Jacka Industries JackaJay User manual

Installation Guide
JackaJay
Version 4.0
Jacka Industries Pty Ltd – 468 Hawksbury Rd, Winmalee, NSW, 2777– 1300 052052 –
www.jackaindustries.com

© 2018 Jacka Industries Pty Ltd. All rights reserved.
468 Hawkesbury Road, Winmalee, 2777, NSW, Australia
1300 052 052
www.jackaindustries.com
Trademarks / Patents
Jacka Industries Pty Ltd are the proprietary owners of all associated registered trademarks and
pending patents.
Patent Pending No. - 2019903079
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 fitness 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
profits 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
[e-mail] 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: [Date].
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.jackaindsutries.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:
[e-mail]
If you have issues, comments, or questions about specific 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.

Jacka Industries Pty Ltd JackaJay Installation Manual
Version 3.0
© Company 2021. All rights reserved. Page 3 of 36
Table of Contents
1 Introduction ............................................................................................................ 5
1.1 P
URPOSE OF THIS DOCUMENT
............................................................................................................ 5
1.2 I
MPORTANT POINTS TO BE OBSERVED THROUGHOUT THE
G
UIDE
.......................................................... 5
1.3 I
DENTIFICATION
................................................................................................................................. 5
1.4 R
EFERENCE INFORMATION
................................................................................................................ 6
1.5 P
OINTS OF
C
ONTACT
......................................................................................................................... 6
1.6 W
ARRANTY
....................................................................................................................................... 6
2 Installation Plan ...................................................................................................... 7
2.1 M
AIN
T
ASKS AND
I
NSTALLATION
S
TEPS
.............................................................................................. 7
2.2 E
NVIRONMENT
.................................................................................................................................. 8
2.3 E
QUIPMENT
...................................................................................................................................... 8
3 Installation Setup .................................................................................................. 10
3.1 O
PEN
JACKAJAY
KIT AND READ ALL
U
SER AND
I
NSTALLATION GUIDES
. ............................................ 10
3.2 I
DENTIFY A FLAT AND LEVEL LOCATION
.............................................................................................. 10
3.3 I
DENTIFY CORRECT OPERATION OF THE MANUAL WINCH SYSTEM
........................................................ 11
3.4 E
XPOSE MANUAL WINCH SYSTEM
. .................................................................................................... 11
3.5 S
ET ROOF HEIGHT AND INSTALL CORNER SUPPORTS
. ........................................................................ 12
3.6 R
EMOVE THE MANUAL WINCH SYSTEM
. ............................................................................................. 14
4 Installation of JACKAJAY lift system .................................................................... 16
4.1 C
ORNER
B
END
I
NSTALLATION
.......................................................................................................... 16
4.2 F
LEXIBLE PUSHRODS
....................................................................................................................... 17
4.3 C
OLOURED SQUARE DRIVE TUBES AND MOTOR ASSEMBLIES
.............................................................. 17
4.4 F
IXING
D
OWN OF ALL COMPONENTS
................................................................................................. 20
4.5 INSTALLING CONTROLLER & HARNESSES ............................................................................. 23
4.6 I
NSTALLATION CLEAN UP
. ................................................................................................................. 27
5 Commissioning ..................................................................................................... 29
5.1 P
OWERING UP THE
C
ONTROLLER
..................................................................................................... 29
C
USTOM
I
NSTALLATION
............................................................................................................................... 31
6 Post Installation Care and Maintenance ............................................................... 32

Jacka Industries Pty Ltd JackaJay Installation Manual
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6.1 Y
EARLY
C
HECKS
............................................................................................................................. 32
7 Troubleshooting .................................................................................................... 33
8 Documentation Feedback .................................................................................... 36

