Clarke CTJ 1500QL, 7612633 User guide

1.5 TONNE TROLLEY JACK

MODEL NO: CTJ1500QL

PART NO: 7612633

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL0122 - ISS 3

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.

Users must read these instructions before using this product.

Keep this document in a safe place for future reference.

SPECIFICATIONS

Model number CTJ1500QL

Part number 7612633

Rated Load 1.5 tonne (1500kg)

Length (not including handle): 555 mm

Width 240 mm

Height 200 mm

Height of saddle from floor (minimum) 88 mm

Height of saddle from floor (maximum) 358 mm

Lifting height with rated load 210 to 358 mm

Saddle cup diameter 95 mm

Distance raised per stroke 60 mm

Quick lift Yes

No of strokes from min to max height 8-9

Weight 14.3kg

Pump oil capacity 105 ml

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SAFETY PRECAUTIONS

WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS
INSTRUCTION BOOKLET

1. Only trained persons should operate this lifting equipment.

2. ALWAYS ensure that sufficient light is provided and that the work area is
kept clear of unrelated items.

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

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

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

7. DO NOT try to lift more than the 1.5 Tonne rated load for the jack.

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

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

10. Make sure that the jack is on a firm level base and there is no possibility of
it slipping when under load.

11. Only use the jack on solid ground, preferably concrete. Avoid
tarmacadam as the jack could sink in.

12. 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.

13. 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.

14. NEVER push a load off the jack.

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

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

17. It is necessary that the operator watch both the jack and the load during
operation.

18. Check the condition of the labels regularly and replace if required.

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UNPACKING AND ASSEMBLY

1. Loosen the thumbscrew in the
yoke until the lower handle can
be inserted fully into the handle
socket.

• The handle has a groove which

should engage with the thumb
screw once it is re-tightened.

• The socket in the handle will

engage with the jack control
valve at the base of the yoke.

2. Remove the travel block by
pressing the handle yoke down­wards and pulling the block
away.

3. Tighten the thumb screw to
secure the lower handle to the
jack.

4. Add the upper handle by sliding it
onto the lower handle until the
spring loaded pin clips in place.

PURGING AIR FROM THE SYSTEM

If air bubbles become trapped inside
the hydraulic system during shipping
or transport, the efficiency of the jack
will be reduced and the jack will feel
spongy.

1. Use the handle to turn the control
valve anti-clockwise, relieving the
pressure inside the jack.

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

3. Turn the control valve clockwise and test the jack. If efficiency is still low,
check the oil level as described under Maintenance ON PAGE 6.

The jack is now ready to use.

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

WARNING: NEVER WORK ON THE VEHICLE WHEN SUPPORTED ONLY BY A
JACK. THIS IS HIGHLY DANGEROUS. THE VEHICLE MUST BE SUPPORTED ON
AXLE STANDS OR SUITABLE SUPPORTS, BENEATH THE CORRECT JACKING/
SUPPORT POINTS.

1. Ensure the vehicle to be raised is stable and on firm level ground with the
wheels chocked. Ensure the vehicle’s handbrake is on, the engine is
switched off and the transmission is in gear or Park if automatic.

2. Ensure the vehicle will not come into contact with adjacent objects when
tilted by the jacking operation.

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

• Consult the vehicle handbook to determine suitable lifting points.

4. Ensure the jack wheels are free to move and there are no obstructions.

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

6. Pump the handle to raise the saddle until it reaches the jacking point, or
alternatively, pump the handle to raise the saddle.

7. Make sure that the saddle is in full contact with the lifting point and that
there is nothing that will prevent a clean lift. Keep all personnel at a safe
distance before lifting the vehicle.

8. Position suitably rated axle stands directly beneath suitable supporting
points on the vehicle and very gently twist the handle anti-clockwise to
lower the vehicle.

9. Make sure that the axle stands are in good condition and that they can
support the weight of the vehicle.

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10. Ensure that the axle stands cannot move when supporting the load and
are on firm, level ground. Use suitable wheel chocks to stop the vehicle
from moving.

11. The jack may move slightly during operation. It is important therefore, that
the floor is clean and completely free from debris.

12. Do not lift the vehicle if there is any chance of spillage of fuel, battery acid
or other liquids.

13. Carefully lower the vehicle onto the axle stand(s), checking constantly that
the vehicle rests snugly and cleanly on the axle stand and that the stand is
stable before the weight is taken.

