Clarke CTJ2500SUV Instruction Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC03/23

2.5T TROLLEY JACK WITH SUV SADDLE

MODEL NO: CTJ2500SUV

PART NO: 6601517

INTRODUCTION

Thank you for purchasing this CLARKE Trolley Jack.

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.

SPECIFICATIONS

Model number CTJ2500SUV

Weight 18.3 kg

Dimensions (L x W x H) without handle 622 x 242 x 158mm

Rated Load 2.5 tonne (2500kg)

Height of saddle from floor (minimum) 150 mm (245 with extension)

Max height of saddle with adaptor 530 mm

Max height of saddle without adaptor 435 mm

Pump oil capacity 120 ml

Number of strokes min-max height approx 45

Distance raised per stroke 6.5

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.

SAFETY PRECAUTIONS

1. Read this instruction manual before use.

2. Only trained persons should operate this lifting equipment.

3. ALWAYS ensure that sufficient light is provided and that the work area is

kept clear of unrelated items.

4. ALWAYS inspect the jack before use. Make sure that all parts are in good

condition and operating smoothly and that no cracks or distortion is

apparent. If in doubt DO NOT use. Have the damaged parts replaced or

consult your CLARKE dealer.

5. The jack must be maintained and repaired by suitably qualified persons.

6. DO NOT make any modifications to this jack or adjust any valves.

7. DO NOT use the jack if an oil leak is apparent. Consult your CLARKE dealer.

8. DO NOT use to lift people and ensure that no-one is in the vehicle during

lifting.

9. NEVER exceed the rated load for the jack See “Specifications” on page 2.

Overloading can cause the jack to fail, resulting in personal injury.

10. Make sure that the jack is on a hard, level surface, and there is no possibility

of it slipping when under load.

11. Only use the jack on solid ground, preferably concrete. Avoid tarmac as

the jack could sink in.

12. Make sure the load is taken by the full saddle and that the lifting point on

the vehicle is of sufficient strength to support the weight.

13. ALWAYS use axle stands to stabilise the load once lifted.

14. Consult the vehicle handbook to determine the correct lifting points.

15. Ensure the vehicle is chocked and the handbrake applied before lifting.

16. NEVER work on or under a vehicle unless it is fully and adequately

supported.

17. NEVER rely upon the jack to hold the vehicle in position.

18. NEVER push a vehicle off the jack.

19. Ensure that all personnel are well clear of a load being raised or lowered.

20. Take care not to trap fingers in the moving parts.

21. Use only as a lifting device; do not use as a dolly to move a load.

UNPACKING AND ASSEMBLY

Unpack the components and

remove packing materials. Check

that no damage has occurred during

transit and immediately advise the

CLARKE dealer where you purchased

the product of any deficiency.

1. Connect the two halves of the

handle together and clip

together with the spring-loaded

ball.

2. Fit the adaptor into the socket if

an SUV is the vehicle to be lifted.

3. Add the saddle either to the lifting

arm or to the top of the adaptor

as required.

OPERATION

Before use, inspect the jack for oil leaks or any other sign of damage. Should

any be apparent, have the jack repaired by a qualified technician.

1. Ensure the vehicle to be raised is stable and on firm level ground with the

wheels chocked.

2. Position the jack so that the saddle is directly beneath the lifting point. In

the case of high riding SUVs, insert the adaptor between the jack and the

saddle, seating both items in the socket provided.

• Consult the vehicle handbook to determine suitable lifting points.

3. Engage the end of the handle with the jack control valve. Twist the handle

clockwise to close the control valve.

WARNING: NEVER WORK ON THE VEHICLE WHEN SUPPORTED ONLY BY A

JACK WHICH IS A HIGHLY DANGEROUS PRACTICE. THE VEHICLE MUST BE

SUPPORTED ON AXLE STANDS OR SUITABLE SUPPORTS, BENEATH THE

CORRECT JACKING/SUPPORT POINTS.

4. Insert the handle into the quick lift

operating arm on the side of the

jack. Depress fully down to quickly

raise the arm to the height

needed for a high riding SUV.

5. Next, insert the handle into the

yoke and pump the handle to

raise the saddle until it reaches

the jacking point.

6. Take care that no obstruction

prevents a clean lift. Keep all personnel at a safe distance before lifting the

vehicle.

NOTE: The jack may move slightly during operation. It is important

therefore, that the floor is free from debris.

7. Position axle stands directly beneath suitable supporting points under the

vehicle

8. Very gently twist the handle anticlockwise to open the control valve and

lower the vehicle onto the axle stands. ALWAYS avoid a rapid descent by

turning the handle slowly.

9. To stop it lowering at any point, turn the handle clockwise again.

10. Carefully lower the vehicle onto the axle stand, checking constantly,

preferably with an assistant, that the vehicles jacking point rests snugly and

cleanly on the axle stand, and that the stand is stable before the weight is

taken.