Jacka Industries Pty Ltd JackaJay Installation Manual
Version 3.0
© Company 2021. All rights reserved. Page 5 of 36
1 Introduction
This Installation guide is design to assist the installer by guiding through progressive
recommend steps and important check points to achieve a successful and fully operative
JackaJay Electric Lift System.
1.1 Purpose of this document
This installation guide covers the installation of the JackaJay lift system and all its
related components, for the benefit of removing the manual winch lift system and upgrading to a
fully automatic electric lift system.
1.2 Important points to be observed throughout the
Guide
IMPORTANT NOTE
This box is designed to highlight important information that is relevant to the current
steps.
STOP CHECK POINT
This is a Box / Highlight to enforce the importance of doing a detailed check and
confirmation that the works / items that are being directed is completed.
DANGER: This note is designed to issue a WARNING to the installer of any
impending DANGER / EVENT that has the potential to cause injury or death if
directives are not followed.
1.3 Identification
 The JackaJay lift system and all related information regarding installation and operation
guide directives are only applicable for Jayco related camper trailers. Please contact Jacka
Industries for approval and directives for any application of the JackaJay product outside of
this documents guideline.

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1.4 Reference information
 Please also refer to the User Operation guide for JackaJay System operation and ensure
that all documents have been read and understood prior to carrying out the installation.
1.5 Points of Contact
 For all queries, please contact Jacka Industries Pty Ltd or authorised distributor for your
area.
1.6 Warranty
 Recreational warranty 5 years from purchase date. See Appendix A for definition.
 Commercial warranty 1 year from purchase date. See Appendix A for definition.
 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 for 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 claims.
 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 will need to be registered with Jacka Industries
Pty Ltd to maintain current Warranty offer.
 Any warranty claims will need to be inspected by authorized personnel and deemed
claimable within Jacka Industries Pty Ltd procedures.

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© Company 2021. All rights reserved. Page 7 of 36
2 Preparation
The scope for the Installation Plan is to provide a definitive guide to the installer, to
enable a smooth removal of the manual winch system and installation of the JackaJay lift
system.
It is important that you have checked that you have all the necessary componentry 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 assist you in a
successful installation and not void any warranty
.
2.1 Main Tasks and Installation Steps
The installation guide is broken up in to 7 areas to progress through. Please familiarise yourself
with relevant terminology and all aspects of the below steps prior to beginning the installation.
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

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2.2 Environment
 During the installation 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 or
moves in, ensure that all equipment is 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.
 Ensure the camper trailer is in a clean and tidy condition.
 Ensure that all the cabinetry is empty, and access is not hindered, ready for
installation.
 Unzip the top 200mm of all windows for air flow and place all the curtains in behind
the window. This will ensure that they are up and out the way when moving greased
and soiled components around the van.
2.3 Equipment
During the installation there is a requirement for multiple tools and JackaJay kit
componentry that should be sourced prior to beginning the installation. Please see
the below list in this section.
2.3.1 Tools
 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

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2.3.2 JackaJay Kit componentry
2.3.2.1 HARDWARE
 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.
 4 x Motor covers
 2 x Saddles (securing harnesses near controller)
 1 x JACKAJAY Badge – plate
2.3.2.2 ELECTRICAL
 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
2.3.2.3 MOUNTING KIT
 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 25mm Cap head bolts, nuts, and washers (general Use)
 4 x M4 x 18 self-drilling screws (control box)
 8 x M4 x 6mm self-drilling timber screws (saddle)
 4 x 8G x30mm black screws (JackaJay plaque)
2.3.2.4 GENERAL
 1 x Grease (small Tub)
 16 x Sticky tabs
 1 x Packet of Cable ties

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© Company 2021. All rights reserved. Page 10 of 36
3 Installation Setup
Please note that this Chapter is for guide purposes only. There may be individual circumstances
/ layout / equipment that may require you go carry outside of this guide. For any queries please
contact your local provider or Jacka Industries Pty Ltd.
3.1 Open JackaJay kit and read all User and Installation
guides.
 Take the time to open the JackaJay kit, layout all the components and understand the
location and use for each piece, this will assist in ensuring that no pieces are missing and
when referred to in this guide, you will understand what is required.
STOP POINT 1
Ensure that all componentry is accounted for in the JackaJay kit.
3.2 Identify a flat and level location
 It is critical, as when always putting up a camper trailer to ensure that you have a flat and
level location and if required, use the levelling legs to prop the camper into position.
STOP POINT 2
Ensure Camper Trailer is LEVEL in both horizontal axis – sideways and lengthways.