NOTE: Ensure this is carried out under complete control. DO NOT allow

the load to drop suddenly as this impose undue strain on the jack
internal parts and damage the vehicle.

14. Always avoid a rapid descent by turning the handle slowly.

15. Completely remove the jack from the vehicle.

SUITABLE AXLE STANDS FOR USE WITH THIS JACK

• CAX2TF 2 Tonne Folding Axle Stand (part no 7600015)

• CAX2TA 2 Tonne Aluminium Axle Stand (part no 7600010)

• CAX3TP 3 Tonne Axle Stand (part no 7600065)

• CAX3TBC 3 Tonne Axle Stand (part no 7600060)

• CAX3TA 1.5 Tonne Aluminium Axle Stand (part no 7600030)

• CAX6TP 6 Tonne Axle Stand (part no 7600076)

• CAX6TBC 6 Tonne Axle Stand (part no 7600070)

16. CAX10TP 10 Tonne Axle Stand (part no 7600090)

- sold singly

MAINTENANCE

CHECKING/TOPPING UP 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 fully anti­clockwise.

2. Remove the filler plug.

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

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• Oil can be topped up using CLARKE Hydraulic Oil (p/n 3050830 1

litre). Never use brake fluid or instead of oil.

• Take care not to move the handle while topping up the oil.

3. Replace the filler plug and cover
plate and purge any air from the
system.

4. Wipe up any spillage and dispose
of old or spilled oil appropriately.

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.

STORAGE

Store in a dry, child-proof 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.

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.

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.

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TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

Jack will not lift
the rated load

Jack lifts but
lowers when
under load

Pump feels
Spongy

Handle raises or
flies back under
load

Low oil level.

Release valve not
closed.
Air in hydraulic system.
Damage to moving
parts.

Release valve not fully
closed
Air in hydraulic system
Dirt on valve seats or
faulty seals.

Low oil level.

Air in hydraulic system

Air in hydraulic system. Purge the system as on page 4.

Check for leakage and top up if
required as on pages 6/ 7.
Turn the release knob fully
clockwise
Purge the system as on page 4.
Replace or return to your dealer
for repair.

Turn the release valve fully
clockwise.
Purge the system as on page 4.
Replace or return to your dealer
for repair.

Check for leakage and top up if
required as on pages 6/ 7.
Purge the system as on page 4.

Jack will not lift
full height

Jack will not
lower completely

Jack will not
lower at all.

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

Low oil level.

Air in hydraulic system

Return spring damaged
Piston or frame bent.
Release valve partly
open.
Air in system.

Release valve still
closed.

Check for leakage and top up if
required as on pages 6/ 7.
Purge the system as on page 4.

Replace or return to your dealer
for repair.
Check and fully open release
valve.
Open release valve and pump
handle a few times. Close valve
and re-try.

Check and fully open release
valve.

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DECLARATION OF CONFORMITY

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COMPONENT PARTS - GENERAL ASSEMBLY

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COMPONENT PARTS - GENERAL ASSEMBLY

No Description No Description

1 Hydraulic ram assembly 27 Lifting arm

2 Universal joint assembly 28 Saddle base pivot shaft

3 Steel ball 29 Circlip 14mm

4 Oil plug 30 Connecting bar

5 Cotter pin 4dia x 4.5 31 Circlip 13mm

6 Coupling connector 32 Flat head socket screw M8x20

7 Socket screw M8x19.5mm 33 Slide plate

8 Handle socket 34 Pan head screw M8x20

9 Circlip 8mm 35 Washer M6

10 Roller 36 Pan head screw M6x16

11 Hinge pin 37 Carry handle

12 Supporting axle 38 Washer M8

13 Handle assembly 39 Spring washer M8

14 Foam protective pad 40 Washer M14

15 Spring section 41 Nut M14

16 Pan head socket screw M8x16 42 Washer M10

17 Castor mounting block 43 Pan head screw M10x20

18 Rear castor assembly with nut 44 Handle socket shaft

19 Saddle pad 45 Return spring

20 Saddle pivot 46 Circlip 19mm

21 Saddle 47 Rubber sleeve

22 Front wheel shaft 48 Frame tie bar

23 Saddle support shaft 49 Connecting bar socket

24 Saddle base 50 Shaft

25 Front wheel assembly 51 Seal kit

26 Bush for (23)

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