Clarke CTJ3000C Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1221
3 TONNE GARAGE JACK
MODEL NO: CTJ3000C
PART NO: 7623037

2
INTRODUCTION
Thank you for purchasing this CLARKE 3 Tonne 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
Model CTJ3000C
Part number 7623037
Length (not including handle): 660 mm
Width 350 mm
Cup diameter 117 mm
Height of saddle from floor (minimum) 135 mm
Height of saddle from floor (maximum) 525 mm
Distance raided per stroke 28 mm
Strokes to max height 18
Weight 36.2 kg
Rated Load 3 tonne (3000kg)
Pump oil capacity 240 ml
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.

3
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.
21. Use only as a lifting device, do not use as a dolly to move a load.

4
UNPACKING AND ASSEMBLY
1. Remove the wire retaining clip by
pressing the handle yoke down-
wards and disengaging the clip.
2. Loosen the thumb screw in the
yoke until the lower handle can
be inserted fully into the handle
socket, ensuring the square drive
on the end of the handle,
engages fully with the square
spiggot within the housing.
3. Retighten the locating thumb
screw.
4. Connect the two halves of the
operating handle and secure with
a nut and bolt.

5
PREPARING FOR USE
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 counter-clockwise, relieving the pressure inside the
jack.
2. Pump the handle several strokes to purge air from the system.
3. Turn the control valve clockwise 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.
5. The jack is now ready to use.

6
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.
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.
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, 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.
11. Completely remove the jack from 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.

7
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 anti-
clockwise.
2. 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).
3. Purge any air from the system and replace the filler plug.
4. 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.
• A grease nipple is provided for the main hinge.
2. Store in a dry location. with the ram fully retracted.
3. In the event of damage or broken components, 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.
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.

8
TROUBLESHOOTING
PROBLEM CAUSE REMEDY
Jack will not lift
the rated load
Low oil level Check for leakage and top up if
required.
Release valve not
closed
Turn the release knob fully clockwise
Air in the hydraulic
system
Purge the system as on page 5
Jack lowers when
under load
Release valve not
fully closed
Turn the release knob fully clockwise
Air in the hydraulic
system
Purge the system as on page 5
Pump feels
spongy
Low oil level Check for leakage and top up if
required.
Air in the hydraulic
system
Purge the system as on page 5
Handle raises or
flies back under
load
Air in the hydraulic
system
Purge the system as on page 5
Jack will not lift
full height
Low oil level Check for leakage and top up if
required.
Air in the hydraulic
system
Purge the system as on page 5
Jack will not
lower completely
Return spring may
be faulty.
Return to your CLARKE dealer for
repair
If any of these remedies fail to restore your jack, consult your CLARKE dealer.

9
DECLARATION OF CONFORMITY

10
COMPONENT PARTS - GENERAL ASSEMBLY

No Description No Description
1Circlip 20 mm 20 Flat Gear
2Washer 20 mm 21 Washer
3Front Wheel 22 Gear Mounting Bolt
4Frame 23 Handle Set Screw
5Support Pivot Bolt 24 Torsion Spring
6Saddle 25 Screw M6 x 35
7Lift Arm Pivot Shaft 26 Washer 8 mm
8Lift Arm 27 Split Pin 2.5 x 12
9Trunnion Block 28 Right Handle Yoke Bolt
10 Circlip 25 mm 29 Nut M16
11 Split Pin 4 x 55 30 Washer 16
12 Return Spring 31 Tie Rod
13 Hydraulic Pump Unit 32 Handle - Lower Half
14 Left handle Yoke Bolt 33 Handle - Upper Half
15 Washer 18 mm 34 Rear Caster Assembly
16 Piston Lock Pin 35 Screw M12 x 25
17 Handle Yoke 36 Washer 12
18 Nut M12 37 Rubber Handle Grip
19 Washer 10 mm
11
COMPONENT PARTS - GENERAL ASSEMBLY