Clarke CTJ1250AC Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0122
1.25 TONNE ALUMINIUM
RACING JACK
MODEL NO: CTJ1250AC
PART NO: 7621828

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INTRODUCTION
Thank you for purchasing this CLARKE Aluminium Racing 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.
Users must read these instructions before using this product.
Keep this document in a safe place for future reference.
SPECIFICATIONS
Model number CTJ1250AC
Part number 7621828
Rated Load 1.5 tonne (1500kg)
Length (not including handle): 520 mm
Width 245 mm
Height 200 mm
Height of saddle from floor (minimum) 85 mm
Height of saddle from floor (maximum) 370 mm
Lifting height with rated load 210 to 358 mm
Saddle cup diameter 97 mm
Distance raised per stroke 75 mm
Quick lift Yes
No of strokes from min to max height 5
Weight 12kg
Pump oil capacity 120 ml
Twist lock/unlock valve Yes

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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 See “Specifications” on page.
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.
1. Use only as a lifting device, do not use as a dolly to move a load.

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UNPACKING AND ASSEMBLY
1. Loosen the thumbscrew in the
yoke until the lower handle can
be inserted fully into the handle
socket.
• The handle has a groove which
should engage with the thumb
screw once it is re-tightened.
• The socket in the handle will
engage with the jack control
valve at the base of the yoke.
2. Tighten the thumb screw to
secure the lower handle to the
jack.
3. Add the upper handle by sliding it
onto the lower handle until the
spring loaded pin clips in place.
Remove the travel retaining block by
pressing the handle yoke downwards
and pulling the block away.
• Take care of pinching fingers
between parts
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. Use the handle to turn the control
valve anti-clockwise, relieving the
pressure inside the jack.

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
2. Pump the handle several times to purge air from the system.
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.
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
reaches 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 defect. Should any be
apparent, have the jack repaired by a qualified technician.
1. Ensure the vehicle to be raised is stable and on firm level ground with the
wheels chocked. Ensure the vehicle’s handbrake is on, the engine is
switched off and the transmission is in gear or Park if automatic.
2. Ensure the vehicle will not come into contact with adjacent objects when
tilted by the jacking operation.
3. Position the jack so that the saddle is directly beneath the lifting point.
• Consult the vehicle handbook to determine suitable lifting points.
4. Ensure the jack wheels are free to move and there are no obstructions.
5. Twist the handle clockwise to close the control valve.
6. Pump the handle to raise the saddle until it reaches the jacking point, or
alternatively, pump the handle to raise the saddle.
7. 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.
8. Position suitably rated axle stands directly beneath suitable supporting
points on the vehicle and very gently twist the handle anti-clockwise to
lower the vehicle.
9. Make sure that the axle stands are in good condition and that they can
support the weight of the vehicle.
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.

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
10. Ensure that the axle stands cannot move when supporting the load and
are on firm, level ground. Use suitable wheel chocks to stop the vehicle
from moving.
11. The jack may move slightly during operation. It is important therefore, that
the floor is clean and completely free from debris.
12. DO NOT lift the vehicle if there is any chance of spillage of fuel, battery
acid or other liquids.
13. Carefully lower the vehicle onto the axle stand(s), checking constantly that
the vehicle rests snugly and cleanly on the axle stand and that the stand is
stable before the weight is taken.
NOTE: Ensure this is carried out under complete control. DO NOT allow
the load to drop suddenly as this impose undue strain on the jack
internal parts and damage the vehicle.
14. ALWAYS avoid a rapid descent by turning the handle slowly.
15. Completely remove the jack from the vehicle.
SUITABLE AXLE STANDS FOR USE WITH THIS JACK
• CAX2TFB 2 Tonne Folding Axle Stands (part no 7600020)
• CAX2TA 2 Tonne Aluminium Axle Stands (part no 7600010)
• CAX3TPB 3 Tonne Axle Stands (part no 7600066)
• CAX3TBC 3 Tonne Axle Stands (part no 7600060)
• CAX3TAB 3 Tonne Aluminium Axle Stands (part no 7600035)
• CAX6TP 6 Tonne Axle Stands (part no 7600076)
• CAX6TBC 6 Tonne Axle Stands (part no 7600070)
• CAX10TP 10 Tonne Axle Stand (part no 7600090) - sold individually
MAINTENANCE
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:
1. Ensure the jack is fully lowered by turning the control valve fully anti-
clockwise.
2. Remove the filler plug.
• The oil should be almost level with the bottom of the oil filler hole.

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
• Oil can be topped up using CLARKE Hydraulic Oil (p/n 3050830 1 litre).
Never use brake fluid instead of oil.
• Take care not to move the handle while topping up the oil.
3. Replace the filler plug and purge
any air from the system.
4. Wipe up any spillage and dispose
of old or spilled oil appropriately.
GENERAL CARE
1. Periodically lubricate the hinges,
front roller & rear castors with light
oil.
2. In the event of damage or broken
components, replacements are available from CLARKE Parts & Service.
STORAGE
Store in a dry, child-proof place with the ram 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 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.
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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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Jack will not lift
the rated load
Low oil level.
Release valve not
closed.
Air in hydraulic system.
Damage to moving
parts.
Check for leakage and top up if
required as on pages 6/ 7.
Turn the release knob fully
clockwise
Purge the system as on page 4/5.
Replace or return to your dealer
for repair.
Jack lifts but
lowers when
under load
Release valve not fully
closed
Air in hydraulic system
Dirt on valve seats or
faulty seals.
Turn the release valve fully
clockwise.
Purge the system as on page 4/5.
Replace or return to your dealer
for repair.
Pump feels
Spongy
Low oil level.
Air in hydraulic system
Check for leakage and top up if
required as on pages 6/ 7.
Purge the system as on page 4/5.
Handle raises or
flies back under
load
Air in hydraulic system. Purge the system as on page 4/5.
Jack will not lift
full height
Low oil level.
Air in hydraulic system
Check for leakage and top up if
required as on pages 6/ 7.
Purge the system as on page 4/5.
Jack will not
lower completely
Return spring damaged
Piston or frame bent.
Release valve partly
open.
Air in system.
Replace or return to your CLARKE
dealer for repair.
Check and fully open release
valve.
Open release valve and pump
handle a few times. Close valve
and re-try.
Jack will not
lower at all.
Release valve still
closed.
Check and fully open release
valve.
If any of these remedies fail to restore your jack, consult your CLARKE dealer.

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY

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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS - GENERAL ASSEMBLY

No Description No Description
1Rubber saddle pad 24 Screw M10x25
2Saddle screw 25 Rear castor assembly
3Saddle 26 Rear caster base
4Saddle base 27 Locknut M10
5Pin 28 Handle yoke pivot
6Saddle base pin 29 Return spring clip
7Circlip 13 30 Return spring
8Front roller pin 31 Circlip 19
9Side plate 32 Trunnion block
10 Split washer 10 33 Hydraulic pump unit
11 Screw M10x20 34 Split pin 4 x 26
12 Side carrying handle 35 Handle yoke roller pin
13 Screw M6x20 36 Handle yoke roller
14 Support Pivot Bar 37 Circlip 12
15 Front roller 38 Handle set screw
16 Screw M8 x 16 39 Lower handle
17 Lift arm assembly 40 Upper handle
18 Screw 41 Screw M8x20
19 Split washer 8 42 Tie rod
20 Washer 8 43 Rubber bumper
21 Locknut M16 44 Handle sleeve
22 Screw M6x20 45 Handle yoke
23 Split washer 6
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Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS - GENERAL ASSEMBLY