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3.3 Identify correct operation of the manual winch
system
 Lift the roof of the camper trailer into the UP position using the old winch operation.
3.4 Expose manual winch system.
 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 DISGARD as these all need to be refitted.
 The JackaJay lift system should not require any alterations of panels and / or cabinetry.
 JackaJay fits into the same area as the old winch & cable mechanism.
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.
DANGER: Any Gas Appliances need to be disconnected and reconnected by
an authorised certified technician.

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© Company 2021. All rights reserved. Page 12 of 36
3.5 Set roof height and install corner supports.
 Ensure the roof is lifted to its normal height and the side door is lowered, located into the
side wall of the camper and is closed.
STOP POINT 3
Ensure that the roof height is set to match the SIDE DOOR POSITION WITH THE DOOR
CLOSED– ie, the top half section of the door should be able to lock into position
without undue pressure being applied to top hinge plate (where the door attaches to
the roof).
 The measurement required for the next few step is 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 fixed 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)
IMPORTANT NOTE
Each corner height may vary up to 20mm from the Jayco Factory. This is a Jayco
standard. DO NOT feel as though you need to make each corner even. The canvas
would be mounted to the roof and camper wall with the roof height as it is.
DO NOT change the roof height unless you have to.
STOP POINT 4
Ensure that the canvas is NOT stretched tight on any corners, it should NOT be too
loose either, but soft to touch and slight movement.
 Take the corner height measurements, as reference for later.

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 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.
 Position framing timbers against each telescoping leg at each corner, and use framing shims
to adjust supported roof height, if required. The timbers should be a tight fit, but NOT lifting
the roof.
 Secure the timbers to the telescopic masts with long cable ties / rope / heavy duty duct tape,
etc
DANGER – Ensure that the timber corner supports are firmly secured with
cable ties or another suitable method. These timber supports will be holding
the roof up while you are working inside. They MUST be tight and secure.
 Once your timber corner supports are secured, carry out a check on the side door operation
and position and check your canvas is not too tight. If required, adjust corner heights with the
framing shimms.
VERY IMPORTANT
The Height that you set the roof to, is the final point that the roof will raise to during
the Roof UP Automatic function using the JackaJay lift system. If you want to adjust
the height of a certain corner. You MUST do it now! However, be careful not to make
the door fitting too loose and / or the canvas tight.
 Once you are happy with the corner heights, canvas tension, side door position. Wind down
the manual winch system 3 turns, and again, check your timber supports are secure, side
door position is adequate. The manual lift system is now no longer holding up the roof, the
timber supports are.
STOP POINT 5
Ensure you have the Roof set to the desired height and the canvas and side door
position is correct.
Your corner supports MUST be Secure.
All the manual winch cables should be loose and ready to be removed.

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© Company 2021. All rights reserved. Page 14 of 36
3.6 Remove the manual winch system.
 The Old Winch and Cable Lift Mechanism is found at the front & rear of the camper trailer
laterally across the floor against the front and rear walls. you should have already exposed
all the componentry in earlier steps.
 Locate the winch (position varies, front or rear, according to model of Jayco Camper Trailer).
 Confirm that all cables DO NOT have tension on them.
 At the end of a thick single cable leading from the winch you will see a square fish plate with
4 x smaller cables attached to it. If you wish to keep the old system, and the cables are in
good condition, unscrew the 4 x hooks / eyelets holding the cables. Release the cable from
the hooks. If not, use the Bolt Cutters to cut the 4 x cables close to the fish plate.
 Where the cables would be exposed (not behind cabinetry) the cables are covered by a
plastic channel. Remove this channel and keep for reinstallation later when the JackaJay
System is installed. DO NOT DISCARD channel and screws.
 Pull all the cables back from the fish plate to their retrospective corners for removal.
However, leave one cable in the full-length wall along the Drivers side wall. This is used as a
draw wire later, to pull through the new Electric Harnesses during the JackaJay installation.
STOP POINT 6
All cables should be pulled back through the pullies to their corners.
HOWEVER you should have one cable along the Drivers side wall to be used as a draw
wire.
 Remove external vent cover from behind the fridge on the side of the van. In some models
the old lift cables lay inside a 30mm diameter plastic tube, the JackaJay rear electric harness
will feed through this tube to the rear motors.
 This tube may or may not be sealed either end, however the space around the tube where it
passes through the panelling will be sealed, this is to ensure that if gas leaks behind the
fridge, it will not be released into the living area of the Camper Trailer.
DANGER: This gas seal around the tube MUST not be broken, if it is, it MUST
be resealed and certified.

