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3.5T GARAGE JACK
MODEL NO: CTJ3500LPQLPRO
PART NO: 7623251
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0724 Rev 1
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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
Part number 7623251
Dimensions (exc handle) L x W x H 710 x 320 x 182 mm
Max height with handle fitted 1415 mm
Height of saddle from floor (minimum) 117 mm
Height of saddle from floor (maximum) 513 mm
Weight 38.5 kg
Rated Load 3.5 tonne
Approx distance raised per stroke 44 mm
Number of full strokes to maximum height Approx 9 strokes
Lowering speed under load
Pump oil capacity 270 ml
OIl grade Hydraulic oil ISO-32
less than 0.15m/s
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SAFETY PRECAUTIONS
1. Read Instruction manual before use.
2. Only trained persons should operate this lifting equipment.
3. ALWAYS ensure that sufficient light is provided and that the work area is kept
clear of unrelated items.
4. 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.
5. The jack must be maintained and repaired by suitably qualified persons.
6. DO NOT make any modifications to this jack or adjust any valves.
7. DO NOT use the jack if an oil leak is apparent. Consult your CLARKE dealer.
8. DO NOT use to lift people and ensure that no-one is in the vehicle during lifting.
9. NEVER exceed the rated load for the jack. Overloading can cause the jack to fail
resulting in personal injury.
10. Make sure that the jack is on a hard level surface, 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 lifting point on the load
is of sufficient strength to support the weight.
13. ALWAYS use axle stands to stabilise the load once lifted.
14. Consult the vehicle handbook to determine the correct lifting points.
15. Ensure the load is chocked and the handbrake applied before lifting.
16. NEVER work on or under a load unless it is fully and adequately supported.
17. NEVER rely upon the jack to hold the load in position.
18. NEVER push a load off the jack.
19. Ensure that all personnel are well clear of a load being raised or lowered.
20. Take care not to trap fingers within the moving parts.
21. Use only as a lifting device, DO NOT use as a dolly to move a load.
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UNPACKING AND ASSEMBLY
1. Remove the transit retaining clip by
springing it away from the yoke and
tie rod.
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
which will engage with the 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. Tighten the bolt 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.
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 on page 6.
The jack is now ready to use.
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OPERATION
This jack incorporates a twin piston pump with a ‘quick lift’ facility to provide rapid
raising of the unladen jack. When the jack encounters a load (the vehicle), its
distance raised per stroke reduces to provide gradual lifting
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 A 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.
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. Axle stands must be on a firm, level surface.
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 & the stand is stable before the weight is taken.
• 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.
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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 any old/spilled oil appropriately and wipe up any spillage.
GENERAL CARE
1. Occasionally lubricate the hinges,
front wheels & rear castors with light
oil to inhibit corrosion. A grease
nipple is found on the main cross
shaft for occasional introduction of
grease.
2. Store in a dry location.
3. In the event of damaged
components, replacements are
available from Clarke Parts & Service.
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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.
Handle raises or
flies back under
load
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
Air in the hydraulic
system
Air in the hydraulic
system
Turn the release knob fully clockwise
Purge the system as on page 4
Turn the release knob fully clockwise
Purge the system as on page 4
Purge the system as on page 4
Purge the system as on page 4
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 Check for leakage and top up if required.
Air in the hydraulic
system
Return spring may be
faulty.
Purge the system as on page 4
Return to your Clarke dealer for repair
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COMPONENT PARTS - RAM ASSEMBLY
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COMPONENT PARTS - RAM ASSEMBLY
No Description No Description
1 Plug Screw 25 O-Ring
2 Sealing Ring 26 Cap
3 Spring 27 Plug Screw
4 Spring Base 28 Spring
5 Steel Ball 29 Spring Base
6 Large Plunger 30 Ball
7 Split Washer 31 Base Plate
8 O-Ring 32 Filter Oil Tube
9 Spring Base 33 Copper Washer
10 Spring Barrel 34 O-Ring
11 Spring 35 Back-Up Ring
12 Pump Cylinder 36 Cylinder
13 Washer 37 Y-Ring
14 Universal Joint/Shaft 38 Back-up O-Ring
15 O-Ring 39 Piston
16 Spring Base 40 Rod
17 Spring Barrel 41 T-Washer
18 Spring 42 Reservoir
19 Pump Cylinder 43 O-Ring
20 Back-up Ring 44 O-Ring
21 O-Ring 45 Top Cup
22 Gasket 46 Oil Plug
23 Small Plunger 47 Ball
24 Back-up Ring
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COMPONENT PARTS - GENERAL ASSEMBLY
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COMPONENT PARTS - GENERAL ASSEMBLY
No Description No Description
1 Power unit assembly 23 Nut M16
2 Universal joint assembly 24 Rear castor assembly
3 Steel ball bearing 6mm 25 Spring washer M12
4 Oil plug 26 Button head socket cap screw M12
5 Return spring 27 Shoulder bolt
6 Cotter pin 4 x 45mm 28 Spring washer M12
7 Coupling connector 29 Washer M18
8 C-clip 25mm 30 Supporting shaft
9 Lifting arm assembly 31 Connecting rod pintle
10 Pin for saddle 32 Cover plate
11 Saddle 33 Screw st4.8 x 16
12 C-clip 18mm 34 Handle socket shaft
13 Front wheel 35 Rubber sleeve
14 Frame assembly 36 Handle socket
15 Washer M14 37 Handle socket screw
16 Spring washer M14 38 Pin for roller
17 Nut M14 39 Contact roller
18 C-clip 28mm 40 C-clip 12mm
19 Rear shaft 41 Flexible protective tube
20 Spring washer M8 42 Handle lock pin
21 Bolt M8 x 20 43 Handle assembly
22 Spring washer 44 Seal kit
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DECLARATION OF CONFORMITY - UKCA
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DECLARATION OF CONFORMITY - CE
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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.
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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USEFUL ITEMS FROM THE CLARKE RANGE
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