Jacka Industries JackaJay Manuale utente

Installation

Guide

Version 5.0

JackaJay INSTALLATION GUIDE

Trademarks / Patents

Jacka Industries Pty Ltd are the proprietary owners of all associated registered

trademarks and pending patents.

Patent No. - AU2020 - 050867

Trademark No. - 1998805

Disclaimer

The information provided in this document is provided “as is” without warranty of

any kind. Jacka Industries Pty Ltd disclaims all warranties, either express or implied,

including the warranties of merchantability and tness for a particular purpose. In no

event shall Jacka Industries Pty Ltd be liable for any damages whatsoever including

direct, indirect, incidental, consequential, loss of business prots or special damages,

even if Jacka Industries Pty Ltd or its suppliers have been advised of the possibility of

such damages.

Document Lifetime

Jacka Industries Pty Ltd may occasionally update online documentation between

releases of the related software. Consequently, if this document was not downloaded

recently, it may not contain the most up-to-date information. Please refer to www.

jackaindustries.com or make contact via email at [email protected] for

the most current information.

From the Web site, you may also download and refresh this document if it has been

updated, as indicated by a change in this date: 23rd of November 2021

Where to get help

Jacka Industries Pty support, product, and licensing information can be obtained as

follows.

Product information — Documentation, release notes, software updates, and

information about Jacka Industries Pty products, licensing, and service, are at Jacka

Industries Pty website at: http://www.jackaindustries.com

Technical support — Go to http://www.jackaindustries.com and contact a

representative by the provided means.

Your comments

Your suggestions will help us continue to improve the accuracy, organization, and

overall quality of the user publications. Please send your opinion of this document to:

[email protected]

If you have issues, comments, or questions about specic information or procedures,

please include the title and, if available, the part number, the revision, the page

numbers, and any other details that will help us locate the subject that you are

addressing.

JackaJay INSTALLATION GUIDE

Table of Contents

1. Introduction 5

1.1 Purpose of this document 5

1.2 Important points to be observed throughout the Guide 5

1.3 Identication 5

1.4 Reference information 6

1.5 Points of Contact 6

1.5 Warranty 6

2. Preparation 7

2.1 Main Tasks and Installation Steps 7

2.2 Enviroment 7

2.3 Equipment 8

3. Installation Setup 10

3.1 Open JackaJay kit and read all User 10

and Installation guides.

3.2 Identify a at and level location 10

3.3 Expose manual winch system 10

3.4 Set roof height and install corner supports 11

3.5 Remove the manual winch system 13

4. Installation of JACKAJAY lift system 15

4.1 Corner Bend Installation 15

4.2 Flexible pushrods 16

4.3. Coloured square drive tubes and Motor Assemblies 16

4.4 Fixing Down of all components 20

4.5 Installing controller & harnesses 22

4.6 Installation clean up 27

5. Commissioning 28

5.1 Powering up the Controller 28

6. Post Installation Care and Maintenance 31

6.1 Yearly Checks

7. Troubleshooting 32

8. Documentation Feedback 34

JackaJay INSTALLATION GUIDE

1. Introduction

1.1 Purpose of this document

1.2 Important points to be observed throughout the Guide

1.3 Identication

This Installation guide is designed to assist you with essential information to enable

you achieve a successful and fully operative JackaJay, JackaHD or ERS Electric

Lift System.

The guide covers the following areas:

Installation of the JackaJay lift system and all its related components.

Removing the manual winch lift system and upgrading to a fully automatic

electric lift system.

The guide covers the following areas:

Installation of the JackaJay lift system and all its related components.

Removing the manual winch lift system and upgrading to a fully automatic

electric lift system.

This note issues a WARNING to the installer of any impending DANGER/

EVENT that has the potential to cause injury or death if the stipulated

directives are not followed.

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.

IMPORTANT NOTE: This will emphasize important information that is

relevant to the current steps.

This box aims to emphasize the importance of conducting

a detailed check and conrmation on the works/items

that are meant for completion.

STOP POINT

Tick here

JackaJay INSTALLATION GUIDE

1.4 Reference information

1.5 Points of Contact

1.6 Warranty

Additionally, refer to the User Operation guide for JackaJay System

operation and ensure that all documents have been read and

understood prior to carrying out any installation of our products.

For all queries, please contact Jacka Industries Pty Ltd or any authorised

distributor within your area.

Recreational warranty commences 5 years from purchase date. See

Appendix A for denition.

Commercial warranty commences 1 year from purchase date. See

Appendix A for denition.

Jacka Industry Pty Ltd goods come with guarantees that cannot be

excluded under the Australian Consumers Law (ACL). You are entitled

to a replacement or refund for a major failure and compensation for

any other reasonable and foreseeable loss or damage. You are also

entitled to have the goods repaired or replaced if the goods fail to be of

acceptable quality and the failure does not amount to a major failure.

Any operation or installation of the JackaJay lift system, other than as

directed, will void any warranty claim.

Any unintended use / residue, regarding extreme conditions including but

not limited to, the submerging of any components of the camper trailer,

not including wheels, in water will void all warranty claims.

Any major water leaks or insurance claims must be registered with Jacka

Industries Pty Ltd to maintain current warranty offer.

Any warranty claim will need to be inspected by authorized personnel

and deemed claimable within Jacka Industries Pty Ltd procedures.

JackaJay INSTALLATION GUIDE

2 Preparation

2.1 Main Tasks and Installation Steps

We prepared this installation document for you as a denitive guide, to enable a

smooth removal of the manual winch system and installation of the 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. This will help you

achieve a successful installation, so you don’t void any warranty.

