2.5 TONNE TROLLEY JACK
MODEL NO: CTJ2500QLP
PART NO: 7621804
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0721 - rev 1
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 724 x 342 x153mm
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.
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SAFETY PRECAUTIONS
WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS
INSTRUCTION BOOKLET
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.
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UNPACKING AND ASSEMBLY
1. Remove the retaining clip by
pressing the handle yoke down-
ds and pulling the clip away.
war
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
ch should engage with the
whi
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
o the lower handle until the
int
spring-loaded latch pops into the
hole.
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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.
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.
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.
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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 tur
2. Remove the cover plate and the oil filler plug.
• The oil should be almost level with the bottom of
• 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
GENERAL CARE
ning the control valve anticlockwise.
the oil filler hole.
wipe up any spillage.
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
ponents, replacements are
com
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.
6
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Jack will not lift
the rated load
Jack lower when
under load
Pump feels
Spongy
Jack will not lift
full height
Jack will not
lower completely
If any of these remedies fail to restore your jack, consult your CLARKE dealer
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
Release valve not fully
closed
Air in the system Purge the system as on page 6
Low oil level See ‘Checking the Oil Level‘on p 6
Air in the system Purge the system as on page 6
Low oil level See ‘Checking the Oil Level‘on p 6
Air in the system Purge the system as on p 6
Return spring may be
faulty
Turn the release knob fully clockwise
Return to your dealer for repair
DECLARATIONS OF CONFORMITY
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COMPONENT PARTS - GENERAL ASSEMBLY
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COMPONENT PARTS-GENERAL ASSEMBLY
No Description No Description
1 Front wheel 22 n/a
2 Circlip 20mm 23 Locating screw
3 Washer M16 24 Idler roller
4 Nut M16 Chassis frame 25 Washer 12 mm
5 Rear castor assembly 26 Upper handle
6 Lifting arm shaft 27 Locating pin
7 Circlip 25mm Screw M5x12 28 Handle sleeve
8 Washer M10 29 Lower handle
9 Bolt 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
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.
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COMPONENT PARTS - HYDRAULIC PARTS
No Description No Description
1 Snap ring 27 Steel ball 6dia G16
2 O-ring 37.5 diax2.65# 28 O-ring 8 dia x 1.8#
3 Retaining ring 29 Oil drain valve stem
4 O-ring 29.8 dia x 3.1# 30 Copper washer#
5 Piston rod 31 Hydraulic valve body
6 Retaining ring 32 O-ring B#
7 Piston rod head 33 Nylon gasket#
8 Washer# 34 Pump core A
9 O-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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COMPONENT PARTS - HYDRAULIC PARTS
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