Cornwell Tools CTJ35BK User manual

• Operating Manual • Warning Information • Parts List
Capacity ................................3.5 Ton
Low Height ...............................3.75"
Raised Height............................21.25"
Overall Length ...........................27.95"
Overall Width ............................14.84"
Overall Height..............................6.5"
Handle Length ..............................50"
Saddle Diameter (diagonal) ..................4.72"
Weight ..............................112.4 Lbs.
SPECIFICATIONS
CTJ35BK 9/15/16
CTJ35BK
3-1/2 Ton Service
Jack - Black
Manufactured to comply with the
ASME PASE-2014 Safety Standard
Copyright © Professional Tool Products, 2016
All rights reserved

CTJ35BK 2 9/15/16
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
IMPORTANT: READ THESE INSTRUCTIONS BEFORE OPERATING
BEFORE USING THIS DEVICE, READ THIS MANUAL COMPLETELY AND THOROUGHLY, UNDERSTAND ITS OPERATING
PROCEDURES, SAFETY WARNINGS AND MAINTENANCE REQUIREMENTS.
It is the responsibility of the owner to make sure all personnel read this manual prior to using the device. It is also the responsibility of
the device owner to keep this manual intact and in a convenient location for all to see and read. If the manual or product labels are lost
or not legible, contact Cornwell for replacements. If the operator is not fluent in English, the product and safety instructions shall be
read to and discussed with the operator in the operator's native language by the purchaser/owner or his designee, making sure that
the operator comprehends its contents.
THE NATURE OF HAZARDOUS SITUATIONS
The use of portable automotive lifting devices is subject to certain hazards that cannot be prevented by mechanical means, but only
by the exercise of intelligence, care, and common sense. It is therefore essential to have owners and personnel involved in the use
and operation of the equipment who are careful, competent, trained, and qualified in the safe operation of the equipment and its
proper use. Examples of hazards are dropping, tipping or slipping of loads caused primarily by improperly securing loads, overloading,
off-centered loads, use on other than hard level surfaces, and using equipment for a purpose for which it was not designed.
METHODS TO AVOID HAZARDOUS SITUATIONS
• Read, study, understand and follow all instructions before operating this device.
• Inspect the jack before each use. Do not use jack if damaged, altered, modified, in poor condition, leaking hydraulic fluid, or
unstable due to loose or missing components. Make corrections before using.
• Lift only on areas of the vehicle as specified by the vehicle manufacturer.
• Wear eye protection that meets ANSI Z87.1 and OSHA standards, users and bystanders.
• Do not use jack beyond its rated capacity. Do not shock load.
•This is a lifting device only. Immediately after lifting, support the vehicle with jack stands capable of sustaining the load before
working on the vehicle.
• Use only on a hard level surface free from obstructions so the jack is free to reposition itself during lifting and lowering operations.
• Center load on saddle. Be sure setup is stable before working on vehicle.
• Do not move or dolly the vehicle while on the jack.
• Do not use any materials that may serve as risers, spacers or extenders between the stock lifting saddle and the load.
• Do not use any adaptors that replace the stock lifting saddle unless approved or supplied by the jack manufacturer.
• Do not use (or modify) this product for any other purpose than that for which it was designed without consulting the manufacturer's
authorized representative.
• Always lower the jack slowly and carefully.
• This product may contain one or more chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm. Wash hands thoroughly after handling.
• Failure to heed these warnings may result in serious or fatal personal injury and/or property damage.
CONSEQUENCES OF NOT AVOIDING HAZARDOUS SITUATIONS
Failure to read this manual completely and thoroughly, understand its OPERATING INSTRUCTIONS, SAFETY WARNINGS,
MAINTENANCE INSTRUCTIONS and not comply with them, and neglecting the METHODS TO AVOID HAZARDOUS SITUATIONS
could cause accidents resulting in serious or fatal personal injury and/or property damage.