NOTE: Ensure this operation is carried out under complete control. DO

NOT allow the load to drop suddenly as this could damage

internal parts or the vehicle.

11. Completely remove the jack from the vehicle.

12. Store the handle in the socket on the side of the jack.

MAINTENANCE

GENERAL CARE

1. Periodically lubricate the hinges, front wheels & rear castors with light oil.

2. In the event of damage or broken components, replacements are

available from CLARKE Parts & Service.

PURGING AIR FROM THE SYSTEM

If air bubbles become trapped inside

the hydraulic components, the

efficiency of the jack will be

reduced. If the air cannot be

dispersed just by pumping the handle

with the valve open, it can be

purged from the system as follows.

1. Turn the control valve counter-

clockwise, relieving the pressure

within the jack, then prise off the

cover plate & unscrew the filler

plug.

• A broad-bladed screwdriver is required for the plug.

2. Pump the handle several times to purge air from the system.

3. Replace the oil filler plug, then turn the control valve clockwise and test the

jack. If efficiency is still low, check the oil level as below.

CHECKING THE OIL LEVEL

If the jack has been stored for long periods, check for oil leaks before use. If

necessary, check the oil level as follows:

1. Ensure the jack is fully lowered by turning the control valve anticlockwise.

2. Remove the cover plate and the oil filler plug.

• The oil should be almost level with the bottom of the oil filler hole.

• It can be topped up using CLARKE Hydraulic Oil (p/no 3050830 for 1L).

3. Purge any air from the system and replace the oil filler plug.

4. Dispose of any old/spilled oil appropriately and wipe up any spillage.

STORAGE

1. Store in a dry place with the ram fully lowered. For servicing, contact your

CLARKE dealer or CLARKE International Service Department.

ENVIRONMENTAL PROTECTION

One of the most damaging sources of environmental pollution is oil products.

NEVER throw away used hydraulic oil with domestic refuse or flush it down a

sink or drain. Collect any hydraulic oil in a leak proof container and take it to

your local waste disposal site.

If disposing of this product or any damaged components, DO NOT dispose of

with general waste. This product contains valuable raw materials and should

be taken to your local civic amenity site for recycling of metal products.

TROUBLESHOOTING

COMPONENT PARTS - HYDRAULIC RAM

PROBLEM CAUSE SOLUTION

Jack will not lift

the rated load

Low oil level See ‘Checking the Oil Level‘on page6

Valve not closed Turn the release knob fully clockwise

Air in the system Purge the system as on page 6.

Jack lower when

under load

Valve not fully closed Turn the release knob fully clockwise

Air in the system Purge the system as on page 6

Pump feels

spongy

Low oil level See ‘Checking the Oil Level‘on page6

Air in the system Purge the system as on page 6.

Jack will not lift

full height

Low oil level See ‘Checking the Oil Level‘on page6

Air in the system Purge the system as on page 6.

Jack will not

lower fully

Return spring may

be faulty

Return to your Clarke dealer for repair.

If any of these actions fail to restore function, consult your Clarke dealer.

COMPONENT PARTS - HYDRAULIC RAM

No Description No Description

1Piston 17 Valve spring

2Piston head 18 Spring seat

3O-ring 19 Steel ball

4Y-ring seal 20 Top cup

5Cylinder 21 O-ring

6Cylinder gasket 22 Seal

7Filter oil tube 23 Cylinder

8Steel ball 24 Oil plug

9Valve body 25 Cylinder oil seal

10 Steel ball 26 O-ring

11 O-ring 27 Retaining ring

12 Cotter pin 28 Pump operating piston

13 Oil return valve stem 29 Piston connector

14 Pump core gasket 30 Hinge pin-small

15 Pump body 31 Hinge pin-large

16 Regulator screw 32 Handle yoke

COMPONENT PARTS - GENERAL ASSEMBLY

No Description No Description

1Handle cover 22 Front wheel

2Handle 23 Front axle

3Support shaft 24 Tie rod

4Circlip 13mm 25 Main hinge pin

5Connecting rod 26 Left side plate

6Cover plate 27 Spacer rod

7Lifting arm assembly 28 Supporting shaft

8Circlip 22mm 29 Rear caster

9Saddle 30 Retaining washer 10mm

10 Saddle adaptor (SUV) 31 Nut M10

11 Right side plate 32 Return spring

12 Washer 16mmm 33 Oil plug

13 Retaining washer 16mm 34 Hydraulic ram assembly

14 Nut M16 35 Steel ball

15 Handle socket 36 Valve piston

16 Retaining washer 5mm 37 Operating piston

17 Philips head screw 38 Retaining clip

18 Retaining washer 8mm 39 Handle yoke

19 Nut M8 40 Hinge pin (small)

20 Pin 41 Cotter pin

21 Front wheel bush 42 Hinge pin (large)

COMPONENT PARTS (GENERAL ASSEMBLY)

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