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3. AsseMBlY iNstRUctioNs
use the Parts List diagram in conjunction with the following instructions to assist in assembly.
WARNiNG! Failure to assemble the jack correctly may result in serious damage and/or personal injury.
3.1.
Attach a castor (104) to each of the legs (101) with screws (105), washers (106) and nuts (107).
3.2.
Attach legs to hydraulic unit (001) using screws (103) and washers (102). Before finally tightening screws ensure that all four castors
are
on the ground and the hydraulic unit is vertical.
3.3.
Attach the handle (014) to the hydraulic unit using screws (013).
3.4.
Attach saddle assembly to upper end of hydraulic unit and locate with screw (204).
3.5.
Attach saddle plate (203) to saddle with pin (207) and snap rings (208).
3.6.
slide bearing (212) onto end of adjuster (209) and fit end of adjuster through pin (211) in head plate. fit bearing (212) and nut (213) to
end of adjuster.
3.7.
Assemble saddle brackets (215) to saddle plate using screws (216), washers (217) and nuts (218).
3.8.
fit restraint chain brackets (219 and 220 - 2 off each) and chains.
4. pRe-Use cHecK list
WARNiNG! DO NOT use the jack if any suspect part is found, or if you believe the jack to have been subjected to abnormal
load or shock. Immediately remove from service and contact your authorised service agent.
iMpoRtANt: Before eAcH use, check that jack is in sound working order. Use the following list to form an habitual pre-check
procedure. check that items are not: broken, cracked, bent, malfunctioning, distorted, worn, loose, damage to welds, leaking, dirty,
noisy or missing.
1.. . . . . saddle attachments
2.. . . . . saddle base
3.. . . . . saddle tilt controls
4.. . . . . tilt mechanism
5.. . . . . piston rod
iMpoRtANt:
BeFoRe FiRst UsiNG JAcK pURGe AiR FRoM tHe HYDRAUlic ciRcUit.
Before using the jack for the first time, purge the hydraulic circuit, in order to eliminate any air that may have
accumulated in the system during transit, as follows:
1.
remove transit screw (fig.1.016) and replace with attached air bleed screw (017). retain transit screw
for future use.
2.
With ram fully retracted depress and hold down release pedal (020), then pump foot pedal (002) for
about 20 strokes (assistance will be required).
3.
If jack does not operate correctly after this then raise ram as far as possible and loosen bleed screw
(053) in top cylinder nut. Push ram down, to expel any air, until oil appears from bleed screw. tighten
screw.
5. opeRAtiNG iNstRUctioNs
5.1.
sADDle tilt MecHANisM
Adjusting the pitch and tilt of saddle will assist you to support and transport the transmission
safely. the saddle (fig.2. A) may be tilted left or right 12° by turning knob 'B' and forward or
backward 40+° by turning 'c'. the saddle brackets 'D' can be adjusted, on slotted holes, to give
a saddle width from 225 to 330mm.
5.2.
positioNiNG JAcK BeNeAtH loAD
WARNiNG! Ensure that you prepare vehicle correctly before attempting to use the jack.
WARNiNG! Before use ensure that you read, understand and apply Section 1 safety
instructions.
Before use ensure that the transmission weight and size do not exceed the capacity of the jack.
5.2.1. Ensure that the vehicle from which the gearbox is to be removed is correctly positioned, raised
and locked on an appropriate lift system.
5.2.2. Ensure that there are no other persons around or under the vehicle.
5.2.3. Ensure that the saddle is in the lowest position and use handle (014) to move and centrally position the jack beneath the gearbox.
5.2.4. check that the release pedal is fully closed, and pump foot pedal to raise saddle to the load.
5.2.5. When the saddle is just beneath transmission re-adjust alignment if necessary to centralise saddle.
5.2.6. Position so that the load weight will be equally distributed on saddle, and adjust pitch and tilt controls (fig. 2) to suit gearbox.
5.2.7. Position, adjust and tighten corner support brackets and secure load.
WARNiNG! Never put transmission on the saddle by lowering the vehicle. Always raise jack to transmission.
5.3.
loWeRiNG tHe loAD
WARNiNG! ensure that the load is central and stable on the jack saddle before attempting to lower.
5.3.1. sloWlY depress the release pedal (fig. 1. 020) to GENTLY lower the saddle to minimum height before attempting to transport the
load.
iMpoRtANt: speed of lowering is controlled by amount you depress the pedal. the more the pedal is depressed the more rapid the
saddle descent. Ensure that the descent is slow and controlled to avoid the risk of sudden dropping.
6.. . . . . Handle
7.. . . . . cylinder/Hydraulic unit
8.. . . . . stopper rings and cotter pins
9.. . . . . All nuts and bolts
10.. . . . All seals
Original Language Version
11.. . . . Jack main frame/legs
12.. . . . pump handle and/or foot pump
13.. . . . swivel castor wheels
14.. . . . chains, hooks & pins
fig. 2
800GtA.V2
fig. 1
Issue: 2 - 23/10/09
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