Clarke CTJ 2500QLGB, 7621803 User guide

2.5 TONNE TROLLEY JACK

MODEL NO: CTJ2500QLGB

PART NO: 7621803

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL0122 - Rev 1

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 CTJ2500QLGB

Part number 7621803

Rated Load 2.5 tonne (2500kg)

Length (not including handle): 660 mm

Width 290 mm

Height 220 mm

Height of saddle from floor (minimum) 100 mm

Height of saddle from floor (maximum) 465 mm

Lifting height with rated load 285 to 465 mm

Saddle cup diameter 108 mm

Distance raised per stroke 70 mm

Quick lift Yes

Weight 30.5 kg

Pump oil capacity 210 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 then the 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 tarmac 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 f
socket.

• The handle has a groove which

should
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.

ully into the handle

engage with the thumb

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.

4. 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 lift 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 pedal to raise the saddle.

IMPORTANT: The foot pedal is used to quickly bring the saddle to the lifting
point, NOT to raise a load.

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)

• 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 four retaining screws and lift off the cover plate.

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3. Remove the filler plug.

• The oil should be almost level

with the b
hole.

• Oil can be topped up using

CLARKE Hydraulic Oil (p/n
3050830 1 litre). Never use
brake fluid or instead of
hydraulic oil.

• Take care not to move the handle while filling with oil.

4. Replace the filler plug and cover plate
(see page 4).

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

ottom of the oil filler

and purge any air from the system

GENERAL CARE

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

2. Store in a dry location.

3. In the event of damage or broken components, replacements are
available from CLARKE Par

ts & Service.

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 2500
load

Jack lifts but
lowers when
under load

Pump feels
Spong

Handle raises or
flies back under
load

Jack will not lift
full heig

Jack will not
lower compl

KG rated

y

ht

etely

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 4/5.

Low oil level.

Air in hydraulic system

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

Check for leakage and top up if
required a
Turn the release knob fully
clockwise
Purge the system as on page 4/5.
Replace or return to your dealer

repair.

for

Turn the release valve fully
clockwise.
Purge the system as on page 4/5.
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 4/5.

Check for leakage and top up if
required as on pages 6/7.
Purge the system as on page 4/5.

Replace or return to your Clarke
dealer for repair.
Check and fully open release
valve.
Open release valve and pump

andle a few times. Close valve

h
and re-try.

s on pages 6/7.

Jack will not
lower at all.

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

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

Release valve still
closed.

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 Saddle pad 26 Washer M10

2 Saddle pin 27 Handle socket shaft

3 Saddle 28 Circlip 12mm

4 Lifting arm assembly 29 Roller

5 Front wheel axle 30 Socket screw M10x19

6 Connecting bar 31 Handle socket

7 Circlip 16mm 32 Pin for roller

8 Side frame 33 Nylon sleeve

9 Front wheel 34 Limited rod

10 Sleeve for front wheel 35 Cap head socket screw M10x20

11 Washer M12 36 Cover plate

12 Nut M12 37 Connecting rod bush

13 Position rod 38 Handle assembly

14 Flat head socket screw M8x20 39 Handle lock pin

15 Spring washer M8 40 Foam protective pad

16 Pan head socket screw M8x20 41 Circlip 25mm

17 Carrying handle 42 Coupling connector

18 Washer M8 43 Return spring

19 Self tapping screw M4x16 44 Cotter pin 4dia x 4.5

20 Spring washer M12 45 Ram assembly

21 Cap head socket screw M12 x 25 46 Oil plug

22 Castor base 47 Steel ball 6mm

23 Rear castor assembly 48 Universal joint assembly

24 Cap head socket screw M10 x 25 49 Seal kit

25 Spring washer M10

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