Bosch 81 22 2 219 012 User manual

Universal Jack
81 22 2 219 012
en Original Instructions

1 General Information
Product Name: Universal Jack
Product Type: Lifting Device
Product Number: 81 22 2 219 012
Weight: 100 kg
Maximum Load Capacity: 600 kg
Lifting Height: 1005 mm
Maximum Dimensions: 1200 mm (Length)
1200 mm (Width)
1950 mm (Extended Height)
Applicable Standard: EN 1494:2000+A1:2008:
Mobile or movable jacks and associated lifting equipment
Intended Use:
To lift and lower vehicle parts for repair work with the help of corresponding accessories.
Terms of Use:
To be used only by qualified personnel trained in accordance with BMW standards.
Use only for loads up to 600 kg.
Use only to lift or lower loads vertically. Use only for centred loads. Do not apply lateral force to the hydraulic
cylinder.
Use only on level ground.
Use only at ambient air temperatures between +10°C and +40°C.
Use only at air humidity levels < 50%. Protect the Universal Jack from weather effects.
Use only for work expressly approved by BMW (see BMW service and repair manual).
Use only with accessories expressly approved by BMW (see BMW service and repair manual).
Included in Delivery:
81 22 2 219 013 Hydraulic Cylinder (use only when assembled with base frame)
Base Frame
6 screws M6x12
8 screws M12x25
8 washers
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

Figure 1: Universal Jack
AKnob (to lower the jack)
BHydraulic Cylinder
CBase Frame
DPedal (to raise the jack)
E5 Wheels, including 3 with a brake
FHandle
Available Accessories:
Product Number Product Name
83 30 0 495 498 Universal Gearbox Support for Passenger Vehicles
83 30 0 495 567 Universal Axle Support
83 30 0 495 827 Gearbox Support for MINI
83 30 0 496 009 Rear Axle Gearbox Support
83 30 0 496 226 Support Equipment for Convertible Tops
83 30 0 496 458 Support Bar for Convertible Tops
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

2 General Safety Instructions
WARNING
Improper use could cause serious personal injury or severe damage to materials!
The safety of the lifting device can no longer be ensured if it is misused or modified in ways not expressly
approved by the manufacturer. These actions could result in serious personal injury or severe damage to
materials.
Read and follow these instructions carefully.
Ensure that each person using the lifting device is familiar with these instructions and can access them at
all times.
Read and follow the BMW service and repair manual carefully.
Use the lifting device only for work expressly approved by BMW.
Use the lifting device only with accessories expressly approved by BMW.
The lifting device is only to be used by qualified personnel trained in accordance with BMW standards.
WARNING
Disregarding the safety regulations could cause serious personal injury or severe damage to
materials!
The load could slide or tip if the user does not follow the safety regulations. These actions could cause serious
personal injury or severe damage to materials.
Do not exceed the maximum load capacity of 600 kg.
Ensure that the load centre is placed on the middle of the Universal Jack. Do not apply lateral force to the
hydraulic cylinder.
Always lock the three wheel brakes on the base frame when raising or lowering the Universal Jack.
Move the Universal Jack when loads are on it only if the hydraulic cylinder has been lowered completely. Do
not exceed speeds of 2.5 km/h.
Move the Universal Jack when loads are on it only if the ground is level. Do not move the Universal Jack over
steps or slopes.
Follow the inspection and maintenance instructions.
CAUTION
Crushing Hazard!
Handling special tools and vehicle parts carelessly could cause hands or feet to be crushed.
Wear safety shoes that meet the ISO 20345, S2 standard.
Position hands and feet so as to avoid potential crushing hazards.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

3 Assembly
Only qualified personnel are allowed to assemble the Universal Jack.
1. Unpack the parts and inspect them for transit damage. Contact the manufacturer if parts have been damaged
during shipment.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany
2. Lay out the necessary tools.

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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany
3. Remove the pedal.

5. Place the hydraulic cylinder in the base frame.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany
4. Lock the three wheel brakes on the base frame.

