Clarke CTJ3GLS Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC 0721 -rev 2
3 TONNE HEAVY DUTY LONG CHASSIS
TROLLEY JACK
MODEL NO: CTJ3GLS
PART NO: 7623085

2
INTRODUCTION
Thank you for purchasing this CLARKE 3 Tonne Heavy Duty Long Chassis Trolley
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 CTJ3GLS
Part number 7623085
Length (not including handle): 1305 mm
Width 322 mm
Height 305 mm
Height of lifting cup (minimum) 130 mm
Height of lifting cup (maximum) 600 mm
Weight 65 kg
Rated Load 3 tonne

3
SAFETY PRECAUTIONS
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 solid 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, (See “Specifications”
on page 2.)
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. Such maintenance and repair must be carried out by qualified
persons.
15. Do not make any adjustments or modifications to this jack or any valves on
the jack.
WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS
INSTRUCTION BOOK;
WARNING: THE OPERATOR SHALL BE PROVIDED WITH ALL NECESSARY
INFORMATION ABOUT TRAINING AND ABOUT PUMPING AND
TRANSLATING FORCES.

4
OVERVIEW

5
BEFORE USE
ASSEMBLY
1. Insert the shaft of the handle into
the handle socket.
2. Tighten the clamp bolt shown to
lock the handle in position.
LOCKING/RELEASING THE HANDLE
To lock the handle in the upright
position, put the handle lock in to the
‘Locked’ position as shown.

6
CHECK OIL LEVEL
1. With the handle in a vertical
position, turn the knob on the
handle counterclockwise to open
the release valve.
2. Push the saddle to its lowest
position.
3. Loosen the two bolts shown and
lift off the cover.
4. Lever off the filler cap using a flat
screwdriver.
• Oil must be up to the edge of
the hole.
5. Top up if necessary with Clarke
hydraulic oil available from your
local Clarke dealer (part number
3050830).

7
BLEED THE HYDRAULIC SYSTEM
During transportation, air can get into the hydraulic system which will cause
the ram to feel "spongy".
1. Turn the knob on the handle
counterclockwise to open the
release valve.
2. Pump the foot pedal 10 times to
purge the air from the hydraulic
system.
• The jack is now ready to use.
POSITIONING THE JACK
• Make sure that the load is stable and on solid level ground.
• Use suitable wheel chocks to stop the vehicle from moving.
1. Put the handle lock in to the
‘Locked’ position as shown.
2. Turn the knob on the handle
counterclockwise to open the
release valve.
3. Put the saddle directly below the
lifting point of the vehicle (see the
manufacturers handbook for the
locations).
• Make sure that there is no
obstruction that will prevent a clean lift.
• Make sure that all personnel are in a safe position before you lift the
vehicle.

8
OPERATION
TO LIFT
1. Turn the knob on the handle clockwise to close the release valve.
2. Put the handle lock in to the
‘Unlocked’ position as shown.
3. Operate the jack by pumping the
jack handle or foot pedal.
• Make sure that the saddle is in
full contact with the lifting point
and that there is nothing that
will prevent a clean lift.
4. Put axle stands below the support
points on the vehicle.
• Make sure that the axle stand is centred below the support point
and are stable before full weight of the vehicle is taken on it.
• Make sure that the axle stands are in good condition and that they
can hold the load.
• Ensure that the axle stands cannot move when supporting the load.
• DO NOT jerk the handle, make sure that it lowers slowly and in a
controlled manner on to the axle stands
TO LOWER
1. Lift the vehicle to remove the weight from any supports.
2. Remove the axle stands or other supports from below the vehicle.
3. SLOWLY turn the knob on the handle counterclockwise to open the release
valve.
NOTE: This operation must be done very slowly and in full control.
DO NOT let the load lower suddenly as this could damage
internal components.
4. Remove the jack from below the vehicle.
NOTE: The jack can move slightly during operation. It is important that
the area is clean and free from all debris.

9
MAINTENANCE
1. When the jack is not in use, keep the ram fully lowered and the release
valve closed.
2. Keep the jack clean and apply lubricating oil to all pivot points every three
months.
3. Frequently check oil level. For procedure See “Check Oil Level” on page 6.
4. Check the pump piston and piston rod periodically for signs of corrosion.
Clean exposed areas with a clean oiled cloth.
5. Change the oil once a year as follows.
CHANGING THE OIL
1. Lower the saddle fully.
2. Loosen the two cover screws and
lift off the cover.
3. Lever off the filler plug using a flat
screwdriver.
4. Lay the jack on its side to drain the
oil into a suitable container.
5. Dispose of the oil in accordance
with local regulations.
6. Fill with Clarke hydraulic oil,
available from your local Clarke
dealer.
• Oil must be up to the edge of the hole.
7. Replace the oil filler cap.
STORAGE
1. Store in a dry 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.

10
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Jack will not lift
the rated load
Low oil level See “Changing the Oil” on page 9.
Release valve not
closed
Turn the release knob fully clockwise
Air in the hydraulic
system
Bleed the system. See page 7
Jack lower when
under load
Release valve not
fully closed
Turn the release knob fully clockwise
Air in the hydraulic
system
Bleed the system. See page 7
Pump feels
Spongy
Low oil level See “Changing the Oil” on page 9.
Air in the hydraulic
system
Bleed the system. See page 7
Handle raises or
flies back under
load
Air in the hydraulic
system
Bleed the system. See page 7
Jack will not lift
full height
Low oil level See “Changing the Oil” on page 9.
Air in the hydraulic
system
Bleed the system. See page 7
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
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]