Clarke CTJ2001G Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
05/08
HYDRAULIC GARAGE JACK
MODEL NO: CTJ2001G
PART NO: 7623045

2
INTRODUCTION
Thank you for purchasing this CLARKE Hydraulic 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.
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.
SPECIFICATIONS
Model number CTJ2001G
Part number 7623045
Length (not including handle): 597 mm
Width 345 mm
Height of lifting cup (at rest): 131 mm
Height of lifting cup (maximum) 376 mm
Maximum lifting height from floor: 507 mm
Distance raised per stroke: 19 mm
Weight 30.6 kg
Number of full strokes to maximum height: 19
Rated Load 2 tonnes

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SAFETY PRECAUTIONS
1. This jack is for lifting only, do not move a load using the jack as a dolly
2. 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 parts replaced or consult your
CLARKE dealer.
3. Make sure that the jack is on a firm solid base, and there is no possibility of it
slipping when under load.
4. Make sure the load is taken by the full saddle and that the point of lift on
the load, is of sufficient strength to support the full load adequately.
5. Always use supports to stabilise the load once lifted. NEVER work on or
under a load unless it is fully and adequately supported. NEVER rely upon
the jack to hold the load in position.
6. Never push a load off the jack.
7. Ensure that all personnel are well clear of a load being raised, or lowered.
8. NEVER exceed the rated load for the jack (See “Specifications” on
page 2.).
9. Do not use if an oil leak is apparent. Consult your Clarke dealer.
SPARE PARTS
The following user serviceable parts are available from your Clarke dealer, or
Clarke International Parts Department.
1. Saddle
2. Castor Assembly
3. Front Wheel Assembly
4. Handle (upper and lower)

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OPERATION
Ensure the load is chocked and stable and on firm level ground
1. Position the jack so that the saddle is directly beneath the lifting point and
that there are no obstacles to prevent a clean lift, also, make sure that all
personnel are well away from the area, before raising the vehicle.
• Consult the vehicle handbook to determine the correct lifting points.
USING THE TROLLEY JACK
2. Place the two parts of the handle
together and secure together using the
10 mm bolt provided. Insert the handle
into position and secure using the small
bolt and washer on the rear of the handle
port.
3.
Bolt
Handle Port
Turn the handle, fully clockwise to close
the release valve and pump the handle
up and down to raise the saddle,
• As it meets the lifting point, make sure
that the saddle is in full contact and
that there are no obstacles to prevent
a clean lift.
4. Place axle stands or suitable supports
beneath the vehicle, before VERY GENTLY turning the handle
anticlockwise.
• This action will open the release valve to lower the load on to the
stands.
5. DO NOT jerk the handle, ensure it lowers slowly and under complete
control on to the axle stands which must be correctly positioned and take
the weight evenly.
• Ensure the axle stands are centred about the support point and
perfectly stable before full 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 components.
6. Remove the jack from the vehicle.
NOTE: The jack may move slightly during operation. It is important
therefore that the immediate vicinity is clean and completely
free from debris.

5
MAINTENANCE
BEFORE USE.
Check the hydraulic jack for damage and loose fittings. If in doubt, do not
use. Have damaged parts repaired or replaced by your CLARKE dealer.
EVERY 6 MONTHS
Oil all joints, linkages and front wheel hubs and apply grease to the caster
bearings.
ANNUALLY
Check the ram oil level see below.
STORAGE
Store in a dry place, with the ram fully retracted. 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.
CHECK THE RAM OIL LEVEL
1. Ensure the ram is fully retracted by turning the Handle fully anticlockwise.
2. Press down on the handle port (1)
and insert the wedge supplied as
shown (2).
3. Remove the oil plug (3) and top up
with CLARKE HYDRAULIC OIL. Part No.
3050830 for 1 litre, Part No. 3050835 for
5 litres.)
4. Replace filler plug and purge system
of air.....see below.
SYSTEM AIR PURGE
1. Turn handle 1 full turn anticlockwise and pump handle 8 full strokes.
2. Turn handle clockwise FULLY, and pump handle to maximum height, then
continue to pump 5 or 6 times to remove trapped air.
3. Turn handle anticlockwise and allow arm to lower and ram to fully retract.
4. Turn handle clockwise FULLY, and pump handle to maximum height to test
pump action.
NOTE: It may be necessary to perform the above action more than
once to ensure that air is totally evacuated.

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TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Jack will not
raise to the full
height
Low Oil Level See “Check the ram oil level” on page 5.
Jack will not
hold the load
Release valve not
closed
Turn the handle fully clockwise
Pump valves not
seating
Consult your CLARKE dealer
Air in ram See “System Air Purge” on page 5.
Arm will not
lower
Broken return
Spring
Consult your CLARKE dealer
Lift arm linkage
bent orbinding
Consult your CLARKE dealer
Cylinder ram
binding
Consult your CLARKE dealer
Parts Worn Consult your CLARKE dealer
Jack feels
spongy when
lifting
Air May Be
Trapped In The
System
See “System Air Purge” on page 5.
If any of these remedies fail to restore your jack, consult your Clarke dealer
For Spare Parts and Servicing, please contact your nearest dealer, or
CLARKE International, on one of the following numbers.
PARTS & SERVICE TEL: [phone]
PARTS & SERVICE FAX: [phone]

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DECLARATION OF CONFORMITY
DECLARATION OF CONFORMITY
This is an important document and should be retained.
CTJ2001G Trolley Jack DOC-RV1.doc Page 1 of 1
We declare that this product complies with the following directives:
98/37/ EC Machinery Directive.
The Following Standards have been applied to the product:
The technical documentation required to demonstrate that the products meet the
requirements of the Machinery directive has been compiled and is available for inspection
by the relevant enforcement authorities.
The CE mark was first applied in: 2005
Product Description: 2 Ton Garage Trolley Jack
Model number(s): CTJ2001G
Serial / batch Number: Current Manufacture.
Date of Issue: 09-07-08
Signed
A.C.AIKEN
Senior Manager Clarke International.