GARAGE JACK
MODEL NO: CTJ3000QLB
PART NO: 7623205
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL0122 - ISS 5
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 CTJ3000QLB
Part number 7623205
Length (not including handle): 630 mm
Width 328 mm
Height 165 mm
Height of saddle from floor (minimum) 130 mm
Height of saddle from floor (maximum) 465 mm
Lift range under rated load 330 - 465 mm
Weight 29.3 kg
Rated Load 3 tonne
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.
2
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 level base, and 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 suitably qualified persons.
15. Do not make any modifications to this jack or adjustment any valves.
3
UNPACKING AND ASSEMBLY
1. Remove the retaining clip by
pressing the handle yoke downwards and pulling the clip away.
2. Loosen the thumb screw 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
thumb screw once it is retightened.
• The socket in the handle will engage with the jack control valve at
the base of the yoke.
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 plunger clips in
place.
5. Place the protective rubber pad
onto the saddle.
4
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 counterclockwise, relieving the pressure
inside the jack, then remove the
cover plate.
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. If efficiency is still low,
check the oil level as described under Maintenance.
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
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. 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.
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. 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.
5
6. Position axle stands directly beneath suitable supporting points on the
vehicle and very gently twist the handle anti-clockwise.
7. This will open the control valve to lower the load onto the stands.
• Make sure that the axle stands are in good condition and that they
can hold the load.
8. Ensure that the axle stands cannot move when supporting the load. Use
suitable wheel chocks to stop the vehicle from moving.
NOTE: The jack may move slightly during operation. It is important
therefore, that the floor is clean and completely free from debris.
9. To stop it lowering at any point, turn the handle clockwise again. Always
avoid a rapid descent by turning the handle slowly.
10. 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.
11. Completely remove the jack from the vehicle.
MAINTENANCE
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 fully anticlockwise.
2. Remove the retaining screws and
lift off the cover plate.
3. Remove the filler plug.
• The oil should be almost level
with the bottom of the oil filler
hole.
• Oil can be topped up using Clarke Hydraulic Oil (p/n 3050830 1 litre).
4. Purge any air from the system and replace the filler plug and cover plate.
5. Dispose of old/spilled oil appropriately and wipe up any spillage.
6
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 Parts & 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.
7
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Jack will not lift
the rated load
Jack lowers when
under load
Pump feels
Spongy
Low oil level Check for leakage and top up if
required.
Release valve not
closed
Air in the hydraulic
system
Release valve not
fully closed
Air in the hydraulic
system
Low oil level Check for leakage and top up if
Air in the hydraulic
system
Turn the release knob fully clockwise
Purge the system as on page 6
Turn the release knob fully clockwise
Purge the system as on page 6
required.
Purge the system as on page 6
Handle raises or
flies back under
load
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.
Air in the hydraulic
system
Low oil level Check for leakage and top up if
Air in the hydraulic
system
Return spring may
be faulty.
Purge the system as on page 6
required.
Purge the system as on page 6
Return to your Clarke dealer for
repair
8
COMPONENT PARTS - RAM ASSEMBLY
9
COMPONENT PARTS - RAM ASSEMBLY
No Description No Description
1Safety Valve Body 25O-Ring
2 Sealing Ring 26 Plug
3 Spring 27 Plug Screw
4 Spring Socket 28 Spring
5 Steel Ball 29 Spring Base
6 Large Plunger 30 Ball
7Split Washer 31Valve Body
8 O-Ring 32 Filter Oil Tube
9 Primary Pump Spring Base 33 Washer
10 Primary Pump Spring Sleeve 34 O-Ring
11 Primary Pump Spring 35 Back-Up Ring
12 Primary Pump 36 Cylinder
13 Washer 37 Y-Ring
14 Joint 38 O-Ring
15 O-Ring 39 Rod Head
16 Secondary Pump Spring Base 40 Rod
17 Secondary Pump 41 T-Washer
18 Secondary Pump Spring 42 Reservoir
19 Secondary Pump 43 O-Ring
20 Back-up Ring 44 O-Ring
21 O-Ring 45 Top Cup
22 Washer 46 Plug
23 Small Plunger 47 Ball
24 Split Washer
10
COMPONENT PARTS - GENERAL ASSEMBLY
11
COMPONENT PARTS - GENERAL ASSEMBLY
No Description No Description
1 Ram Assembly 23 Nut M12
2 Universal Joint Assembly 24 Socket Head screw M12 x 25
3 Steel Ball Bearing 25 Rear Shaft
4 Oil Plug 26 Handle Socket
5 Return Spring 27 Handle Socket Screw M10 x19
6 Cotter Pin 4 x 40mm 28 C-Clip 12 mm
7 Coupling Connector 29 Contact Roller
8 C-Clip 25 mm 30 Pin
9 Supporting Shaft 31 Washer M18
10 Lifting Arm Assembly 32 Spring Washer M18
11 Pin for Saddle 33 Shoulder Bolt M18 x 54
12 Saddle 34 Cover Plate
13 C-Clip 16 mm 35 Bolt ST4.8x16mm
14 Connecting Rod Pintle 36 Handle Socket Shaft
15 Frame Assembly 37 Rubber Set
16 Front Wheel 38 Spring Washer M8
17 C-Clip 18 mm 39 Bolt M8x16
18 Washer M14 40 Handle Assembly
19 Spring Washer M14 41 Handle Lock Pin
20 Nut M14 42 Handle Cover
21 Rear Castor Assembly 43 Seal Kit TZ830023-GS.MF
22 Spring Washer M12
12
DECLARATION OF CONFORMITY - UKCA
13
DECLARATION OF CONFORMITY - CE
14
NOTES
15
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