Clarke CTJ1000 User guide

TRANSMISSION JACK

MODEL NO: CTJ1000

PART NO: 7612606

OPERATION AND MAINTENANCE

INSTRUCTIONS

GC0925

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 1000 kg

Min Height with head 1265 mm

Max Height with head 2075 mm

Base size 985 x 985 mm

Overall lift range 870 mm

No of strokes from rest to max height 59 (approx)

Distance per pump action 15 mm

Dimensions (L x W x H) 1000 x 1000 x 1265 mm

Weight 51 kg

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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.

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.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

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.

CONTENTS

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:

• 1 x Column Assembly • 1 x Foot Pedal

• 2 x Wheel brackets (legs) • 1 x Saddle

• 4 x Castors with brake • 1 x Fixings Kit (19mm bolts,
washers, nuts & circlips)

Visually inspect all components to ensure that no damage was suffered in transit. Any
damage should be reported to your CLARKE dealer immediately.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

ASSEMBLY

TOOLS REQUIRED

• 19mm wrench

• Circlip pliers

• 5 mm Allen key

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.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

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: 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.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

OPERATING INSTRUCTIONS

WARNING: BEFORE LIFTING, ENSURE THE SAFETY PRECAUTIONS
ARE STRICTLY FOLLOWED. NO RESPONSIBILITY CAN BE ACCEPTED
FOR INCORRECT USE OF THE JACK.

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: ALWAYS LOWER IN A SLOW AND CONTROLLED
MANNER, AND THAT THERE ARE NO OBSTRUCTIONS IN THE PATH
OF THE LOAD’S DESCENT.

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

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 any rust and repaint to prevent further corrosion.

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

4. An occasional shot of grease may be applied via the grease nipple at the top of
the ram, to protect the tip of the ram from corrosion.

5. 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.

6. DO NOT leave the jack in the open, exposed to the elements. Keep under cover.

7. 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 “

Adjust”

.

Do not

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).

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

DECLARATIONS OF CONFORMITY

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]

COMPONENT PARTS

No Description No Description

1 Bolt M8 x 40 36 Base for Steel Ball

2 Release Handle 37 Steel Ball

3 Nut M8 38 Spring

4 Base for Handle 39 Bolt M12 x 25

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No Description No Description

5 Nut M10 40 Connecting Rod

6 Screw M6 x 6 41 Pin

7 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 70 Position piin

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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]