Clarke CTJ3GLS Instruction Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC 0721 -rev 2

3 TONNE HEAVY DUTY LONG CHASSIS

TROLLEY JACK

MODEL NO: CTJ3GLS

PART NO: 7623085

INTRODUCTION

Thank you for purchasing this CLARKE 3 Tonne Heavy Duty Long Chassis 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.

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.

SPECIFICATIONS

Model number CTJ3GLS

Part number 7623085

Length (not including handle): 1305 mm

Width 322 mm

Height 305 mm

Height of lifting cup (minimum) 130 mm

Height of lifting cup (maximum) 600 mm

Weight 65 kg

Rated Load 3 tonne

SAFETY PRECAUTIONS

1. This jack is for lifting only, do not move a load using the jack as a dolly.

2. Do not use to lift people.

3. 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.

4. Make sure that the jack is on a firm solid base, and there is no possibility of it

slipping when under load.

5. Make sure the load is taken by the full saddle and that the point of lift on

the load, is strong enough to support the load adequately.

6. Do not work under the raised vehicle until it is supported by suitable means

e.g. axle stands, NEVER rely on the jack to support the vehicle by itself.

7. Never push a load off the jack.

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

9. Do not try to lift more then the rated load for the jack, (See “Specifications”

on page 2.)

10. Do not use the jack if an oil leak is apparent. Consult your Clarke dealer.

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

12. It is necessary that the operator watch the jack and the load during

operation.

13. Check the condition of the labels regularly and replace as required.

14. The jack must be maintained and repaired in accordance with the these

instructions. Such maintenance and repair must be carried out by qualified

persons.

15. Do not make any adjustments or modifications to this jack or any valves on

the jack.

WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS

INSTRUCTION BOOK;

WARNING: THE OPERATOR SHALL BE PROVIDED WITH ALL NECESSARY

INFORMATION ABOUT TRAINING AND ABOUT PUMPING AND

TRANSLATING FORCES.

OVERVIEW

BEFORE USE

ASSEMBLY

1. Insert the shaft of the handle into

the handle socket.

2. Tighten the clamp bolt shown to

lock the handle in position.

LOCKING/RELEASING THE HANDLE

To lock the handle in the upright

position, put the handle lock in to the

‘Locked’ position as shown.

CHECK OIL LEVEL

1. With the handle in a vertical

position, turn the knob on the

handle counterclockwise to open

the release valve.

2. Push the saddle to its lowest

position.

3. Loosen the two bolts shown and

lift off the cover.

4. Lever off the filler cap using a flat

screwdriver.

• Oil must be up to the edge of

the hole.

5. Top up if necessary with Clarke

hydraulic oil available from your

local Clarke dealer (part number

3050830).

BLEED THE HYDRAULIC SYSTEM

During transportation, air can get into the hydraulic system which will cause

the ram to feel "spongy".

1. Turn the knob on the handle

counterclockwise to open the

release valve.

2. Pump the foot pedal 10 times to

purge the air from the hydraulic

system.

• The jack is now ready to use.

POSITIONING THE JACK

• Make sure that the load is stable and on solid level ground.

• Use suitable wheel chocks to stop the vehicle from moving.

1. Put the handle lock in to the

‘Locked’ position as shown.

2. Turn the knob on the handle

counterclockwise to open the

release valve.

3. Put the saddle directly below the

lifting point of the vehicle (see the

manufacturers handbook for the

locations).

• Make sure that there is no

obstruction that will prevent a clean lift.

• Make sure that all personnel are in a safe position before you lift the

vehicle.

OPERATION

TO LIFT

1. Turn the knob on the handle clockwise to close the release valve.

2. Put the handle lock in to the

‘Unlocked’ position as shown.

3. Operate the jack by pumping the

jack handle or foot pedal.

• Make sure that the saddle is in

full contact with the lifting point

and that there is nothing that

will prevent a clean lift.

4. Put axle stands below the support

points on the vehicle.

• Make sure that the axle stand is centred below the support point

and are stable before full weight of the vehicle is taken on it.

• Make sure that the axle stands are in good condition and that they

can hold the load.

• Ensure that the axle stands cannot move when supporting the load.

• DO NOT jerk the handle, make sure that it lowers slowly and in a

controlled manner on to the axle stands

TO LOWER

1. Lift the vehicle to remove the weight from any supports.

2. Remove the axle stands or other supports from below the vehicle.

3. SLOWLY turn the knob on the handle counterclockwise to open the release

valve.

NOTE: This operation must be done very slowly and in full control.

DO NOT let the load lower suddenly as this could damage

internal components.

4. Remove the jack from below the vehicle.

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

the area is clean and free from all debris.

MAINTENANCE

1. When the jack is not in use, keep the ram fully lowered and the release

valve closed.

2. Keep the jack clean and apply lubricating oil to all pivot points every three

months.

3. Frequently check oil level. For procedure See “Check Oil Level” on page 6.

4. Check the pump piston and piston rod periodically for signs of corrosion.

Clean exposed areas with a clean oiled cloth.

5. Change the oil once a year as follows.

CHANGING THE OIL

1. Lower the saddle fully.

2. Loosen the two cover screws and

lift off the cover.

3. Lever off the filler plug using a flat

screwdriver.

4. Lay the jack on its side to drain the

oil into a suitable container.

5. Dispose of the oil in accordance

with local regulations.

6. Fill with Clarke hydraulic oil,

available from your local Clarke

dealer.

• Oil must be up to the edge of the hole.

7. Replace the oil filler cap.

STORAGE

1. Store in a dry place with the ram fully lowered. If stored for long periods,

inspect at least once a year, clean and re-oil. For servicing, contact your

CLARKE dealer, or CLARKE International Service Department.

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Jack will not lift

the rated load

Low oil level See “Changing the Oil” on page 9.

Release valve not

closed

Turn the release knob fully clockwise

Air in the hydraulic

system

Bleed the system. See page 7

Jack lower when

under load

Release valve not

fully closed

Turn the release knob fully clockwise

Air in the hydraulic

system

Bleed the system. See page 7

Pump feels

Spongy

Low oil level See “Changing the Oil” on page 9.

Air in the hydraulic

system

Bleed the system. See page 7

Handle raises or

flies back under

load

Air in the hydraulic

system

Bleed the system. See page 7

Jack will not lift

full height

Low oil level See “Changing the Oil” on page 9.

Air in the hydraulic

system

Bleed the system. See page 7

Jack will not

lower completely

Return spring may

be faulty

Return to your Clarke dealer for

repair

If any of these remedies fail to restore your jack, consult your Clarke dealer

For Spare Parts and Servicing, please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400

PARTS & SERVICE FAX: 020 8558 3622

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