6. Tighten the four M12x25 screws and washers with a torque of 80 Nm.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

7. Align the hydraulic cylinder in the centre and tighten the four M12x25 screws and washers onto the base
frame with a torque of 80 Nm.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

8. Re-attach the pedal.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

9. Mount the cover plate. Tighten the six M6x12 screws and washers with a torque of 6 Nm.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

4 Operating Instructions
Only qualified personnel are allowed to use the Universal Jack.
1. Inspect the Universal Jack before use, as described in Chapter 5, "Inspection and Maintenance". Do not use
the Universal Jack if damaged or in poor condition.
2. Attach the necessary accessories onto the Universal Jack (see the BMW service and repair manual).
3. Move the Universal Jack to the work site. Lock the three wheel brakes on the base frame of the Universal
Jack.
4. Raise the piston by pressing the pedal several times.
WARNING
Danger from raising the piston too high!
The vehicle could be damaged or it could be lifted off of the lifting platform if the pistion is raised too high.
This could result in serious personal injury.
Raise the piston just until the accessory bears the weight of the vehicle part.
5. Attach and secure the load onto the accessory (see the BMW service and repair manual).
WARNING
Danger of Falling Loads!
The load could fall if the accessories have not been attached to the Universal Jack correctly or if the load
has not been secured onto the accessory correctly. This could result in serious personal injury or severe
damage to materials. Off-centred loads could damage the Universal Jack.
Ensure that the accessory has been attached to the Universal Jack correctly.
Ensure that the load has been secured onto the accessory correctly.
Ensure that the load centre is placed in the middle of the Universal Jack.
6. Remove the parts to be taken out of the vehicle (see the BMW service and repair manual).
7. Lower the piston carefully by turning the knob counter-clockwise.
CAUTION
Lowering or rotating loads could cause personal injury!
Persons who are in the danger zone while the load is being lowered or rotated risk being injured.
Ensure that no one is in the danger zone while lowering or rotating the load.
Stay out from under loads.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

8. Release the wheel brakes on the base frame after the piston has been lowered completely. Move the Universal
Jack to a suitable location.
WARNING
Improper use could cause serious personal injury or severe damage to materials!
The load could slide or tip if the user does not follow the safety regulations when moving the Universal
Jack. This could result in serious personal injury or severe damage to materials.
The Universal Jack is only to be used by qualified personnel trained in accordance with BMW standards.
Move the Universal Jack when loads are on it only if the hydraulic cylinder has been lowered completely.
Do not exceed speeds of 2.5 km/h.
Move the Universal Jack when loads are on it only if the ground is level. Do not move the Universal Jack
over steps or slopes.
CAUTION
Risk of Stumbling!
The shape of the base frame could cause persons handling the Universal Jack to stumble.
Position feet so as to avoid stumbling risks.
Do not climb onto the base frame.
9. Leave the piston completely lowered and lock the three wheel brakes on the base frame to perform any further
work with the Universal Jack.
WARNING
Risk of personal injury!
Working under loads could cause serious personal injury.
Do not work under loads.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

5 Inspection and Maintenance
Only qualified personnel are allowed to perform maintenance work on the Universal Jack. Ensure that no loads
are on the Universal Jack before beginning any maintenance work on it.
The manufacturer has limited the pressure relief valve to 600 kg and sealed it. Do not make any changes to this
valve.
Only the manufacturer shall perform any necessary repair work on the Universal Jack.
1. Before Each Use:
Ensure that the Universal Jack has been assembled correctly and inspect it for visible damage (e.g. leaks in
the hydraulic cylinder, cracked parts or cracks on welded seams, defective wheels). Do not use the Universal
Jack if damaged or in poor condition. Take the Universal Jack out of operation and secure it against
unauthorised use.
Inspect the hydraulic cylinder for smooth movements. If the movement is jerky, bleed the hydraulic cylinder
as described in the troubleshooting section (Step 3 of Inspection and Maintenance).
CAUTION
Uncontrolled piston movements could cause personal injury!
Uncontrolled piston movements could occur if compressed air is in the hydraulic cylinder.
Place body parts so as to avoid the risk of personal injury.
2. Monthly:
Lubricate the pedal axle (EE) with WD-40 multi-purpose lubricant or W18 TL 9150-0078 lubricant.
Clean and then lubricate the pump piston (FF) with WD-40 multi-purpose lubricant or
W18 TL 9150-0078 lubricant.
Ensure that all detachable fasteners are tight.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

