Related Manuals for Jacka Industries JackaJay Kit
Summary of Contents for Jacka Industries JackaJay Kit
- Page 1 Installation Guide Version 5.0 © 2018 Jacka Industries Pty Ltd. All rights reserved.
- Page 2 Jacka Industries Pty Ltd be liable for any damages whatsoever including direct, indirect, incidental, consequential, loss of business profits or special damages, even if Jacka Industries Pty Ltd or its suppliers have been advised of the possibility of such damages.
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Page 3: Table Of Contents
Preparation Main Tasks and Installation Steps Enviroment Equipment Installation Setup Open JackaJay kit and read all User and Installation guides. Identify a flat and level location Expose manual winch system Set roof height and install corner supports Remove the manual winch system... -
Page 4: Introduction
The JackaJay lift system and all installation related information and operational directives are only applicable for wind-up related camper trailers. Please contact Jacka Industries for approval and directives for any application of the JackaJay product outside of this document’s guideline. -
Page 5: Reference Information
Points of Contact For all queries, please contact Jacka Industries Pty Ltd or any authorised distributor within your area. Warranty Recreational warranty commences 5 years from purchase date. -
Page 6: Preparation
JackaJay lift system. It is important that you have all the necessary components in the JackaJay kit, all required associated tools and equipment, and fully understand all aspects and CHECKS that MUST be conducted during the installation process. -
Page 7: Equipment
This will ensure they are not obstacles when moving greased and soiled components around the van. Equipment During installation, it is required that JackaJay kit componentry must be sourced prior to installation. Please see the list below in this section. 2.3.1 Tools •... - Page 8 JackaJay INSTALLATION GUIDE 2.3.2.2 ELECTRICAL • 1 x Rear Harness (Long with Large Plug) • 1 x Front Harness (Short with large Plug) • 1 x Power Harness (Smaller Plug) • 1 x Jumper Harness (Smaller plug and alligator clamps) •...
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Page 9: Installation Setup
Swan Outback. Open JackaJay kit and read all User and Installation guides. Open the JackaJay kit, layout all the components and understand the location and use for each piece. This will assist you in ensuring that no pieces are missing. This guide will show you all that is required. -
Page 10: Set Roof Height And Install Corner Supports
JackaJay INSTALLATION GUIDE IMPORTANT NOTE: The manual winch system lift cables run along the driver’s side wall inside cabinets and behind the refrigerator and / or oven. Only remove these appliances if you really need to. Any Gas Appliances must be disconnected and reconnected by an authorised certified technician. - Page 11 JackaJay INSTALLATION GUIDE Position framing timbers against each telescoping leg at each corner, and use framing shims to adjust supported roof height, if required. The timbers should be a tight fit, but NOT lifting the roof. Secure the timbers to the telescopic masts with long cable ties / rope / heavy duty duct tape, etc Ensure that the timber corner supports are firmly secured with cable ties or another suitable method.
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Page 12: Remove The Manual Winch System
JackaJay INSTALLATION GUIDE Remove the manual winch system. Please be aware that the removal of the existing winch system is half of the job! Take your time. Remove any panelling that you need to and note down what you have done. Keep in mind, if you can remove the old winch components, you can install the JackaJay components. - Page 13 JackaJay INSTALLATION GUIDE Remove external vent cover from behind the fridge on the side of the van. In some models the old lift cables lay inside a 30mm diameter plastic tube, the JackaJay rear electric harness will feed through this tube to the rear motors.
- Page 14 JackaJay INSTALLATION GUIDE Do a thorough clean up of the whole area where the old manual lift system was installed. Generally, there is accumulated dirt and swarf from modifications / original build. If the Camper Trailer is an older model check for rot in the floor. If required, during the JackaJay installation use metal screws to drill into steel chassis or backing plate.
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Page 15: Installation Of Jackajay Lift System
JackaJay INSTALLATION GUIDE Installation of JackaJay lift system JackaJay COLOUR - CODING POSITIONS It is CRUCIAL that the correct colour Motor Assembly and Tube Assembly are mounted in the instructed positions. Motor Assembly and Tube Assembly slide together with matching colours. Wiring Harnesses have matching colour tags fitted to match the corresponding Motor Assemblies and Tube Assemblies, i.e. -
Page 16: Flexible Pushrods
JackaJay INSTALLATION GUIDE Flexible pushrods Locate the NEW 4 x Flexible Springs/Pushrods, they will be pre-greased. Remove them from the plastic sleeve one at a time as required. Locate the dome headed end of the Spring, slide it into the corner elbow, and feed up until it stops. - Page 17 JackaJay INSTALLATION GUIDE Before installing the drive tube assemblies, visually inspect the position of the bronze drive block. The bronze drive block is found at the end of the drive tube where the micro switch is mounted. The bronze drive block MUST be 1-2mm away from the small roller mounted on the arm of the microswitch.
- Page 18 JackaJay INSTALLATION GUIDE ENSURE that the drive shaft is fully located into the coupler between the Motor drive shaft and the Drive Tube drive shaft. APPLY pressure on them and tighten the grub screws with a 2.5mm Allen Key. Ensure that BOTH grub screws are firmly tightened;...
- Page 19 JackaJay INSTALLATION GUIDE Once all the above points have been completed, proceed to the next corner assembly, until all 4 corner assemblies are in position. IMPORTANT NOTE: Once all 4 corner assemblies are in place, you MUST ensure that the Drive tubes can be placed as straight as possible with at least 5mm between opposing corner assemblies.