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 Remove all bolts and screws from the old winch system and remove the winch, square
tubes, flexible springs/pushrods, cables, pullies, and corner elbows. Be careful of dirt &
grease staining curtains, cabinetry, and flooring.
 DO NOT attempt to remove the telescopic legs from the wall of the camper. Also, there is a
small plate on the wall of the camper, near where the corner guide enters the base of the
telescopic mast. DO NOT remove this plate, it MUST remain, it secures the base of the
telescopic mast.
 Thoroughly clean up the whole area where the old manual lift system was installed.
Generally, there is accumulated dirt and swarf from modifications / original build.
 If the Camper Trailer is an older model check for rot in the floor. If required, during the
JackaJay installation use metal screws to drill into steel chassis or backing plate.
 If deemed necessary, use a variety of screws / bolts with washers and nuts to ensure secure
attachment of corner elbows and motor assembly.
 If the floor timbers are substantially damaged you MUST repair the floor to ensure there is an
adequate timber / metal to secure the JACKAJAY lift mechanism.
STOP POINT 7
Ensure that all manual winch system components have been removed.
The camper floor has been cleaned and is ready for JACKAJAY installation.

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© Company 2021. All rights reserved. Page 16 of 36
4 Installation of JACKAJAY lift system
JACKAJAY COLOUR - CODING POSITIONS
It is CRITICALLY IMPORTANT that the correct colour Motor Assembly and Tube Assembly is
mounted in the instructed position.
Motor Assembly and Tube Assembly slide together with matching colours.
Wiring Harnesses have matching colour tags fitted to match the corresponding Motor
Assemblies and Tube Assemblies, i.e. red to red, green to green, blue to blue and yellow to
yellow.
Position for each colour
The position relates to the telescoping leg being lifted by that coloured JackaJay corner., i.e. the
Green components lift the driver’s side front telescoping leg.
DRIVER’S SIDE FRONT - GREEN
PASSENGER SIDE FRONT - RED
DRIVER’S SIDE REAR - YELLOW
PASSENGER REAR - BLUE
4.1 Corner Bend Installation
 Position, but DO NOT fix to the floor, 4 x Corner Elbows (black) into each corner such that
the upper end of elbow fits into the largest (bottom) stage of the telescoping leg. It should
slide in by only around 10mm.
 Place a large dob of grease into the bottom of the corner elbow. This is where the flexible
pushrod will slide in and will lubricate the inside of the corner bend.
STOP POINT 8:
You will have all 4 x corners elbows located into the lower section of the telescopic
mast, NOT screwed down, with a dob of grease inside the lower end.

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© Company 2021. All rights reserved. Page 17 of 36
4.2 Flexible pushrods
 Locate the NEW 4 x Flexible Springs/Pushrods, they will be pre-greased.
 Remove from plastic sleeve one at a time as required.
 Locate the dome headed end of the Spring, slide into the corner elbow, and feed up until it
stops. The dome headed end will be in contact with the final (smallest) stage of the
telescoping leg.
 You will have around 30 – 50mm of spring / pushrod exposed from the lower end of the
corner elbow (This varies due to corner height variation). Position something heavy enough
to hold the spring / pushrod temporarily in position.
STOP POINT 9
You will have all 4 x Flexible push rods installed with grease seen inside the
protruding spring that is coming out of the corner elbow.
You should have 30 – 60mm of spring protruding.
4.3 Coloured square drive tubes and Motor Assemblies
Follow the below steps for each of the corner’s complete assembly. Do one at a time and move
on to the next one:
 Locate one full set, i.e., RED Drive tube and RED motor assembly.
 Check that they slide together completely, and the drive shaft fits into the motors Plum drive
coupler all the way in.

