Clarke CTJ 3QLGB, 7621000 User guide

3 TONNE TROLLEY JACK
MODEL NO: CTJ3QLGB
PART NO: 7621000
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL1021
INTRODUCTION
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 CTJ3QLGB
Length (not including handle): 616 mm
Width 360 mm
Overall Height (not including handle): 300 mm
Height of Saddle from Floor (min. - max.) 135 mm - 510 mm
Weight 36.2 kg
Rated Load 3 tonne (3000kg)
Pump Oil Capacity 0.23 L
Number of Strokes to Max. Height Handle Only: 22
With Foot Pedal: 10
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. ALWAYS wear protective footwear when using a trolley jack.
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.
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 adjust any valves.
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UNPACKING AND ASSEMBLY
1. Connect the two halves of the Operating Handle and secure with the locking pin.
2. Remove the packing/storage clip shown.
NOTE: DO NOT dispose of packing/
storage clip, as this is needed for access to the oil plug, see page 7.
3. Loosen the locating screw from the rear of the handle housing shown and insert the handle into the housing, ensuring the square drive on the end of the handle, engages fully with the square spigot within the housing.
4. Tighten the locating screw.
5. Place the foot pedal on the socket located on the side of the jack and tighten the locking bolt (M5 x 12mm).
NOTE: The foot pedal can be used
with the handle to pump up the jack.It will give you approximately twice the rise height per pump than the handle alone.
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SAFETY SYMBOLS
Always read manual fully before use.
Always chock wheels
Never use a single axle stand and jack to support the vehicle
Always wear protective footwear
Always lift from the central jacking point (See vehicle manual for location)
Never support the vehicle on 4 axle stands
FIRST TIME OPERATION & 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 handle counter-clockwise, relieving the pressure inside the jack.
2. Pump the handle several strokes to purge air from the system.
3. Turn the control handle clockwise and pump to raise the jack to its full height. Pump the handle again several full strokes.
4. Test the jack and if efficiency is still low, repeat the above procedure with the oil filler plug loosened. Check the oil level as described under Maintenance section on page7.
5. The jack is now ready to use.
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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 SHOULD 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. To ensure safe lifting, position the jack at a 90 under the appropriate jacking point.
• Consult the vehicle handbook to determine suitable jacking points.
3. Twist the handle clockwise until it stops to close the control valve.
4. Pump the handle to raise the saddle is in contact with 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. Continue pumping the handle until the vehicle is at the required height.
CAUTION: Observe the vehicle carefully during the lifting operation.
The jack should move in the direction of the vehicle during lifting. Should this not be the case, there is a strong possibility that the vehicle will slide off the jack.
7. Position axle stands directly beneath suitable supporting points on the vehicle and very gently twist the handle anti-clockwise.
o
angle to the vehicle and
8. 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.
9. 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.
10. To stop it lowering at any point, turn the handle clockwise again. Always avoid a rapid descent by turning the handle slowly.
11. Carefully lower the vehicle onto the axle stand, checking constantly, preferably with an assistant, that the vehicles jacking point rests snugly and
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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.
12. 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 handle and attach the packing/storage clip.
3. Remove the oil 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 oil plug.
5. Dispose of old/spilled oil appropriately and wipe up any spillage.
GENERAL CARE
1. Periodically lubricate the hinges, front wheels & rear castors with light oil.
2. Store in a dry location. with the ram fully retracted.
3. In the event of damage or broken components DO NOT USE, 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.
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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.
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
The lifting arm won’t raise when pumping under load.
The lifting arm is sinking under load.
The lifting arm can’t be lowered.
Check whether the drain value is fully closed.
Low oil level in the pump.
As Above Follow the instructions provided for
The tension spring for the lifting arm has unhooked or broken.
Close it by rotating the handle clockwise.
Check the oil level by placing the trolley jack in a horizontal position.
Top up the hydraulic oil and purge the hydraulic system - See “Checking and Maintaining the Oil Level” section on page 7.
previous problem. Should this still not eliminate the fault, the trolley jack needs to be repaired by an authorised repairer.
Re-hook the spring or replace the broken spring with an equivalent new spring.
The trolley jack presumably needs lubricating.
Too much oil in the hydraulic system.
If any of these remedies fail to restore your jack, consult your CLARKE dealer.
All moving parts must be cleaned and lubricated or greased (see Instructions for use). IMPORTANT: The rods of the pumping and lifting cylinder should NEVER be lubricated or greased.
Screw out the drain valve and drain out the excess oil - See “Checking and Maintaining the Oil Level” section on page 7.
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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 26 Handle Cover
2 Lifting Arm Assembly 27 Shoulder Bolt M18 x 66.5mm
3 C-Clip Ø18mm 28 Torsion Spring
4 Right Frame Assembly 29 Handle Socket
5 Shaft for Front Wheel 30 Handle Socket Screw M10 x
19mm
6 Front Wheel 31 Washer M8
7 Side-mount External Retaining
Ring Ø15mm
8 Connected rod 33 Cotter Pin Ø2 x 16mm
9Left Frame Assembly 34Spur Gear
10 Spring Washer M8 35 Spring Washer M10
11 Nut M8 36 Nut M10
12 Connecting Rod Pintle 37 Pump Plunger Pin
13 Washer M16 38 Power Unit Assembly
14 Spring Washer M16 39 Oil Plug
15 Nut M16 40 Helical Gear
16 Rear Caster Assembly M12 41 Coupling Connector
17 Back Shaft 42 Cotter Pin Ø4 x 45mm
18 Spring Washer M12 43 C-Clip Ø30mm
19 Socket Head Cap Screw M12 x
25mm
32 Shaft for Spur Gear
44 Return Spring
20 Washer M18 45 Foot Pedal Assembly
21 Spring Washer M18 46 Hex Bolt M5 x 12mm
22 Shoulder Bolt M18 x 35.5mm 47 Spring Washer M5
23 Nut M12 48 Washer M5
24 Handle Assembly 49 Seal Kit
25 Handle Lock Pin
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