Cornwell Tools CTJHW35BL User manual

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CTJHW35BL/CTJHW35NG/CTJHW35RG 1 03/12/20
Manufactured to comply with the
ASME PASE-2019 Safety Standard
Copyright © Professional Tool Products, 2020
All rights reserved
OPERATING MANUAL •WARNING INFORMATION •PARTS LIST
CTJHW35BL/NG/RG
3-1/2 Ton Service Jack
Capacity ................................3.5 Ton
Maximum Height ..........................21.3"
Minimum Height ............................3.8"
Overall Length ..............................28"
Overall Width .............................14.8"
Overall Height..............................6.5"
Handle Length ..............................50"
Saddle Diameter (diagonal) ...................4.7"
Net Weight ...........................112.4 Lbs.
Shipping Weight .......................116.8 Lbs.
SPECIFICATIONS CTJHW35BL (BLUE)
CTJHW35NG (NEON GREEN)
CTJHW35RG (ORANGE)
3-1/2 Ton Service Jack

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CTJHW35BL/CTJHW35NG/CTJHW35RG 2 03/12/20
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 supporting devices are 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 if damaged, altered, modified, in poor condition, leaking hydraulic fluid or unstable due
to loose or missing components. Make corrections before using.
• Use only on a hard level surface free from obstructions so the jack is free to reposition itself during lifting and lowering operations.
• Lift only on areas of the vehicle as specified by the vehicle manufacturer.
• User and bystanders must wear eye protection that meets ANSI Z87.1 and OSHA standards.
• Do not use stand 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.
• 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.
• Always lower the jack slowly and carefully.
• 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.
• Failure to heed these warnings may result in serious or fatal personal injury and/or property damage.
WARNING: This product can expose you to chemicals including nickel, which is known to the State of California to cause cancer and
birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.
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.
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.
WARNING: Indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
WARNING
WARNING
WARNING
WARNING
WARNING INFORMATION
CTJHW35BL/NG/RG
3-1/2 Ton Service Jack

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CTJHW35BL/CTJHW35NG/CTJHW35RG 3 03/12/20
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 yoke (#21) and remove the handle set screw (#20) from the handle yoke (#21). Insert the handle
all the way in the handle yoke (#21) until it engages the universal joint assembly (#26). Secure the handle to the handle yoke (#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.
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.
CTJHW35BL/NG/RG
3-1/2 Ton Service Jack

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CTJHW35BL/CTJHW35NG/CTJHW35RG 4 03/12/20
WARRANTY COVERAGE
Cornwell Quality Tools Company (“Cornwell”) warrants against defects on this product for a period of TWO (2) YEARS 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.
CTJHW35BL/NG/RG
3-1/2 Ton Service Jack

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CTJHW35BL/CTJHW35NG/CTJHW35RG 5 03/12/20
CTJHW35BL/NG/RG
3-1/2 Ton Service Jack
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.
*
*
*
*
Numbers shown in this illustration match the
step numbers above (Regular Maintenance)
*

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PARTS LIST
CTJHW35BL/NG/RG
3-1/2 Ton Service Jack
CTJHW35BL/CTJHW35NG/CTJHW35RG 6 03/12/20
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
1 RS35T01 Star Washer 2
2 RS35T02 Flat Washer 2
3 CTJHW35WHEEL Front Wheel - Black 2
4 Jack Frame - Blue 1
Jack Frame - Neon Green 1
Jack Frame - Orange 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 Retaining 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 Yoke Retaining Bolt (incl. #15) 2
15 Spring Bushing (18) (incl. with #14) 2
16 RS35THB Handle Button 1
17 RS35010C Handle Bumper 1
18 RS35024 Upper Handle - Flat Black 1
19 RS35025 Lower Handle - Flat Black 1
20 RS35T13 Set Screw - Handle Yoke 1
21 RS35011MCBL Handle Yoke - Blue 1
RS35011MCNG Handle Yoke - Neon Green 1
RS35011MCRG Handle Yoke - Orange 1
22 Retaining Ring (12) 1
23 Roller 1
Item Part
No. No. Description Qty. Item Part No. No. Description Qty.
24 Roller Pin 1
25 CTJHW35PUNIT Power Unit Assembly 1
26 RS35T18 Release Valve Assembly 1
27 RS35T19 Return Spring 2
28 RS35022BL Cover Plate - Blue 1
RS35022NG Cover Plate - Neon Green 1
RS35022RG Cover Plate - Orange 1
29 RS35023 Tie Rod 2
30 Lift Arm Axle 1
31 Retainer Ring (25) 2
32 RS35T06BK Block Linkage (incl. #31, 33) 1
33 Pin (4x55) 1
34 RS35T12 Grease Fitting 1
35 Lift Arm Assembly - Blue 1
Lift Arm Assembly - Neon Green 1
Lift Arm Assembly - Orange 1
36 Long Linkage Bolt 2
37 Long Linkage - Black 2
38 RS35T04 Retainer Ring (16) 2
39 RS35039BL Saddle -Blue 1
RS35039NG Saddle - Neon Green 1
RS35039RG Saddle - Orange 1
40 RS35018 Saddle Screw 1
41 RS35041 Rubber Saddle Pad - Black 1
RSCTJHW35BLPLK Product Label Kit (not shown) 1
RSCTJHW35NGPLK Product Label Kit (not shown) 1
RSCTJHW35RGPLK Product Label Kit (not shown) 1
Only items identified by part number are available for purchase.