2 TONNE SERVICE JACK
MODEL NO: CTJ2GLS
PART NO: 7621026
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0721 rev 1
INTRODUCTION
Thank you for purchasing this CLARKE Long Chassis Service 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
Part number 7621026
Length (not including handle): 1180 mm
Width 400 mm
Height 230 mm
Height of lifting cup (minimum) 145 mm
Height of lifting cup (maximum) 805 mm
Weight 56 kg
Rated Load 2 tonne
No of strokes from min to max height 42
Pump Oil Capacity 500 ml
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SAFETY PRECAUTIONS
WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS
INSTRUCTION MANUAL.
1. This jack is for lifting only, do not move a load using the jack as a dolly.
2. Do not use the jack 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 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 by a suitably qualified persons.
15. Do not make any modifications to the jack or adjustments to the valves.
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BEFORE USE
1. Press down hard enough on the
yoke to overcome the resistance
of the re
the packing clip shown.
2. Attach the foot pedal using the
socket-headed bolt as shown.
3. Loosen the nut and pinch bolt just
beside the hole for the handle, to
make it easier to insert the handle
into the socket.
4. Fit the handle into the handle
socket and re-tighten the nut and
pinch bolt, ensuring that the
op
engages with the square drive
spigot of the control valve.
turn spring and remove
erating socket of the handle
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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. Turn the control valve knob
counter-clockwise, relieving the
pressure inside the jack.
2. Pump the handle several times to
purge air from the system, while
pressing down on the filler plug when the air is expelled.
3. Turn the control valve clockwise
and test the jack.
4. If efficiency is still poor, check the
oil level
‘Maintenance’.
The jack is now ready to use.
as described under
OPERATION
POSITIONING THE JACK
1. Make sure that the load is stable and on firm level ground.
2. Use suitable wheel chocks to stop the vehicl
3. Turn the knob on the handle counterclockwise to open the release valve.
4. Put the saddle directly below the lifting point of the vehicle (see the vehicle
m
anufacturers handbook for the locations).
5. Make sure that there is no obstruction that will prevent a clean lift.
6. Ensure that all personnel are in a safe position
RAISING THE JACK
1. Turn the handle control fully clockwise to close the release valve.
2. Pump the handle so that the saddle rises to
5
e from moving.
before you lift the vehicle.
the jacking point.
3. 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.
5. 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.
6. Make sure that the axle stands are in good condition and that they can
hold the load.
7. Ensure that the axle stands cannot move when supporting the load.
8. Make sure to lower slowly and in a controlled manner on to the axle stands.
LOWERING THE JACK
1. Lift the vehicle to remove the weight from axle stands or other supports.
2. Remove the axle stands or other supports from below the vehicle.
3. VERY SLOWLY and CAREFULLY, turn the release valve anticlockwise - as you
do so the jack will lower. To stop it lowering turn the release valve clockwise
again.
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.
MAINTENANCE
GENERAL CARE
1. When the jack is not in use, keep fully lowered and the release valve
closed.
2. Keep the jack clean and occasionally apply lubricating oil to all pivot
points, front wheels & rear castors.
3. Periodically check the oil level.
4. Check the pump piston and piston rod periodically for signs of corrosion.
Clean exposed areas with a clean oiled cloth.
In the event of damage or broken components, replacements are available
from Clarke Parts & Service.
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:
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1. Ensure the jack is fully lowered by
turning the handle fully
anticlockwise.
2. Loosen the cover securing bolt
and lift off the cover plate.
3. Remove the filler plug, located on
top of the cylinder, using a flat
ded screwdriver.
bla
• Oil must be level with the
bot
tom of the filler hole.
4. Top up if necessary with Clarke
hydraulic
Clarke dealer (part number
3050830).
5. Dispose of old/spilled oil appropriately and wipe up any spillage.
6. Purge any air from the system and replace the filler plug.
oil available from your
STORAGE
Store in a dry place with the lifting arm 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 leakproof 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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TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Jack will not lift
the rated load
Jack lower when
under load
Pump feels
Spong
y
Handle raises or
flies back under
load
Jack will not lift
full heig
Jack will not
lower compl
ht
etely
Low oil level Top up the oil as on page 6
Release valve not
closed
Air in the hydraulic
system
Release valve not
fully c
losed
Air in the hydraulic
system
Low oil level Top up the oil as on page 6
Air in the hydraulic
system
Air in the hydraulic
system
Low oil level Top up the oil as on page 6
Air in the hydraulic
system
Return spring may
be faulty or parts
corroded.
Turn the release knob fully clockwise
Purge the system as on page 5
Turn the release knob fully clockwise
Purge the system as on page 5
Purge the system as on page 5
Purge the system as on page 5
Purge the system as on page 5
Return to your Clarke dealer for
repair
If any of these remedies fail to restore your jack, consult your Clarke dealer.
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DECLARATIONS OF CONFORMITY
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COMPONENT PARTS
10
COMPONENT PARTS
No Description No Description No Description
1 Nut M6 29 Seal 57 Pedal Link
2 Washer 30 Steel Ball 5 dia 58 Nut M10
3 Front Wheel 31 Oil Filler Plug 59 Foot Pedal
4 Bush 32 Hydraulic Ram 60 Bolt
5 Left Frame 33 Circlip 61 Torsion Shaft A
6 Front Wheel Axle 34 O-Ring Retainer 62 Bolt M10x60
7 Right Frame 35 O-Ring 63 Handle Socket
8 Tie Rod A 36 Sealing Washer 64 Washer
9 Washer 8dia 37 Piston Ring 65 Nut M10
10 Nut M8 38 Piston Rod 66 Control Rod
11 Washer 18 dia 39 Washer 67 Pin 4 dia x 20
12 Nut M18 40 O-Ring 68 Control Rod
13 Nut M12 41 Circlip 69 Handle
14 Rear Castor 42 Spring 70 Handle Sleeve
15 Nut M12 43 Steel Ball 6 dia 71 Handle Knob
16 Washer 12 dia 44 Screw M8 72 Pin 4 dia x 50
17 Tie Rod C 45 Steel Ball 4 dia 73 Tension Spring
18 Pump Plunger Pin 46 Va l v e S e at 74 Top Cover
19 Circlip 47 Spring 75 Pin 5 dia x 50
20 Pump Plunger 48 Pressure Screw 76 Lubrication Nipple
21 Dustproof Boot 49 Sealing Washer 77 Arm Pivot Shaft
22 O-Ring 50 Safety Valve Screw 78 Connecting Rod
Y-Seal 51 Washer 79 Arm Assembly
23
24 Pump Cylinder 52 Torsion Spring B 80 Arm Pin
25 Copper Washer 53 Torsion Spring A 81 Shaft
26 Spring 54 Rear Shaft 82 Saddle Base
27 Steel Ball 55 Circlip 26mm 83 Saddle
28 Release Valve Rod 56 Bolt M10 x 60
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