Clarke CTJ3QLGB Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL1021
3 TONNE TROLLEY JACK
MODEL NO: CTJ3QLGB
PART NO: 7621000

2
INTRODUCTION
Thank you for purchasing this CLARKE 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.
SPECIFICATIONS
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.
Model number CTJ3QLGB
Length (not including handle): 616 mm
Width 360 mm
Overall Height (not including handle): 300 mm
Height of Saddle from Floor (min. - max.) 135 mm - 510 mm
Weight 36.2 kg
Rated Load 3 tonne (3000kg)
Pump Oil Capacity 0.23 L
Number of Strokes to Max. Height Handle Only: 22
With Foot Pedal: 10

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SAFETY PRECAUTIONS
1. ALWAYS wear protective footwear when using a trolley jack.
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. 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 by suitably qualified persons.
15. DO NOT make any modifications to this jack or adjust any valves.
WARNING: THE OPERATOR MUST FOLLOW ALL INSTRUCTIONS WITHIN THIS
INSTRUCTION BOOKLET

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UNPACKING AND ASSEMBLY
1. Connect the two halves of the
Operating Handle and secure
with the locking pin.
2. Remove the packing/storage clip
shown.
NOTE: DO NOT dispose of packing/
storage clip, as this is
needed for access to the oil
plug, see page 7.
3. Loosen the locating screw from
the rear of the handle housing
shown and insert the handle into
the housing, ensuring the square
drive on the end of the handle,
engages fully with the square
spigot within the housing.
4. Tighten the locating screw.
5. Place the foot pedal on the
socket located on the side of the
jack and tighten the locking bolt
(M5 x 12mm).
NOTE: The foot pedal can be used
with the handle to pump up
the jack.It will give you
approximately twice the rise
height per pump than the
handle alone.

5
SAFETY SYMBOLS
FIRST TIME OPERATION & 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 handle counter-clockwise, relieving the pressure inside the
jack.
2. Pump the handle several strokes to purge air from the system.
3. Turn the control handle clockwise and pump to 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 section on page7.
5. The jack is now ready to use.
Always read
manual fully
before use.
Always wear
protective
footwear
Always chock
wheels
Always lift from
the central
jacking point (See
vehicle
manual for
location)
Never use a single
axle stand and
jack to support
the vehicle
Never support the
vehicle on 4 axle
stands

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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. To ensure safe lifting, position the jack at a 90oangle to the vehicle and
under the appropriate jacking point.
• Consult the vehicle handbook to determine suitable jacking points.
3. Twist the handle clockwise until it stops to close the control valve.
4. Pump the handle to raise the saddle is in contact with 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. Continue pumping the handle until the vehicle is at the required height.
•CAUTION: Observe the vehicle carefully during the lifting operation.
The jack should move in the direction of the vehicle during lifting.
Should this not be the case, there is a strong possibility that the
vehicle will slide off the jack.
7. Position axle stands directly beneath suitable supporting points on the
vehicle and very gently twist the handle anti-clockwise.
8. 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.
9. 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.
10. To stop it lowering at any point, turn the handle clockwise again. Always
avoid a rapid descent by turning the handle slowly.
11. Carefully lower the vehicle onto the axle stand, checking constantly,
preferably with an assistant, that the vehicles jacking point rests snugly and
WARNING: NEVER WORK ON THE VEHICLE WHEN SUPPORTED ONLY BY A
JACK. THIS IS HIGHLY DANGEROUS. THE VEHICLE SHOULD BE SUPPORTED
ON AXLE STANDS OR SUITABLE SUPPORTS, BENEATH THE CORRECT
JACKING/SUPPORT POINTS.

7
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.
12. Completely remove the jack from the vehicle.
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 handle and attach the
packing/storage clip.
3. Remove the oil 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).
4. Purge any air from the system and replace the oil plug.
5. 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.
2. Store in a dry location. with the ram fully retracted.
3. In the event of damage or broken components DO NOT USE, 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.

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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.
TROUBLESHOOTING
If any of these remedies fail to restore your jack, consult your CLARKE dealer.
PROBLEM CAUSE SOLUTION
The lifting arm
won’t raise when
pumping under
load.
Check whether the
drain value is fully
closed.
Close it by rotating the handle
clockwise.
Low oil level in the
pump.
Check the oil level by placing the
trolley jack in a horizontal position.
Top up the hydraulic oil and purge
the hydraulic system - See “Checking
and Maintaining the Oil Level”
section on page 7.
The lifting arm is
sinking under
load.
As Above Follow the instructions provided for
previous problem. Should this still not
eliminate the fault, the trolley jack
needs to be repaired by an
authorised repairer.
The lifting arm
can’t be lowered.
The tension spring
for the lifting arm
has unhooked or
broken.
Re-hook the spring or replace the
broken spring with an equivalent new
spring.
The trolley jack
presumably needs
lubricating.
All moving parts must be cleaned
and lubricated or greased (see
Instructions for use). IMPORTANT: The
rods of the pumping and lifting
cylinder should NEVER be lubricated
or greased.
Too much oil in the
hydraulic system.
Screw out the drain valve and drain
out the excess oil - See “Checking
and Maintaining the Oil Level”
section on page 7.

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DECLARATION OF CONFORMITY

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COMPONENT PARTS - GENERAL ASSEMBLY

11
COMPONENT PARTS - GENERAL ASSEMBLY
No Description No Description
1 Saddle 26 Handle Cover
2 Lifting Arm Assembly 27 Shoulder Bolt M18 x 66.5mm
3 C-Clip Ø18mm 28 Torsion Spring
4 Right Frame Assembly 29 Handle Socket
5 Shaft for Front Wheel 30 Handle Socket Screw M10 x
19mm
6 Front Wheel 31 Washer M8
7 Side-mount External Retaining
Ring Ø15mm
32 Shaft for Spur Gear
8 Connected rod 33 Cotter Pin Ø2 x 16mm
9LeftFrameAssembly 34SpurGear
10 Spring Washer M8 35 Spring Washer M10
11 Nut M8 36 Nut M10
12 Connecting Rod Pintle 37 Pump Plunger Pin
13 Washer M16 38 Power Unit Assembly
14 Spring Washer M16 39 Oil Plug
15 Nut M16 40 Helical Gear
16 Rear Caster Assembly M12 41 Coupling Connector
17 Back Shaft 42 Cotter Pin Ø4 x 45mm
18 Spring Washer M12 43 C-Clip Ø30mm
19 Socket Head Cap Screw M12 x
25mm
44 Return Spring
20 Washer M18 45 Foot Pedal Assembly
21 Spring Washer M18 46 Hex Bolt M5 x 12mm
22 Shoulder Bolt M18 x 35.5mm 47 Spring Washer M5
23 Nut M12 48 Washer M5
24 Handle Assembly 49 Seal Kit
25 Handle Lock Pin