Clarke CFTJ500 Troubleshooting guide

OPERATION AND MAINTENANCE
ORIGINAL INSTRUCTIONS GC12/16
INSTRUCTIONS
TRANSMISSION JACK
MODEL NO: CFTJ500
PART NO: 7612635

2
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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

3
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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.

4
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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.

5
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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

6
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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

7
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
• 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.

8
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
PARTS LIST & DIAGRAM

9
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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

10
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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

11
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY