2 TONNE GARAGE JACK Model No: CTJ2QLP PART NO:

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1 TONNE GARAGE JACK Model No: CTJQLP PART NO: 7680 OPERATING & MAINTENANCE INSTRUCTIONS GC03

2 INTRODUCTION Thank you for purchasing this CLARKE Garage Jack. Before attempting to use this product, please read this manual throughout and follow the instructions carefully. Thoroughly familiarise yourself with this product & its operation in order to ensure the safety of yourself and others around you. In doing so, you can look forward to the product giving you long and satisfactory service. GUARANTEE This product is guaranteed against faulty manufacture for a period of 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 it s intended purpose. 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. SPECIFICATION Feature Weight Dimensions (L x W x H ) without handle Specification 30 kg 680 x 340 (less wheels) x 0 mm R ated Load /000 (Tonne/kg) Min Height Max Oil of Saddle Height of Saddle Capacity 75 mm 50 mm 0.9 litre No of Strokes from Min to Max Height 6 Please note that details and specifications contained herein, are correct at the time of going to print. However, CLARKE International reserve the right to change specifications at any time without prior notice.

3 GENERAL GENERAL SAFETY PRECAUTIONS. ALWAYS read and ensure you fully understand the following precautions and the hazards associated with this product. Do not allow anyone who has not read these instructions to use the jack.. Only use this jack for its intended purpose. 3. NEVER carry out any modifications to this product. If experiencing difficulty of any kind consult your local dealer. WORK AREA. NEVER use the jack on sloping surfaces, only on level ground. The jack may move away slightly as soon as it lifts the tyre from the ground.. DO NOT start the vehicle engine with the jack in use. 3. This jack is for lifting only. DO NOT move a load using the jack as a dolly. 4. Ensure 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. Never allow children or bystanders in the area while the jack is in use. 6. NEVER work underneath a vehicle supported only by this jack. If working under a vehicle, always use axle stands designed for the purpose. 7. Ensure the jack is on a firm solid base and that there is no likelihood of it slipping when under load. 8. Ensure that all personnel are well clear of a load being raised or lowered. SERVICING & REPAIRS. Check the jack for damage before use and do not use if damaged. If in doubt, DO NOT use. Consult your local dealer.. ALWAYS use spare parts supplied by Clarke International. Using nonstandard parts could be extremely dangerous. 3. Ensure that the jack is properly maintained at all times and that no corrosion or other damage is allowed to weaken any part of it. 4. When necessary, have your jack serviced or repaired by a qualified technician using identical replacement parts. This will ensure that the safety of the jack is maintained. 5. NEVER use the jack if it has been subjected to excess load (over tonnes). The jack should be removed from service immediately and fully inspected by qualified personnel and passed as serviceable before further use. Please keep these instructions in a safe place for future reference. 3

4 UNPACKING AND ASSEMBLY. Remove the retaining clip by pressing the handle yoke downwards and pullng the clip away.. Loosen the bolt in the yoke until the lower handle can be inserted fully into the handle socket. The lower handle has a groove which should engage with the bolt once it is re-tightened. The socket in the handle will engage with the jack control valve at the base of the yoke. 3. Tighten the bolt to secure the lower handle to the jack. 4. Add the upper handle by sliding it onto the lower handle and secure with the bolt provided. Handle Yoke Securing bolt Lower Handle Groove Bolt Retaining clip 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 encounters a load (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 sign of damage. Should any be apparent, have the jack repaired by a qualified technician. WARNING! NEVER WORK ON THE VEHICLE WHEN SUPPORTED ONLY BY A JACK WHICH IS A HIGHLY DANGEROUS PRACTICE. THE VEHICLE MUST BE SUPPORTED ON AXLE STANDS OR SUITABLE SUPPORTS, BENEATH THE CORRECT JACKING/SUPPORT POINTS.. Ensure the vehicle to be raised is stable and on firm level ground with the wheels chocked.. 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. 4

5 5. Take care that no obstruction prevents a clean lift. Keep all personnel at a safe distance before lifting the vehicle. NOTE: The jack may move slightly during operation. It is important therefore, that the floor is clean and completely free from debris. 6. Position axle stands directly beneath suitable supporting points on the vehicle, and very gently twist the handle anticlockwise. This will open the control valve to lower the load onto the stands. 7. To stop it lowering at any point, turn the handle clockwise again. Always avoid a rapid descent by turning the handle slowly. 8. 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. 9. Completely remove the jack from the vehicle. PROBLEM TROUBLESHOOTING Jack will not raise to the full height. Jack will not hold the load. Jack does not lower when valve opened. Jack feels spongy when lifting. CAUSE Low oil Air O-rings level. in system. worn. Release valve not tightly closed. Release valve not seating. Air in system. Cylinder over-filled with oil. Piston or pivot arm bent or binding. Disconnected or broken return spring. Hinged components not moving freely. Air trapped in system. 5 SOLUTION Check for leakage and top up if required. Purge air from system as described in 'Maintenance'. Return to your Clarke dealer for overhaul. Check valve is closing fully. Return to your overhaul. Clarke dealer for Purge air from system as described in 'Maintenance'. Drain off excessive oil. Return to your repair. Return to your repair. Clarke dealer for Clarke dealer for Lubricate hinged joints. Purge air from system as described in 'Maintenance'.

6 MAINTENANCE PURGING AIR FROM THE SYSTEM If air bubbles become trapped inside the hydraulic system, the efficiency of the jack will be reduced. If the air cannot be dispersed just by pumping the handle with the valve open, it can be purged from the system as follows.. Turn the control valve counterclockwise, relieving the pressure within the jack, then remove the cover plate & oil filler plug. A broad-bladed screwdriver is required for the plug.. Pump the handle several times to purge air from the system. Grease Nipple 3. Replace the oil filler plug, then turn the control valve clockwise and test the jack. If efficiency is still low, check the oil level as below. CHECKING /MAINTAINING THE OIL LEVEL Cover Plate Filler Plug If the jack has been stored for long periods, check for oil leaks before use. If necessary, check the oil level as follows:. Ensure the jack is fully lowered by turning the control valve fully anticlockwise.. Remove the cover plate and the oil 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/no for litre). 3. Purge any air from the system and replace the oil filler plug. 4. Dispose of old/spilled oil appropriately and wipe up any spillage. GENERAL CARE. Periodically lubricate the hinges, front wheels & rear castors with light oil. Should the arm become stiff, apply a shot of grease to the grease nipple on the top of the lifting arm as shown above.. Store in a dry location. 3. In the event of damage or broken components, replacements are available from Clarke Parts & Service. 6

7 DECLARATION OF CONFORMITY 7

8 HYDRAULIC COMPONENT PARTS No Parts List Qty No Description Sealing Ring Copper Sealing Ring Reservoir High Pressure Piston Housing 3 Sealing Ring 3 O-Ring 0 x.65 # 4 O-Ring 9 x 3.55 # 4 Retaining Ring 5 x0.6 x.5 5 Top Nut 5 High Pressure Piston 6 Ram 6 Spring 7 Circlip 30mm 7 Dust Cover 8 Ram Base 8 Spring Base 9 Washer # 9 Retaining Ring 5mm 0 O-Ring 4.6 x 5. # 30 U-Joint Cylinder 3 Steel Ball 6mm Copper Sealing Ring 3 Screw M6 x 3 Body Casting 33 Low Pressure Piston Housing 4 Steel Ball 4mm 34 O-Ring 7 x.65 # 5 Valve Base 35 Retaining Ring x7.6 x.5 6 Spring 36 Low Pressure Piston 7 Safety Valve Screw 37 Spring 8 O-Ring 7. x Dust Cover 9 Safety Valve End Screw 3 39 Spring Base 0 Steel Ball 5mm 5 40 Retaining Ring mm Qty Items marked # are components of a separate Seal Repair Kit 8

9 HYDRAULIC COMPONENT PARTS When requesting replacement parts, please quote the prefix; HACTJQLP, followed by the number listed above. 9

10 GENERAL COMPONENT PARTS No Parts List Qty No Description Qty Circlip 8 Upper Handle Washer mm 9 Lower Handle 3 Front Wheel 0 Screw M6 x 35 4 Chassis Frame U-Joint 5 Nut M6 4 Hydraulic Unit 6 Washer M6 4 3 Return Spring 7 Screw M5x 4 4 Circlip 8 Rear Caster Assembly 5 Connecting Block 9 Screw M0 x 4 6 Split Pin A4 x 55 0 Washer M0 4 7 Circlip 5 Yoke Bolt 8 Lifting Arm Shaft Washer M8 9 Cover Plate 3 Circlip mm 30 Lifting Arm 4 Yoke Roller 3 Saddle 5 Handle Yoke 3 Saddle Screw 6 Yoke Roller Pin 33 Rubber Pad 7 Handle Set Screw 34 Handle Grip When requesting replacement parts, please quote the prefix; HACTJQLP followed by the number listed above. 0

11 GENERAL COMPONENT PARTS 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.

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