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Summary of Contents for Lippert Lonestar Jack Systems
- Page 1 Lonestar Jack Systems OEM INSTALLATION MANUAL...
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Page 2: Table Of Contents
TABLE OF CONTENTS Introduction Safety Resources Required Installation Dual-Jack 20K System Single-Jack 20K System Adding Fluid and Purging Air from the System Fluid Recommendation Adding Fluid Operating the Switch Pendant Dual-Jack Switch Pendant Single-Jack Switch Pendant Post-installation Checks Wiring Diagram Dual-Jack/1-Valve System Dual-Jack/2-Valve System Single-Jack/1-Valve System... -
Page 3: Safety
Failure to correctly follow the provided instructions may result in death, serious personal injury, severe product and/or property damage, including voiding of the Lippert limited warranty. The "WARNING" symbol above is a sign that a procedure has a safety risk involved and may cause death or serious personal injury if not performed safely and within the parameters set forth in this manual. -
Page 4: Installation
Use a 3/4" socket or wrench to install and secure two 1/2"-13 UNC partially threaded bolts (Fig. 3A) and two 1/2"-13UNC flange lock nuts (Fig. 3B) to each jack. NOTE: Lippert recommends a minimum of two bolts to secure each jack. Bolts should be no less than Grade 8 per SAE J429. - Page 5 Fig. 2 Fig. 3 Page 5 Rev: 06.12.24 CCD-0008349...
- Page 6 Connect Hydraulic Hoses NOTE: Refer to the Hydraulic Diagram for all hydraulic hose connections. Attach curbside jack's long extend hose (orange) (Fig. 4A) from the center port on the curbside jack to the extend tee fitting (Fig. 4) at the center of the roadside jack. Attach curbside jack's long retract hose (black) (Fig.
- Page 7 Fig. 5 Dry-fit and level the switch pendant (Fig. 6A) in the desired location. Fig. 6 Page 7 Rev: 06.12.24 CCD-0008349...
- Page 8 Mark the mounting hole locations at the top of the switch's mounting slot (Fig. 7A) on both sides of the pendant. Fig. 7 Level Install two #8 Phillips pan head self-drilling screws (Fig. 8A) partially into the trailer's wall. Fig. 8 Page 8 Rev: 06.12.24 CCD-0008349...
- Page 9 D. Place the switch pendant's mounting clearance holes over the pan head screws (Fig. 9). Fig. 9 Push the switch pendant flat against the trailer's wall, then carefully push down on the pendant until each mounting screw is engaged with the pendant's slot (Fig. 10A). NOTE: If necessary, use a screwdriver to adjust the mounting screw(s) to allow the pendant to sit flat against the trailer's wall.
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Page 10: Single-Jack 20K System
Connect the switch pendant's electrical cable plug (Fig. 11A) to the power unit's electrical cable receptacle (Fig. 11B). Fig. 11 Single-Jack 20K System Determine the vertical location for attaching the single-jack (Fig. 12A)—containing the hydraulic unit—to the middle mounting tube (Fig. 12B). Make sure there is a minimum 10"... - Page 11 Mark the two locations for the mounting bolts on either side of the mounting tube for the single jack (Fig. 13A). Use a 17/32" drill bit to drill two through-holes a minimum of 10" vertically apart in the mounting tube. Fig. 13 Page 11 Rev: 06.12.24 CCD-0008349...
- Page 12 1/2"-13UNC flange lock nuts (Fig. 14B) to the jack. NOTE: Lippert recommends a minimum of two bolts to secure the jack. Bolts should be no less than Grade 8 per SAE J429 and a minimum 10" vertically spaced apart.
- Page 13 Connect Hydraulic Hoses Single-jack system hydraulic hoses are pre-installed. Electrical Connections NOTE: Refer to the Wiring Diagram for all electrical connections. All electrical wiring harnesses shall be loomed and secured to prevent possible damage and installed in accordance with RVIA electrical standards. –...