Figure 2: Universal Jack Maintenance
HPiston Rod LOil Filler Plug
IPiston Tube MAxle
JKnob NPump Piston
KPedal OBleeder Screw
3. Troubleshooting:
The manufacturer has already filled the hydraulic cylinder with hydraulic oil and bled it. In order to ensure
proper operation, check the oil level or bleed the hydraulic cylinder in the cases described below.
CAUTION
Hydraulic oil could cause personal injury!
Hydraulic oil bleeding from the hydraulic cylinder could cause eye or skin injury or create a slipping hazard .
Follow the following maintenance steps exactly.
Bleed the hydraulic cylinder carefully. Avoid skin or eye contact with the hydraulic oil.
Wear safety glasses.
Wash oil off skin thoroughly if any contact occurs. Consult a doctor if oil accidentally comes into contact
with eyes or if skin irritation occurs.
Use suitable means to clean up any oil spills on the floor to avoid slipping hazards immediately.
Check the oil level of the hydraulic cylinder if the piston cannot be raised to its maximum height:
Lower the piston completely.
Loosen the oil filler plug (HH). Use the hole for inspections and for filling the oil.
Check the oil level. The oil level should be filled to the hole (cylinder oil capacity 3.5 L).
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

If the oil level is too low, re-fill with HLP 22 hydraulic oil in accordance with DIN 51524-2. Re-fill only with
new, clean oil and use only clean funnels. Never use brake fluid!
Re-tighten the oil filler plug (HH) with a torque of 6 Nm.
Bleed the hydraulic cylinder if it starts moving jerkily or if the piston rod (AA) and/or the piston tube (BB) no
longer reach the lower end stop:
Lower the unloaded hydraulic cylinder as much as possible by turning the knob (CC).
Loosen the bleeder screw (DD) with one or two turns, using a SW 5 hexagon socket spanner.
Turn the knob (CC) counter-clockwise while pushing the piston rod (AA) and/or the piston tube (BB) to
the lower end stop.
Press the pedal (GG) until bubble-free oil leaks out from the bleeder screw (DD).
Re-tighten the bleeder screw (DD) with a torque of 6 Nm.
Use the oil filler plug (HH) to check the oil level. Refill oil if necessary, as described above.
NOTICE
Modifications to this product which have not been expressly approved by the manufacturer shall void any
warranty. The manufacturer assumes no liability for personal injuries or damages to materials which occur as
the result of improper use of this product.
Contact the manufacturer or BMW for any questions:
Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany
BMW AG
Workshop Equipment
80788 Munich
Germany
[email protected]
6 Disposal
Remove the load from the Universal Jack. Lower the hydraulic cylinder completely.
Keep a suitable oil container, oil-binding agent, and a rag ready.
Drain the hydraulic oil from the hydraulic cylinder completely.
Bring the used oil, oil-binding agent, and rag to an authorised waste oil collection site.
Bring the metal parts of the Universal Jack to a waste management service provider.
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany

Declaration of Conformity with the Machinery Directive 2006/42/EC,
Annex II 1A
Manufacturer: Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany
Person Authorised to Compile
the Technical Documents:
Gregor Leopold, R&D Engineer
Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany
Product Name: Universal Jack
Product Type: Lifting Device
Product Number: 81 22 2 219 012
We hereby declare that the product described above complies with the relevant clauses of the 2006/42/EC
Machinery Directive.
Any modification to the product not expressly approved by the manufacturer shall void the validity of this
declaration.
The following harmonised standards have been applied:
EN 1494:2000+A1:2008 Mobile or movable jacks and associated lifting equipment
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment
and risk reduction
EN 10025:2004 Hot rolled products of structural steels
EN 982:1996+A1:2008 Safety of machinery - Safety requirements for fluid power systems and
their components - Hydraulics
Pollenfeld, 3 December 2013
Place, Date Gary Palmer, Managing Director
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12/2013 Bosch Automotive Service Solutions GmbH
Am Dörrenhof 1
85131 Pollenfeld-Preith
Germany