Clarke Strong-arm CBJ30 Troubleshooting guide

OPERATION AND MAINTENANCE

ORIGINAL INSTRUCTIONS GC0519 ISS 3

INSTRUCTIONS

BOTTLE JACK

MODEL NO: CBJ30

PART NO: 7620050

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

Rated Load 30 tonne

Min Height of saddle 260 mm

Max Height of saddle 390 mm

Pump oil capacity 600 ml

Dimensions (L x W x H) mm 179 x 148 x 265

Weight 15.9 kg

Length of Operating Handle 550 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 let anyone operate the jack unless they have read these safety

precautions.

3. Do not operate the jack if damaged in any way.

4. Use the jack in a 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. Never

use it on soft/unmade ground as the jack may sink in.

7. Make sure that non-essential persons keep a safe distance whilst the jack is

in use.

8. Make sure there are no people or obstructions under the vehicle before

lowering.

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

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

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

jacking operation in case there is any relative movement.

12. Always make sure 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 location of the lifting points by referring to

the vehicle owners manual.

14. Do not tamper with the jack or modify it in any way, as this could prove to

be dangerous and will invalidate the guarantee.

15. Only use the jack for the purpose for which it is intended.

16. Use applicable safety equipment, such as protective footwear, when you

use this jack.

17. Make sure that the jack is correctly maintained and lubricated at all times,

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

18. 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.

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

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

20. Always examine the jack before use. Make sure that all parts are in good

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

apparent. If in doubt do not use.

21. Do not push a vehicle off the jack or start the engine while supported only

by the jack.

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

Department.

23. 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

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 jack does not reach its full height, the oil level may require topping up as

described in the Maintenance section.

1 3 x Handle Tubes

2Ram

3 Oil Filler Plug

4ActuatingLever

5 Release Valve

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

OPERATION

RAISING A VEHICLE

1. Make sure that the vehicle is stable and is on firm level ground with the

wheels chocked before positioning the jack directly below the lifting point.

DO NOT rely upon the vehicle handbrake alone to prevent vehicle

movement.

2. Make sure that the jack is on solid ground. If not, place a piece of solid

wood of sufficient size to provide sufficient support below the jack.

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

points and position the jack below 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. Pump the handle and raise the ram so that the jack and lifting point are in

full contact. Before proceeding further, make one last check to make sure

that:

• the jack is 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. Do not let anyone reach or work below the vehicle until it is firmly

supported on suitable 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 make sure that there are no

WARNING: MAKE SURE THAT 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 VERY CAREFUL WHEN LOWERING HEAVY LOADS.

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

personnel in the immediate vicinity before removing the handle from its

housing, and engaging it with the release valve.

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

and let the jack lower the load, under complete control. Do not jerk the

valve open.

MAINTENANCE

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

INSPECTION

1. Always examine 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 must be fully inspected annually:

• Check for cracks and deformation of components.

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

• Remove rust or corrosion and repaint to prevent corrosion.

• Make sure 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

releases the pressure in 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, examine before use, clean, and re-oil. For

servicing, speak to your CLARKE dealer or CLARKE Service department.

TOPPING UP THE OIL

It can be necessary from time to time to top up the hydraulic oil level as

follows.

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

position.

• It can 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 Reason 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

Speak to the Clarke

Service Department

Jack piston will not

lower

Cylinder ram binding

Parts warn

Internal damage

Lift arm linkage bent or

binding

Speak to the Clarke

Service Department

Jack feels spongy

when lifting

Air trapped in the hydraulic

system

See air purging

procedure above

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

PARTS DIAGRAMS

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

PARTS LIST

NODESCRIPTION PART NUMBER

1 Top cup ZTGCBJ3001

2 O-ring ZTGCBJ3002

3 Rectangular ring ZTGCBJ3003

4 Reservoir ZTGCBJ3004

5 Oil plug ZTGCBJ3005

6 T-ring ZTGCBJ3006

7 Release value assembly ZTGCBJ3007

8 Ball 6mm ZTGCBJ3008

9 Plastic plug ZTGCBJ3009

10 Adjusting screw assembly ZTGCBJ3010

11 Spring ZTGCBJ3011

12 Spring holder ZTGCBJ3012

13 Steel ball 3mm ZTGCBJ3013

14 Base parts ZTGCBJ3014

15 Oil filter pipe ZTGCBJ3015

16 Cylinder ring ZTGCBJ3016

17 Cylinder ZTGCBJ3017

18 O-Ring ZTGCBJ3018

19 Bowl washer ZTGCBJ3019

20 Piston rod assembly ZTGCBJ3020

21 Handle assembly and Hexagon bolts ZTGCBJ3021

22 Cutter pin ZTGCBJ3022

23 Handle socket assembly ZTGCBJ3023

24 Pin ZTGCBJ3024

25 Pump plunger assembly ZTGCBJ3025

26 Pump ZTGCBJ3026

27 Washer ZTGCBJ3027

28 Seal kit ZTGCBJ3028

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