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Page 20: Fixing Down Of All Components
If there is any indication of Rot in the floor or inadequate material to secure to, conduct repairs or upgrades. This is the responsibility of the installer. Multiple means of fixings are supplied with the JackaJay kit. 4.4.1 FIXING CORNER ELBOW Do one corner at a time. - Page 21 JackaJay INSTALLATION GUIDE VERY IMPORTANT: Apply pressure to the end plate of the motor assembly, i.e., pushing the motor and tube assembly with firm pressure towards the corner elbow, so that the lift mechanism has pressure on it. As if you are trying to lift the roof of the camper yourself. IF YOU FAIL TO APPLY PRESSURE, WHEN YOU FIX THE LIFT MECHANISM DOWN TO THE FLOOR, THE ROOF WILL DROP UNTIL IT FINDS THE PRESSURE.
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Page 22: Installing Controller & Harnesses
JackaJay INSTALLATION GUIDE You MUST have all 4 x lift mechanism securely fixed to the floor and conduct the following checks: Are the square drive tubes straight? Are flexible pushrods entering the corner elbow in the middle? Are the square drive tubes secured by their mount points near the limit switch? Is there a minimum 5mm gap between opposing tubes assemblies? - Page 23 JackaJay INSTALLATION GUIDE The JackaJay controller MUST be installed in a position where it is readily accessible and not obstructing STOP POINT 15 storage, so that no damage can be caused to the Tick here cable harness plugs and touch screen. 4.5.2 JackaJay Harness All color coding MUST be matched up correctly.
- Page 24 JackaJay INSTALLATION GUIDE 4.5.2.1 FRONT HARNESS – Green & Red Lay the Front Harness loosely into position. Harness plugs are labelled and have a coloured tab at each end. GREEN Attach tagged plugs to the DRIVER’S SIDE Green Motor and microswitch. VERY IMPORTANT: The Motor has a 2-pin Deutsch Plug.
- Page 25 JackaJay INSTALLATION GUIDE VERY IMPORTANT: When engaging Deutsch Plugs, you MUST push them together until you hear a light ‘click’. To disengage – gently slide back dust cover, you will see a release trigger on both sides. Depress, and disengage the plug. DO NOT pull on the cable, you MUST pull on the plug housing.
- Page 26 JackaJay INSTALLATION GUIDE YELLOW DRIVER’S SIDE REAR Motor Attach tagged plugs to the and Microswitch. BLUE PASSENGER SIDE REAR Motor Attach tagged plugs to the and Microswitch. Plug the large Rear Harness Deutsch Plug into the JackaJay controller and ensure that it is plugged into the correctly label port.
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Page 27: Installation Clean Up
JackaJay INSTALLATION GUIDE Ensure that all the last 19 STOP points have been confirmed. STOP POINT 18 Next, we supply Power to the JackaJay controller. It is a good time now to go back and double check Tick here the installation. The power source connection MUST NOT be made with the JackaJay controller turned ON. -
Page 28: Commissioning
JackaJay INSTALLATION GUIDE Commissioning Powering up the Controller Press the round power button on the face of the JackaJay controller. The touch screen will activate showing the ‘JackaJay Logo” (trademark). If the touch screen fails to activate, refer to the Troubleshooting section in JackaJay User Guide. - Page 29 JackaJay INSTALLATION GUIDE If you have an OBSTRUCTION message on one corner, please refer to the Troubleshooting Guide. Once all 4 x corners display LIFT COMPLETE, please move on. The roof is now permanently set to Upper Automatic roof height point for each corner. All the timbers MUST be slightly loose or easy to remove.
- Page 30 You have now conducted the full operation of the JackaJay lift system. If you have any issues or concerns, please refer to the Troubleshooting Guide or contact your nearest supplier or Jacka Industries Pty Ltd for direction. Replace all panels, cabinetry, and upholstery. And untie curtains.
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Page 31: Post Installation Care And Maintenance
JackaJay INSTALLATION GUIDE Post Installation Care and Maintenance The JackaJay lift system has been designed to be mostly sealed and reasonably maintenance free, with self-test and operation checks. Maintenance checks that can be conducted are as follows: Yearly Checks Ensure all electrical connections are tight and secure. Check all Deutsh plugs at the bottom of the controller and confirm they are secure and dusts covers are adequately positioned. -
Page 32: Troubleshooting
It may also have damaged an internal protection fuse. Contact Jacka Industries. Power supply plug is not Unplug the power lead from pushed in completely at the controller and reinsert it the controller. - Page 33 Tripping out on Fault additional strain on the additional strain on the system. / Obstruction during system and is stopping Contact Jacka Industries to Automatic Lift sequence, the operation. Can discuss. and all colouring and be caused by the roof...
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Page 34: Documentation Feedback
Documentation Feedback If you are reading Jacka Industries product documentation and have any queries or questions, you can submit your comments through email to enqiries@jackaindustries.com We appreciate your comments and feedback. - Page 35 Thank you from Mal & Stu and families. Happy caravaning...
- Page 36 Jacka Industries Pty Ltd – 468 Hawkesbury Rd, Winmalee, NSW, 2777– 1300 052 252 www.jackaindustries.com 468 Hawkesbury Road, Winmalee, 2777, NSW, Australia 1300 052 252 www.jackaindustries.com...