WARNING: Indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
WARNING
WARNING
WARNING
WARNING
WARNING INFORMATION

CTJ35BK 3 9/15/16
OWNER/USER RESPONSIBILITY
The owner and/or user must have an understanding of the manufacturer’s operating instructions and warnings before using this jack. Personnel
involved in the use and operation of equipment shall be careful, competent, trained, and qualified in the safe operation of the equipment and its
proper use when servicing motor vehicles and their components. Warning information should be emphasized and understood. If the operator is not
fluent in English, the manufacturer’s instructions and warning shall be read to and discussed with the operator in the operator’s native language by
the purchaser/owner, making sure that the operator comprehends its contents. Owner and/or user must study and maintain for future reference the
manufacturers’ instructions. Owner and/or user is responsible for keeping all warning labels and instruction manuals legible and intact. Replacement
labels and literature are available from the manufacturer.
INSPECTION
Visual inspection should be made before each use of the jack, checking for leaking hydraulic fluid and damaged, loose or missing parts. Each jack must be
inspected by a manufacturer’s repair facility immediately, if subjected to an abnormal load or shock. Any jack which appears to be damaged in any way, is
found to be badly worn, or operates abnormally MUST BE REMOVED FROM SERVICE until necessary repairs are made by a manufacturer’s authorized repair
facility. It is recommended that an annual inspection of the jack be made by a manufacturer’s authorized repair facility and that any defective parts, decals or
warning labels be replaced with manufacturer’s specified parts. A list of authorized repair facilities is available from the manufacturer.
SETUP
Please refer to the exploded view drawing on page 6 in this manual in order to identify parts:
1. Remove the 2-piece handle from box. Insert narrow portion of top section (#18) into bottom section (#19) and secure with handle button (#16).
2. Grease the inside of the handle socket (#21) and remove the handle set screw (#20) from the handle socket (#21). Insert the handle all the way
in the handle socket (#21) until it engages the universal joint assembly (#26). Secure the handle to the handle socket (#21) with the handle set
screw (#20).
3. Air may become trapped in the hydraulic system during shipping and handling. Trapped air will affect the pumping performance of the jack.
If this occurs, follow the air purging procedure below:
a) Rotate the handle. in a clockwise direction until tight. Rotate the handle in a counterclockwise direction two complete revolutions.
b) Pump the handle approximately 10-15 complete pump strokes.
c) Rotate the handle in a clockwise direction until tight. Proceed to pump the jack to maximum lift height.
d) Repeat steps "a" through "c" until all air has been purged from the system.
OPERATION
This is the safety alert symbol used for the OPERATING INSTRUCTIONS section of this manual to alert you to potential personal injury
hazards. Obey all instructions to avoid possible injury or death. IMPORTANT: Before attempting to raise any vehicle, check vehicle service
manual for recommended lifting surfaces.
1. To raise load: Turn the handle in a clockwise direction until tight. Position the jack under the load. Proceed to pump the handle in order to raise
the lift arm to the load. As the saddle at the end of the lift arm gets closer to the load, reposition the jack so the saddle will contact the load firmly
and the load is centered on the saddle. Make sure the saddle is correctly positioned. Raise the load to the desired work height. Place jack stands
of appropriate capacity at the vehicle manufacturers's recommended support areas that provide stable support for the raised vehicle. DO NOT
CRAWL UNDER VEHICLE WHILE LIFTING VEHICLE OR PLACING OR REMOVING THE JACK STANDS! Once jack stands are positioned, turn
the handle VERY SLOWLY. Lower the load to rest on the jack stands. Inspect the relationship between the jack stands and load to make sure the
setup is stable and safe. If the setup is not stable or safe, follow the preceding steps until corrected.
2. To lower load: Follow the procedures mentioned in "To raise load" section of the OPERATING INSTRUCTIONS in order to raise the load off the
jack stands. Once the load has cleared the jack stands, remove the stands from under the load and away from the work area. Turn handle very
slowly in a counterclockwise direction until the load is completely lowered to the ground. Once the jack's lifting saddle has cleared the load,
remove the jack from under the load. CAUTION: Keep hands and feet away from the hinge mechanism of the jack. DO NOT CRAWL UNDER
VEHICLE WHILE LIFTING VEHICLE OR PLACING OR REMOVING THE JACK STANDS!
PREVENTATIVE MAINTENANCE
This is the safety alert symbol used for the PREVENTATIVE MAINTENANCE section of this manual to alert you to potential personal injury hazards.
Obey all instructions to avoid possible injury or death.
