Clarke CTJ30 Troubleshooting guide

OPERATION AND MAINTENANCE
GC0115
INSTRUCTIONS
TRANSMISSION JACK
MODEL NO: CTJ30
PART NO: 7612605

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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 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

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

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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.

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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 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

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

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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 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.

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

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

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