Clarke CTJ30 Troubleshooting guide

OPERATION AND MAINTENANCE

GC0115

INSTRUCTIONS

TRANSMISSION JACK

MODEL NO: CTJ30

PART NO: 7612605

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 300 kg

Min Height with head 1235 mm

Max Height with head 2045 mm

Base size 630 x 630 mm

No of strokes from rest to max height 26

Distance per pump action 31 mm

Pump oil capacity 0.8 litres

Dimensions (L x W x H) 630 x 630 x 1235 mm (with saddle)

Weight 33 kg

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. 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 according to the packing list, as follows:

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

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

1. Fit the foot pedal to the base unit

using the pivot pin and securing

with the circlips at each end.

2. The pump piston transit bracket,

which retains the pump piston,

requires removal by undoing the

two securing screws.

3. Position the wheel brackets, so

that the offset edge is facing down

and attach the castors using the

washers and nuts provided.

Tighten firmly.

• 1 x Column Assembly complete Foot Pedal

• 2 x Wheel brackets 1 x Saddle

• 2 x Castors with brake 1 x Fixings Kit

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

4. Lay the column on its side, and

bolt on the two wheel bracket

assemblies, with the castors facing

downwards ensuring the bracket

sits over the locating peg. Use the

two bolts and washers. Loosely

tighten the bolts, but DO NOT fully

tighten at this stage.

5. Raise the jack to the upright

position, resting on its castors and

ensure it is on firm level ground.

6. Using a set-square, and testing in two directions at 90° to each other,

ensure the column is vertical. When satisfied, tighten the column securing

bolts fully.

7. Place the saddle on top of the

ram.

8. Loosen the vent valve by hand.

• This will allow air to be vented

when the ram is descending.

NOTE:S

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 valve

and the ram action normalised, by raising and lowering the column a few

times while not under load.

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

topping up, as described in the Maintenance section.

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 jack saddle under the vehicle transmission.

RAISING THE COLUMN

Turn the operating valve handle

clockwise until the valve is fully closed.

Pump the foot lever to reach the

desired height.

Ensure the centre of gravity of the

load is completely centred about the

saddle before the full load is taken,

and secure the load with chains if

necessary.

LOWERING THE COLUMN

With the load fully secured, turn the

operating handle VERY SLOWLY anticlockwise.

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

Be extremely careful when lowering heavy loads.

WARNING: BEFORE LIFTING, 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

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

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

MAINTENANCE

IMPORTANT: Only fully qualified personnel should attempt maintenance or

repair.

1. Always visually inspect the jack before use, to ensure that all parts are

correctly locate 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. A slight dampness 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 in any

way.

• Check the ram 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.

4. 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.

5. Do not leave the jack in the open, exposed to the elements. Keep under

cover.

6. If the jack is transported in the horizontal position, the vent valve should

tightened.

• DO NOT remove the plastic caps at the base of the jack, labelled

“Do not Adjust”.

TOPPING UP THE OIL

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

Proceed as follows.

• Lower the ram to its lowest position, and remove the vent valve.

• Using an oil can, slowly top up the oil until it begins to overflow.

When the excess oil has completely drained off, replace the vent

valve.

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

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

PARTS LIST & DIAGRAM

No Description No Description

1 Bolt M8 x 40 36 Base for Steel Ball

2 Release Handle 37 Steel Ball

3NutM8 38Spring

4 Base for Handle 39 Bolt M12 x 25

5 Nut M10 40 Connecting Rod

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

6ScrewM6x6 41Pin

7 Permanent Seat for Spring 42 Valve Rod

8 Spring 43 O-Ring

9 Spring Sleeve 44 Steel Ball

10 Dust Ring 45 Release Valve Base

11 O Ring 46 Washer

12 Cover 47 Base

13 Screw M6 x 5 48 PTFE Washer

14 Steel Ball 49 O-Ring

15 O-Ring 50 PTFE Washer

16 Washer 51 Small Piston

17 Reservoir 52 Spring

18 Seal Ring 53 PTFE Washer

19 Air Vent Screw 54 O-Ring

20 Cylinder 55 Large Piston

21 Saddle 56 Steel Ball

22 Piston Rod 57 Circlip

23 Piston 58 Pivot Pin

24 Washer 59 Spacing Bush

25 Filter 60 Foot Pedal

26 Steel Ball 61 Steel Ball

27 Hole Ring Shaft 62 Spring

28 Filter 63 Copper Ring

29 Valve Core 64 Screw

30 Spring 65 Nut M12

31 Screw Protector 66 Washer 12 dia

32 Screw 67 Leg

33 O-Ring 68 Castors

34 Screw 69 Lock Washer

35 Spring

No Description No Description

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