Clarke Strong-Arm CTJ2500QLP Instruction Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC1020

2.5 TONNE TROLLEY JACK

MODEL NO: CTJ2500QLP

PART NO: 7621804

INTRODUCTION

Thank you for purchasing this CLARKE Garage 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 CTJ2500QLP

Weight 30.5kg

Dimensions (L x W x H) without handle 730 x 345 x 152mm

Cup diameter 110 mm

Rated Load 2.5 tonne (2500kg)

Height of saddle from floor (minimum) 80 mm

Height of saddle from floor (maximum) 510 mm

Pump oil capacity 0.24L

Number of strokes min-max height 7

Distance per stroke 75 mm

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. 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, level base, and that 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 than 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 and such work be carried out by qualified persons.

15. DO NOT make any adjustments to any valves on the jack.

WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS

INSTRUCTION BOOKLET

UNPACKING AND ASSEMBLY

1. Remove the retaining clip by

pressing the handle yoke down-

wards and pulling the clip away.

2. Loosen the bolt in the yoke until

the lower handle can be inserted

fully into the handle socket.

• The lower handle has a groove

which should engage with the

bolt once it is re-tightened.

• The socket in the handle will

engage with the jack control

valve at the base of the yoke.

3. Add the upper handle by sliding it

into the lower handle until the

spring-loaded latch pops into the

hole.

OPERATION

This jack incorporates a twin piston pump with a ‘quick lift’ facility. This provides

the user with a rapid raising operation for the unloaded jack. When the jack

encounters a load (the vehicle to be raised), its distance raised per stroke

reduces to provide a gradual and controllable lifting 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.

• Consult the vehicle handbook to determine suitable lifting points.

3. Twist the handle clockwise to close the control valve.

4. Pump the handle to raise the saddle until it reaches the jacking point.

5. 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 clean and completely free from debris.

6. Position axle stands directly beneath suitable supporting points on the

vehicle and very gently twist the handle anticlockwise.

• This will open the control valve to lower the load onto the stands.

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

avoid a rapid descent by turning the handle slowly.

8. 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.

9. Completely remove the jack from the vehicle.

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.

MAINTENANCE

PURGING AIR FROM THE SYSTEM

If air bubbles become trapped inside the hydraulic system, the efficiency of

the jack will be reduced.

Before initial operation, purge any air from the system by fully opening the

pump release valve (turning the handle clockwise), then, while holding the

saddle down, pump the handle several times.

CHECKING /MAINTAINING 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 1

litre).

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.

GENERAL CARE

1. Periodically lubricate the hinges,

front wheels & rear castors with

light oil. Should the arm become

stiff, apply a shot of grease to the

grease nipple on the top of the

lifting arm as shown.

2. In the event of damage or broken

components, replacements are

available from CLARKE Parts &

Service.

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

DECLARATION OF CONFORMITY

PROBLEM CAUSE SOLUTION

Jack will not lift

the rated load

Low oil level See ‘Checking the Oil Level‘on p 6

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

Release 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 p 6

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 p 6

Air in the system Purge the system as on p 6

Jack will not

lower completely

Return spring may be

faulty

Return to your dealer for repair

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

COMPONENT PARTS - GENERAL ASSEMBLY

No Description No Description

1Front wheel 22 n/a

2Circlip 20mm 23 Locating screw

3Washer M16 24 Idler roller

4Nut M16 Chassis frame 25 Washer 12 mm

5Rear castor assembly 26 Upper handle

6Lifting arm shaft 27 Locating pin

7Circlip 25mm Screw M5x12 28 Handle sleeve

8Washer M10 29 Lower handle

9Bolt M10x 25 30 Pump assembly

10 Washer M5 31 Tension spring

11 Washer M5 Yoke bolt 32 Pin 4 x 50

12 Screw M5 x 12 33 Link member

13 Washer 16 34 Grease nipple M6

14 Nut M16 35 Bolt

15 Washer 8 36 Long connecting arm

16 Bolt M8 x 20 37 Frame

17 Washer 38 Circlip 14

18 Bolt 39 Lifting arm

19 Shaft 40 Saddle

20 Handle socket/yoke 41 Screw

21 Cover board 42 Rubber pad

COMPONENT PARTS-GENERAL ASSEMBLY

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.

COMPONENT PARTS - HYDRAULIC PARTS

No Description No Description

1Snap ring 27 Steel ball 6dia G16

2O-ring 37.5 diax2.65# 28 O-ring 8 dia x 1.8#

3Retaining ring 29 Oil drain valve stem

4O-ring 29.8 dia x 3.1# 30 Copper washer#

5Piston rod 31 Hydraulic valve body

6Retaining ring 32 O-ring B#

7Piston rod head 33 Nylon gasket#

8Washer# 34 Pump core A

9O-ring# 35 Spring

10 Oil plug# 36 Dust cover

11 Steel ball 7dia G16 37 Washer

12 Steel ball seat 38 Snap ring A

13 Safety valve spring 39 Copper washer#

14 Screw 40 Hydraulic valve body

15 O-ring# 41 O-ring

16 Screw 42 Pump core O-ring#

17 Cap 43 Pump core

18 Steel ball 5dia G16 44 Washer

19 Low pressure spring 45 Snap ring

20 Steel ball 8dia G16 46 Sealing pad

21 High pressure spring 47 O-ring 5 x 1.8mm

22 Steel ball 10dia G16 48 Spring

23 Screw Cap M12x16 49 Throttle block

24 Steel ball 4dia G16 50 Copper washer#

25 Safety valve spring 51 Sealing screw

26 Steel ball 5dia G16 52 Hydraulic power unit base

• Items marked # are components of the Repair Seal Kit.

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