Clarke CTJ4000G User guide

QUICK LIFT HYDRAULIC JACK

MODEL NO: CTJ4000G

PART NO: 7623206

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS DL0123 - ISS 2

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

Length (not including handle): 720 mm

Width: 374 mm

Min height of saddle from floor: 105 mm

Max height of saddle from floor: 520 mm

Weight: 45.5 kg

Number of full strokes to maximum height: 6.5 strokes (63mm per stroke)

Oil Capacity: 250 ml

Rated Load: 4000 kg

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 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. Always 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 by suitably qualified persons.

15. Do not make any modifications to this jack or adjust any valves.

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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BEFORE USE

1. Press down on the actuating yoke
in order to remove the packing
block used to position the yoke
during shipping.

2. If the jack has not been recently
used inspect it for oil leaks or any
other sign of damage. If in doubt,
do not use. Should any defects be
apparent, return the jack to your
Clarke dealer.

3. Install the lower operating handle
by loosening the securing bolt
and sliding the handle into the
actuating yoke as far as it will go.
Re-tighten the securing bolt.

4. Add the upper operating handle
which is held to the lower handle
by a spring loaded plunger.

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OPERATION

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.

• The jack may move slightly during operation. It is important

therefore, that the floor is clean and completely free from debris.

2. Position the jack so that the saddle is directly beneath the lifting point
under the vehicle.

• Consult the vehicle handbook to determine the lifting points.

3. Use the operating handle to close the release valve by turning it fully
clockwise.

4. Pump the operating lever to raise the saddle to the jacking point.

5. Check that there are no obstructions to prevent a clean lift and make sure
all personnel are well clear before raising the vehicle.

6. Pump the handle to raise the vehicle to the required level.

• If, at any time, the jack feels spongy, follow the bleeding procedure

under Maintenance.

7. Position suitable, good quality axle stands directly beneath the supporting
points on the vehicle. Place the operating lever over the release valve and
very gently twist the operating lever anti-clockwise to lower the load onto
the stands.

8. Check constantly, preferably with an assistant, that the vehicle is resting
correctly on the axle stands and that the stands are stable before the
weight is taken.

• Ensure the axle stands are centred under the support point and fully

stable before full weight is taken.

9. To stop it lowering at any point, turn the operating valve clockwise again.
Always avoid a rapid descent by turning slowly.

NOTE: Ensure this is carried out under complete control. DO NOT allow

the load to drop suddenly as this could damage internal parts.

10. Completely remove the jack from the vehicle.

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MAINTENANCE

CHECKING/MAINTAINING THE OIL LEVEL

1. Inspect the hydraulic parts of the
jack for signs of oil leaks. If the oil
needs topping up proceed as
follows.

2. Ensure the jack is fully lowered by
turning the control valve fully anti­clockwise.

3. Remove the cover plate and the
oil filler plug.

• The oil should be almost level

with the bottom of the filler hole.

• Oil can be topped up using Clarke Hydraulic Oil (Part number

3050830 -1 litre).

4. Bleed any air from the system as described below and replace the filler
plug and cover plate.

5. Dispose of old/spilled oil appropriately and wipe up any spillage. 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.

6. If movement of the main arm becomes sluggish a couple of shots of
grease to the grease nipple will be beneficial.

BLEEDING AIR FROM THE HYDRAULIC RAM

1. Use the operating lever to turn the release valve anti-clockwise, relieving
pressure inside the jack.

2. Pump the operating lever several times to purge air from the hydraulic ram.

3. Turn the release valve clockwise and test the jack. If efficiency is still low,
check the oil level as described above.

4. Wipe up any oil spillage and dispose of old/spilled oil appropriately.

STORAGE

1. Store in a dry place with the ram fully retracted, where it cannot be
damaged by moisture. If stored for long periods, clean any grime from the
piston area before use.

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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

Handle raises or flies
back under load

Jack will not lift full
height

Low oil level Check for leakage and top up

if required.

Release valve not
closed

Air in the hydraulic ram Bleed air as on page 6.

Release valve not fully
closed

Air in the hydraulic ram Bleed air as on page 6.

Air in the system Bleed air as on page 6.

Air in the hydraulic ram Bleed air as on page 6.

Low oil level Check for leakage and top up

Turn release knob fully
clockwise

Turn the release knob fully
clockwise

if required.

if required.

Air in the hydraulic ram Bleed air as on page 6.

Jack will not lower
completely

If any of these remedies fail to restore your jack, consult your Clarke dealer.

Return spring may be
faulty.

Return to your Clarke dealer for
repair

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COMPONENT PARTS - GENERAL ASSEMBLY

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COMPONENT PARTS - GENERAL ASSEMBLY

No Description No Description

1 Circlip 20mm 22 Handle Yoke

2 Front Wheel Washer 23 Hydraulic Pump

3Front Wheel 24U-joint

4 Chassis 25 Return Spring

5 Rear Caster 26 Cover Plate

6 Screw M12 x 22 27 Circlip 25mm

7 Washer M12 28 Pin 4 x 55

8 Washer M16 29 Hydraulic Pump Linkage

9 Circlip 30mm 30 Lift Arm Shaft

10 Screw M5 x 12 31 Pivot Rod Bolt

11 Screw M8 x 20 32 Pivot Rod

12 Washer 8mm 33 Circlip 15mm

13 Tie Rod 34 Grease Nipple

14 Handle Yoke Bolt (RH thread) 35 Lifting Arm

15 Washer 18 36 Saddle

16 Nut M16 37 Saddle Screw

17 Washer 18 38 Handle Sleeve

18 Actuating Yoke Bolt (LH thread) 39 Handle Lock Clip

19 Handle Upper half 40 Rubber Saddle Pad

20 Handle Lower Half 41 Handle Yoke Stop Rod

21 Handle Set Screw 42 Filler plug

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DECLARATION OF CONFORMITY - UKCA

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DECLARATION OF CONFORMITY - CE

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