O-ring O-ring 23 Cap Nut Piston Head

3 Steel Ball Steel Ball 24 Circlip O-ring

4 Filler Plug Filler Plug 25 Link Plate Upper Piston

5 Base Casting Base Casting 26 Handle Bracket Circlip

6 O-ring Sealing Ring 27 Hinge Pin Screwed Rod

7 O-ring Circlip 28 Pump Piston Spring

8 Breech Block O-ring 29 Dustproof Ring Cap Nut

9 Circlip O-ring 30 Circlip Circlip

10 Piston Ring Sealing Ring 31 O-ring Link Plate

11 Piston Ring Circlip 32 Housing Handle Bracket

12 Circlip Circlip 33 Valve End Hinge Pin

13 Outer Piston Sealing Ring 34 Gasket Pump Piston

14 Circlip O-ring 35 Nylon Ring Dustproof Ring

15 Nylon Ring O-ring 36 Nylon Ring Circlip

16 Block Ring Circlip 37 O-ring

17 Piston Ring Lower Piston 38 Valve Housing

18 Nylon Ring Circlip 39 Valve End

19 Piston Head Sealing Ring 40 Gasket

20 Gasket Circlip 41 Nylon Ring

21 Inner Piston Sealing Ring 42 Nylon Ring

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