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© Company 2021. All rights reserved. Page 18 of 36
STOP POINT 10
Before installing the drive tube assemblies visually inspect the position of the bronze
drive block.
The bronze drive block is found at the end of the drive tube where the micro switch is
mounted.
The bronze drive block MUST be 1-2mm away from the small roller mounted on the
arm of the microswitch.
If the shaft has been rotated from factory settings, rotate by hand to the correct
position.
All Bronze Drive Blocks must be in the same position. Ie, Bronze drive block MUST be
1-2mm from the micro-switch roller.
 Position the Square Drive Tube Assembly roughly into the Camper Trailer by easing it
through the same pathway the old square tubes were removed. They should fit easier as
they are shorter than the old tubes. DO NOT push into the spring yet.
 Place the correct coloured Motor Assembly into position in the Camper Trailer behind the
shaft end of the Drive Tube Assembly. Check to ensure shaft has not rotated.
 Slide the Motor Assembly and the Drive Tube Assembly together.
 ENSURE that the driveshaft is fully located into the Plum drive motor coupler between the
Motor drive shaft and the Drive Tube drive shaft. KEEP pressure on them and tighten the
grub screws with a 2.5mm Allen Key. Ensure that BOTH grub screws are firmly tightened,
there are 2 grub screws in total, on each plum drive. You may need to turn the coupler to
reach to other screw, ensure that you turn it back.
 THESE GRUB SCREWS MUST BE VERY TIGHT. If they are loose, the shaft may rotate
and not drive the roof up.

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STOP POINT 11
You MUST ensure that the Drive shafts are pushed all the way into the Coupler and
ALL the grub screws are tightened. There are 2 grub screws in total on each plum
drive coupler.
 Once the two Assemblies are locked together check the position of the Bronze Drive Block
again and adjust if required by turning the motor / shaft coupler.
 Insert the protruding end of the drive spigot (at the microswitch end) into the Flexible Spring /
Pushrod that is itself protruding from the corner elbow.
 Firmly push the entire JackaJay assembly towards the corner elbow, until it STOPS. The end
of the square drive tube assembly should be sitting 5 – 50mm away from the corner elbow. It
MUST NOT be resting up against the corner elbow tube.
 If the end of the square tube is resting greater then 50mm away from the corner elbow tube,
you will be required to remove the flexible pushrod from the camper trailer and cut it down
with a grinder.
 After cutting, if required, ensure that the inside of the spring does not have any metal swarf
or bits of metal that will obstruct the drive shaft from spinning freely inside the spring. You
MUST file it out clean.
Once all the above points have been completed, proceed to the next corner assembly, until all 4 corner
assemblies are in position.
IMPORTANT NOTE
Once all 4 corner assemblies are in place, you MUST ensure that the Drive tubes can
be placed as straight as possible with at least 5mm between opposing corner
assemblies.

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© Company 2021. All rights reserved. Page 20 of 36
STOP POINT 12
You MUST have all lift mechanisms including corner elbows, flexible pushrods, square
drive tubes and motor assemblies laying in their correct positions.
You MUST check the colour coding and confirm that it matches as directed.
You MUST confirm that when the lift mechanism is pushed towards the corner elbow
that the end of the square drive tube is not resting against the corner elbow tube,
and, is not resting greater than 50mm from the corner elbow tube.
4.4 Fixing Down of all components
Once all the Corner elbows, flexible pushrods and motor / tube assemblies have been placed into
the camper you need to secure them all into position.
4.4.1 FIXING CORNER ELBOW
 Do one corner at a time.
 Manoeuvre the corner elbow such that it is centred in the base of the telescoping leg.
 Check alignment of all components. Ie. the motor assembly, corner elbow and telescopic leg.
 Use a small drill bit and select ONLY 4 of the mounting holes of the corner elbow that are
best accessible with a drill. Drill a small pilot hole for each hole. We have provided extra
holes for alignment purposes. This corner is not weight bearing, only experiences guide
pressure.
 If the pilot drill drills into metal – use the 14G – 10 x 42mm metal screws.
 If the pilot drill passes through timber – use M6 bolts, washers and nuts. Or use the 14G-10
x 25mm Timber screws.
 Use Hex Nut driver to firmly drive in appropriate screws to attach corner Elbow permanently
to floor.
STOP POINT 13
All 4 x corner elbows MUST be securely fixed to the floor and the vertical tube MUST
be accurately aligned up with the centre of the base tube for the telescopic mast.