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Page 14: Adding Fluid And Purging Air From The System
The hydraulic power unit must be filled with automatic transmission fluid prior to operation. Fluid Recommendation Type “A” automatic transmission fluid (ATF) is to be utilized. Lippert Components, Inc. recommends ATF with Dexron III® or Mercon V® or a blend of both. - Page 15 Remove the reservoir fill cap (Fig. 18A). Fill the reservoir to the (MAX) fill line (Fig. 18B) at the top of the reservoir. Reinstall fill cap. Fig. 18 The hydraulic power unit must be filled with automatic transmission fluid prior to operation. Go to Operating the Switch Pendant section to learn how to operate the system before cycling the jack(s).
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Page 16: Operating The Switch Pendant
The hydraulic power unit must be filled with automatic transmission fluid prior to operation. See Adding Fluid section. To use either a single- or dual-switch pendant, Lippert recommends leaving the pendant in its LOCKED/OFF position (Figs.19A and 20A), remove it from its stored position and only activate (turn on) (Figs. 19B and 20B) and operate the pendant and system while positioned outside of the trailer and jack area. -
Page 17: Single-Jack Switch Pendant
Release both switches when the trailer is either leveled, stabilized or the jacks have been completely retracted. Turn the key to the LOCK/OFF position (Fig. 19A). Return the locked switch pendant to its stored position. Fig. 19 Single-Jack Switch Pendant Before operating the jack, unlock the pendant switch (Fig. 20) to activate it. Turn the key to the ON position (Fig. -
Page 18: Post-Installation Checks
Fig. 20 Post-installation Checks • Check all fasteners for loose, damaged or missing hardware. Tighten,replace or install hardware as necessary. • Check fluid reservoir for bubble, froth or foam on top of the fluid. Refer to Purging Air from System section if necessary. -
Page 19: Wiring Diagram
Wiring Diagram Dual-Jack/1-Valve System Pendant Switch Wire Harness Pendant Valve 10 Amp (Green) Fuse 12V DC Battery (+) Hydraulic Valve Motor (White) 80-100 amp Circuit Protection 12V DC Battery (—) Ground Down (Black) (Black) Solenoid Fill Cap Page 19 Rev: 06.12.24 CCD-0008349... -
Page 20: Dual-Jack/2-Valve System
Wiring Diagram Dual-Jack/2-Valve System Pendant Switch Wire Harness Pendant Roadside 10Amp Left (Green) Curbside 12V DC Fuse Right (Orange) Battery (+) Hydraulic (White) Motor Valves 80-100 amp Circuit Protection 12V DC Battery (—) Ground Down (Black) (Black) Solenoid Page 20 Rev: 06.12.24 CCD-0008349... -
Page 21: Single-Jack/1-Valve System
Wiring Diagram Single-Jack/1-Valve System Pendant Switch Wire Harness Pendant Valve 10 Amp (Green) Fuse 12V DC Battery (+) Hydraulic Valve Motor (White) 80-100 amp Circuit Protection 12V DC Battery (—) Ground Down (Black) (Black) Solenoid Fill Cap Page 21 Rev: 06.12.24 CCD-0008349... -
Page 22: Hydraulic Diagram
Hydraulic Diagram Dual-Jack/1-Valve System Lead Jack Extend (Orange) Extend (Orange) Follow Jack Retract (Black) Retract (Black) Manifold Up/Down (Hydraulic Valve) Fill Cap Pump Reservoir Page 22 Rev: 06.12.24 CCD-0008349... -
Page 23: Dual-Jack/2-Valve System
Hydraulic Diagram Dual-Jack/2-Valve System Retract (Black) Curbside Jack Roadside Jack Extend (Orange) Roadside Retract Extend Extend Valve (Black) (Orange) Manifold Curbside (Hydraulic Valves) Extend Valve Pump Fill Cap Reservoir Page 23 Rev: 06.12.24 CCD-0008349... -
Page 24: Single-Jack/1-Valve System
Hydraulic Diagram Single-Jack/1-Valve System Drive Jack Extend (Orange) Retract (Black) Manifold Valve (Hydraulic Valve) Fill Cap Pump Reservoir Page 24 Rev: 06.12.24 CCD-0008349... - Page 25 Lippert representative has been provided. Any unauthorized use shall void any applicable warranty. The information contained in this manual is subject to change without notice and at the sole discretion of Lippert. Revised editions are available for free download from lippert.com.
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