Jacka Industries JackaJay Manuale utente
Installation
Guide
Version 5.0
© 2018 Jacka Industries Pty Ltd. All rights reserved.
JackaJay INSTALLATION GUIDE
2
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 prots 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.
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:
If you have issues, comments, or questions about specic information or procedures,
please include the title and, if available, the part number, the revision, the page
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addressing.
JackaJay INSTALLATION GUIDE
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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 Identication 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
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1. Introduction
1.1 Purpose of this document
1.2 Important points to be observed throughout the Guide
1.3 Identication
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 conrmation on the works/items
that are meant for completion.
STOP POINT
Tick here
JackaJay INSTALLATION GUIDE
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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 denition.
Commercial warranty commences 1 year from purchase date. See
Appendix A for denition.
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
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2 Preparation
2.1 Main Tasks and Installation Steps
We prepared this installation document for you as a denitive 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
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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
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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
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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 Identifyaatandlevellocation
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 retted.
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
Tick here
JackaJay INSTALLATION GUIDE
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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 certied 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
Tick here
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