1. Always store the jack in a well protected area where it will not be exposed to inclement weather, corrosive vapors, abrasive dust, or any other harmful
elements. The jack must be cleaned of water, snow, sand, grit, oil, grease or other foreign matter before using.
2. The jack must be lubricated periodically in order to prevent premature wearing of parts. A general purpose grease must be applied to all zerk grease
fittings, caster wheels, front axle, elevator arm, handle base pivot bolts, release mechanism and all other bearing surfaces. Worn parts resulting from
inadequate or no lubrication are not eligible for warranty consideration. See page 5 for lubrication instructions.
3. It should not be necessary to refill or top off the reservoir with hydraulic fluid unless there is an external leak. An external leak requires immediate repair
which must be performed in a dirt-free environment by an authorized service center.
IMPORTANT: In order to prevent seal damage and jack failure, never use alcohol, hydraulic brake fluid or transmission oil in the jack. Use Chevron Hydraulic
Oil AW ISO 32, its equivalent Unocal Unax AW 150 or hydraulic jack oil.
4. Every jack owner is responsible for keeping the jack labels clean and readable. Use a mild soap solution to wash external surfaces of the jack but not
any moving hydraulic components.
5. Inspect the jack before each use. Do not use the jack if any component is cracked, broken, bent, shows sign of damage or leaks hydraulic fluid. Do not
use the jack if it has loose or missing hardware or components, or is modified in any way. Take corrective action before using the jack again.
6. Any hydraulic repairs within the warranty period must be performed by an authorized service center.

CTJ35BK 4 9/15/16
WARRANTY COVERAGE
Cornwell Quality Tools Company (“Cornwell”) warrants against defects the hydraulic pump on this product for a period of TWO (2)
YEARS from the date of original retail purchase. Cornwell Quality Tools Company (“Cornwell”) warrants against defects the balance of
components on this product for a period of 90 days from the date of original retail purchase. Subject to the conditions and limitations
set forth below, Cornwell will, at its option, either repair or replace any part of the product(s) that proves defective by reason of improper
workmanship or materials.
This warranty does not cover any damage to this product that results from accident, abuse, misuse, natural or personal disaster, or any
unauthorized disassembly, repair, or modification. Repairs, disassembly and modification are only authorized to be made by Cornwell
or a warranty service center approved by Cornwell.
WARRANTY SERVICE
To obtain warranty service, contact your Cornwell dealer.
EXCLUSIONS AND LIMITATIONS
THIS WARRANTY AND THE REMEDIES SET FORTH ABOVE ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, REMEDIES
AND CONDITIONS, WHETHER ORAL OR WRITTEN, EXPRESS OR IMPLIED. CORNWELL SPECIFICALLY DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES, INCLUDING, TO THE EXTENT PERMITTED BY APPLICABLE LAW, ANY WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE. IF CORNWELL CANNOT LAWFULLY DISCLAIM IMPLIED WARRANTIES UNDER THIS
LIMITED WARRANTY, ALL SUCH IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY. IN
NO EVENT SHALL CORNWELL BE LIABLE TO THE PURCHASER OR TO THE USER OF A CORNWELL PRODUCT FOR ANY SPECIAL,
INCIDENTAL OR CONSEQUENTIAL DAMAGES BASED UPON BREACH OF WARRANTY, BREACH OF CONTRACT, NEGLIGENCE, TORT,
OR ANY OTHER LEGAL THEORY. SUCH DAMAGES INCLUDE, WITHOUT LIMITATION, EXPENSES, LOST REVENUES, LOST SAVINGS,
LOST PROFITS, OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING FROM THE PURCHASE, USE OR INABILITY
TO USE THE CORNWELL PRODUCT.
Some states do not allow the exclusion or limitation of incidental or consequential damages or exclusions or limitation on the duration
of implied warranties or conditions, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal
rights, and you may also have other rights that vary by state.
Repair kits and replacement parts are available for many Cornwell products, regardless of whether or not the product is still covered
by a warranty plan.
PROPER STORAGE
It is recommended that the jack be stored in a dry location with all wheels touching the ground on a relatively level surface.