Section Task

1.0 Introduction

2.0 Preparation

3.0 Installation Setup – Set Roof Height and

Remove old Winch system

4.0 Install the JackaJay lift system

5.0 Test and commission the JackaJay lift system.

6.0 Post Installation care and Maintenance

7.0 Troubleshooting Guide

2.2 Environment

During the installation process, it is important to ensure that no equipment

gets wet, dropped, or damaged and all care is taken to carry out a

successful installation.

Ensure that a dry and secure site is chosen and if inclement weather

is forecast, all equipment should be kept dry. Any water damage or

indication of heavy drops will void the warranty of that component.

Ensure that all personal effects are removed from the van and placed in

a clean and dry location.

JackaJay INSTALLATION GUIDE

2.3 Equipment

2.3.1 Tools

2.3.2 JackaJay Kit componentry

2.3.2.1 HARDWARE

Ensure the camper trailer is in a clean and tidy condition.

Ensure that all the cabinetry is empty, and access is not hindered and

ready for installation.

Unzip the top 200mm of all windows to enable air ow and place all the

curtains behind the window. This will ensure they are not obstacles when

moving greased and soiled components around the van.

During installation, it is required that JackaJay kit componentry must be sourced

prior to installation. Please see the list below in this section.

• Battery Drill

• Screw Drivers. 3/8”

• 90* Drill (optional)

• 32mm Hole saw

• Small Bolt Cutters

• Hammer

• Allen Keys - 2.0mm & 2.5mm

• Framing timber (Advise 90mm x 35mm)

• Framing / window shims

• General Spanners, sockets, and drill bits

• Marking Pen

• Silicone based adhesive

• 4 x Motor Assemblies (1 x Red, 1 x Blue, 1 x Yellow, 1 x Green)

• 4 x Tube Assemblies (1 x Red, 1 x Blue, 1 x Yellow, 1 x Green)

• 4 x Corner Elbows (Black)

• 4 x Flexible Springs/ Pushrods.

• 2 x Saddles (securing harnesses near controller)

• 1 x JACKAJAY Badge – plate

JackaJay INSTALLATION GUIDE

2.3.2.2 ELECTRICAL

2.3.2.3 MOUNTING KIT

• 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)

• 1 x Control Box

• 20 x 14G – 10 x 42mm Hex head self-drilling metal screws

(corner elbows)

• 16 x 14G – 10 x 25mm Hex head self-drilling timber screws

(motor assemblies)

• 16 x M6 x 30mm Cap head bolts, nuts, and washers

(motor assemblies)

• 4 x 8G x 20mm self-drilling screws (control box)

• 4 x 8G x 15mm self-drilling timber screws (saddle)

• 4 x 8G x30mm black screws (JackaJay plaque)

• 8 x 8G x 15mm self-drilling timber screws

(Coloured Tube mounting feet)

• 4 x 8G x 20mm self-drilling screws (JackaJay plaque)

• 1 x 32mm bush

2.3.2.4 GENERAL

• 1 x Grease (small Tub)

• 16 x Sticky tabs

• 1 x Packet of Cable ties

JackaJay INSTALLATION GUIDE

3 Installation Setup

Please note that this Chapter is for guide purposes only. There may be individual

circumstances / layout / equipment that could require you seek further assistance

outside of this guide. For any queries please contact your local provider or Jacka

Industries Pty Ltd. Please note, this guide is based on the installation in a Jayco

Swan Outback.

3.1 Open JackaJay kit and read all User and Installation guides.

3.2 Identifyaatandlevellocation

3.3 Expose manual winch system.

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.

It is critical, when putting up a camper trailer to always ensure that you

have a at and level location and if required, use the levelling legs to

prop the camper into position.

Remove any panelling that is required to gain access to the entire

manual winch system. That is:

- Cabinetry doors

- Covers.

- Appliances.

- Beds and mattresses.

- Seat cushions, etc

DO NOT DISCARD all these need to be retted.

The JackaJay lift system installation may only require slight alterations of

panels and / or cabinetry.

JackaJay ts into the same area as the old winch & cable mechanism.

STOP POINT 1

STOP POINT 2

Ensure that all componentry is accounted for in the

JackaJay kit.

Ensure Camper Trailer is LEVEL in both horizontal axis –

sideways and lengthways.

Tick here

JackaJay INSTALLATION GUIDE

Ensure that the canvas is NOT stretched tight on all

corners, it should NOT be too loose either, but soft to touch

with slight room for movement.

Ensure that the roof height is set to match the SIDE DOOR

POSITION WITH THE DOOR Closed – i.e, the top half section

of the door should be able to lock into position without

undue pressure being applied to the top hinge plate

(where the door attaches to the roof).

Any Gas Appliances must be disconnected and reconnected by an

authorised certied technician.

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.

3.4 Set roof height and install corner supports.

Ensure the roof is lifted to its normal height and the side door is lowered

into the side wall of the camper and is closed.

The measurement required for the next few steps are to make timber

support posts.

The measurement is to be taken from where the telescopic mast exits the

side wall of the camper trailer, up the telescopic mast.

Take the measurement from the top (horizontal face, or spot next to the

telescopic mast) of the xed wall of the camper, to the bottom lip of the

roof (piece that slides over the side wall of the camper when the roof is

down)

Take the corner height measurements, as reference for later.

You have 2 options here. You can attempt to cut 4 x framing timbers

(90mm x 35mm) to the exact right length, or, cut 4 x framing timbers to

1050mm lengths, and use framing / window shimms / spacers to pack out

the rest.

STOP POINT 3

STOP POINT 4

Tick here

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