Parts List and Operating Instructions Form No. 102663
ASSEMBLY OF THE JACK
Assembly of the Cylinder
1. Replace o-ring (13) and U-cup (15) on the toe (16).
2. Grease the bore of the toe (16) with a non-silicone lubricant.
3. Mount the toe (16) on the cylinder rod (9).
4. Tighten the guide (8) on the cylinder rod using a thread locking compound. Remove any excess compound.
5. Grease the exterior machined portion of the toe (16) with a non-silicone lubricant.
6. Assemble the cylinder rod/base plate assembly (9), the toe (16), and the guide (8) into the body of the jack.
7. Grease the rounded end of the spring stock (14) and drive it round end first into the hole at the base of the jack
body using a pliers to guide the spring.
Assembly of the Pump
1. Install o-ring (29), U-cup (28), and wiper (33) on the piston cartridge (32). Grease the pump barrel with a suitable
lubricant.
2. Seat the piston cartridge assembly into its housing in the pump barrel (31) using a small mallet and a piece of soft
metal.
3. Install the inlet check ball (12), spring (17), and hollow lock screw (22) to the end of its travel into the inlet valve
body (23).
4. Replace copper washer (24) on the inlet valve body. Thread the valve body onto the pump barrel (31).
5. Reassemble the outlet check valve (11) into the pump barrel (31).
6. Reinstall the breather valve into the top of the pump barrel (31) by first installing the spring (37), then the ball (38)
and breather seat (3).
7. Coat the inside of the jack body with a suitable lubricant to accept the pump body.
Assembly of the Release Valve
1. Grease and replace o-ring (44).
2. Install the release valve assembly (48) in the pump body.
3. Install the retaining ring (45).
4. Install the release valve knob (46) and secure in place with allen screw (47).
Assembly of the Lever
1. Using two pins (4), attach the connecting link (5) and the piston (25) to the lever (2).
IMPORTANT: Do NOT
damage the piston. Piston surface must be completely free of nicks, scratches, or dents in areas that
come in contact with the seals.
Final Assembly
1. Place the bladder (21) in the reservoir of the jack body.
2. Mount the pump into its housing on the jack body. Tap the pump into place with a mallet, while protecting the top of
the pump with a piece of wood. Secure with four screws (30).
3. Position the jack vertically and hold it in the extended position by wedging the toe on the base.
4. Close the release valve.
5. Using a funnel and filter, fill the jack with Power Team hydraulic fluid through the cylinder plug (6) hole until full to
the top of the cylinder cap thread.
6. Open the release valve and hold the breather valve ball (38) off its seat (36) with a pin or punch until oil with no air
bubbles flows from the breather valve. Release the breather ball and top off the jack with hydraulic fluid to the top
of the cylinder cap threads. Install the cylinder plug (6) and washer (7).
7. Fill the piston cavity with hydraulic fluid, open the release valve, and install the piston lever assembly with the pin,
nut and washer.
8. Remove the wedge from under the toe and allow the cylinder to retact half way. Again, carefully open the breather
ball (38) to expel any air still trapped in the bladder. Retract the piston completely.
9. Operate the pump lever several times. Close the release valve and operate the pump lever. If the pump piston
does not make a full stroke, there is still some air trapped in the pump chamber. Turn the jack 90° so that it is
resting on the back side of the hand grip and the jack column is horizontal. Operate the pump lever several times
with the release knob closed. This will expel any air left in the pump chamber into the column chamber.
Continued -
Sheet No.
2 of 4
Rev 5
Date: 20 May 2003