TROUBLESHOOTING
Important: Service jacks are self-contained devices used for lifting, but not sustaining, a partial vehicular load. In accordance with ASME-PASE Load
Sustaining Test: “A load not less than the rated capacity…shall not lower more than 1/8" (3.18mm) in the first minute, nor a total of .1875" (4.76mm) in 10
minutes.” Lowering within this range is considered normal operation and is NOT a warrantable defect.
PROBLEM ACTION
1. Unit will not lift rated load. Purge air from hydraulic system by following procedure under
SETUP.
2. Unit will not sustain rated load or feels “spongy” under rated load. Purge air from hydraulic system as above.
3. Unit will not lift to full height. Purge air from hydraulic system as above.
4. Handle tends to raise up while the unit is under rated load. Pump the handle rapidly several times to push oil past ball
valves in power unit.
5. Unit still does not operate. Contact Cornwell authorized hydraulic service center.

CTJ35BK 5 9/15/16
HYDRAULIC JACK MAINTENANCE GUIDE
IMPORTANT: Service jacks are designed for lifting purposes only; always support raised load with jack stands.
REGULAR MAINTENANCE
• MONTHLY or as necessary (depending on usage)
1. Using a grease gun, add grease to grease fitting in the lift arm pivot shaft. (Use a multi-purpose NLGI type grease only.)
2. Lubricate all linkages and pivot points. (Use white lithium spray grease only.)
3. Remove handle; lubricate handle receptacle and handle end. (Use white lithium spray grease only.)
4. Lubricate both rear casters, bearing and both front wheels. (Use white lithium spray grease only.)
5. Tighten all accessible hardware.
*
*
*
*
NOTE: Premature wearing of parts or components caused by loose or missing hardware that have not been replaced or tightened in a correct and timely
manner are not eligible for warranty consideration.
Numbers shown in this illustration match the
step numbers above (Regular Maintenance)
*
Rear view
4
4
3
1
2
Front view when lift arm is raised
2
22 2

41
40
39
37
35
34
33
32
31
27
24
25
26
28
29
30
36
4
4
7
7
8
6
5
10
11
9
12
12
6
23
22
21
20
19
18
29
13
13
15
14
16
17
1
2
3
1
2
3
38
PARTS
CTJ35BK: 3-1/2 TON SERVICE JACK - BLACK
1 RS35T01 Star Washer 2
2 RS35T02 Flat Washer 2
3 RS35003BK Front Wheel (Black) 2
4 Jack Frame 1
5 RS35B10 Rear Caster Assembly (Flat Black)
(incl. #6 and 7) 2
6 Hex Nut (M16) (incl. with #5) 4
7 Spring Bushing (16) (incl. with #5) 4
8 Retainer Ring (30) 2
9 Bolt (M12x25) 4
10 Spring Bushing (12) 4
11 Bolt (M5x16) 4
12 Washer (M8) 4
13 Bolt (M8x22) 4
14 RS35B11 Handle Socket Bolt (incl. #15) 2
15 Spring Bushing (18) (incl. with #14) 2
16 RS35THB Handle Button 1
17 RS35010C Handle Cover 1
18 RS35024 Upper Handle (Flat Black) 1
19 RS35025 Lower Handle (Flat Black) 1
20 RS35T13 Handle Socket Screw 1
21 RS35011MC Handle Socket (Black) 1
Item Part
No. No. Description Qty.
Item Part
No. No. Description Qty.
22 Retainer Ring (12) 1
23 Roller 1
24 Roller Pin 1
25 RS35026 Power Unit 1
26 RS35T18 Release Valve Assembly 1
27 RS35T19 Spring 2
28 RS35022BK Check Plate 1
29 RS35023 Tie Rod 2
30 Lift Arm Axle 1
31 Retainer Ring (25) 2
32 RS35T06BK Connecting Rod 1
33 Clip (4x55) 1
34 RS35T12 Oil Plug 1
35 Lift Arm 1
36 Long Linkage Bolt 2
37 Long Linkage 2
38 RS35T04 Retainer Ring (16) 2
39 RS35039BK Saddle (Black) 1
40 RS35018 Saddle Bolt 1
41 RS35041 Rubber Saddle Pad (Black) 1
RSCTJ35BKPLK Product Label Kit (not shown) 1
Only items identified by part number are available for purchase.
CTJ35BK 6 9/15/16