Jacka Industries JackaJay User manual

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

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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 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
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 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
Tick here

JackaJay INSTALLATION GUIDE
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Ensure that the timber corner supports are rmly 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.
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.
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 t, but NOT lifting the roof.
Secure the timbers to the telescopic masts with long cable ties / rope /
heavy duty duct tape, etc
Once your timber corner supports are secured, carry out a check on
the side door operation, position them and check your canvas is not too
tight. If required, adjust corner heights with the framing shimms.
Once you are happy with the corner heights, canvas tension and side
door position, wind down the manual winch system 3 turns. Ensure your
timber supports are secure and the side door position is adequate. At
this point, the manual lift system is now no longer holding up the roof, the
timber supports are.
VERY IMPORTANT:
The Height you set the roof to, should be the nal point that the roof is
raised 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 tting too loose and /
or the canvas tight.
Tick here

JackaJay INSTALLATION GUIDE
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3.5 Remove the manual winch system.
Please be aware that the removal of the existing winch system is half of
the job! Take your time. Remove any panelling that you need to and
note down what you have done.
Keep in mind, if you can remove the old winch components, you can
install the JackaJay components.
The Old Winch and Cable Lift Mechanism is found at the front & rear of
the camper trailer laterally across the oor 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 the model of
the wind-up Camper Trailer).
Conrm 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 sh 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 sh 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 sh plate to their respective corners for
removal. However, once you have pulled the rear 2 x cables along the
Driver-side wall, you will need to ensure that you remove all the pullies
from the wall, and pull back a cable (or draw wire) to the front again
through the kitchen. 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. Tick here

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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.
Remove all bolts and screws from the old winch system and remove the
winch, square tubes, exible springs/pushrods, cables, pullies, and corner
elbows. Be careful of dirt & grease stains on the curtains, cabinetry, and
ooring.
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, where the
corner guide enters the base of the telescopic mast. DO NOT remove this
plate, it MUST be intact, because it secures the base of the telescopic
mast.
This gas seal around the tube MUST not be broken, if it is, it MUST be
resealed and certied.

JackaJay INSTALLATION GUIDE
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Do a thorough clean up of the whole area where the old manual lift
system was installed. Generally, there is accumulated dirt and swarf from
modications / original build.
If the Camper Trailer is an older model check for rot in the oor. 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 oor timbers are substantially damaged you MUST repair the oor
to ensure there is an adequate timber / metal to secure the JackaJay lift
mechanism.
Ensure that all holes in the oor have been sealed up with silicone before
starting you installaiton. This will limit any dust and moisture ingress into the
camper
STOP POINT 7
Ensure that all manual winch system components
have been removed.
The camper oor has been cleaned and is ready for
JackaJay installation. Tick here

JackaJay INSTALLATION GUIDE
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4 Installation of JackaJay lift system
It is CRUCIAL that the correct colour Motor Assembly and Tube Assembly are
mounted in the instructed positions.
Motor Assembly and Tube Assembly slide together with matching colours.
Wiring Harnesses have matching colour tags tted to match the corresponding
Motor Assemblies and Tube Assemblies, i.e. red to red, green to green, blue to
blue and yellow to yellow.
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.
JackaJay COLOUR - CODING POSITIONS
POSITION FOR EACH COLOR
DRIVER’S SIDE FRONT
DRIVER’S SIDE REAR
PASSENGER SIDE FRONT
PASSENGER SIDE REAR
4.1 Corner Bend Installation
Position, but DO NOT x to the oor, 4 x Corner Elbows (black) into each
corner such that the upper end of elbow ts into the largest (bottom)
stage of the telescoping leg. It should slide in by only around 10mm. If
required, remove only one small screw that scures the lower section of
the telescopic mast. You must ensure that it goes back in
Place a large dob of grease into the bottom of the corner elbow. This is
where the exible 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. Tick here

JackaJay INSTALLATION GUIDE
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4.2 Flexible pushrods
Locate the NEW 4 x Flexible Springs/Pushrods, they will be pre-greased.
Remove them from the plastic sleeve one at a time as required.
Locate the dome headed end of the Spring, slide it into the corner
elbow, and feed up until it stops. The dome headed end will be in
contact with the nal (smallest) stage of the telescoping leg.
You will have around 45 – 85mm 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.
Locate one full set, i.e., RED Drive tube and RED motor assembly.
Check that they slide together completely, and the drive shaft ts into the
motors coupler all the way in. See image below for Coupler
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 45 – 85mm of spring protruding.
4.3 Coloured square drive tubes and Motor Assemblies
Follow the steps below for each of the corner’s complete assembly. This should be
done one at a time:
Tick here

JackaJay INSTALLATION GUIDE
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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.
See image below for example.
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,
i.e , Bronze drive block MUST be 1-2mm from the
micro-switch roller.
1-2mm
Position the Square Drive Tube Assembly roughly into the Camper Trailer
by easing it through the same pathway where the old square tubes were
removed. They should t easily as they are shorter than the old tubes. DO
NOT push into the spring yet.
Place and position the correct coloured Motor Assembly into the Camper
Trailer behind the shaft end of the Drive Tube Assembly. Check to ensure
the shaft has not rotated.
Slide the Motor Assembly and the Drive Tube Assembly together.
Tick here

JackaJay INSTALLATION GUIDE
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ENSURE that the drive shaft is fully located into the coupler between the
Motor drive shaft and the Drive Tube drive shaft. APPLY pressure on them
and tighten the grub screws with a 2.5mm Allen Key. Ensure that BOTH
grub screws are rmly tightened; there are 2 grub screws in total, on each
coupler. You may need to turn the coupler to reach the other screw, and
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.
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 protrudes 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
20-60mm away from the corner elbow. It MUST NOT be resting up against
the corner elbow tube. See below for image.
If the end of the square tube is resting greater than 60mm away from the
corner elbow tube, you will be required to remove the exible 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 le it out clean.
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 coupler. Tick here

JackaJay INSTALLATION GUIDE
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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.
STOP POINT 12
You MUST have all lift mechanisms including corner
elbows, exible pushrods, square drive tubes and
motor assemblies laying in their correct positions.
It is imperative that you check the colour coding and
conrm that it matches as directed.
Additionally, you MUST conrm that when the lift
mechanism is pushed towards the corner elbow, the
end of the square drive tube is not resting against the
corner elbow tube, and, is not resting greater than
60mm from the corner elbow tube.
Tick here

JackaJay INSTALLATION GUIDE
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4.4 Fixing Down of all components
Once all the Corner elbows, exible pushrods and motor / tube assemblies have
been placed into the camper you need to secure them all into position.
4.4.2 FIXING SQUARE DRIVE TUBE & MOTOR ASSEMBLIES
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 the alignment of all components. i.e, 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. Then 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 rmly drive in appropriate screws to attach corner
Elbow permanently to oor.
Do one corner at a time.
Ensure that there is no less then 5mm clearance between
the Motor Assembly and the opposing-coloured drive tube
assembly. This allows space for slight adjustments and cabling.
STOP POINT 13
All 4 x corner elbows MUST be securely xed to the
oor and the vertical tube MUST be accurately
aligned up with the centre of the base tube for the
telescopic mast. Tick here
It is imperative that securing down of all components during Section 4.4 is
adequate. So as, to ensure that NO components may come away from the
oor, causing catastrophic dropping of a roof corner or structure during setup
or camping. If there is any indication of Rot in the oor or inadequate material
to secure to, conduct repairs or upgrades. This is the responsibility of the installer.
Multiple means of xings are supplied with the JackaJay kit.