kojack KJ4000S User manual

Model No. KJ4000S/KJ4000T
Hydraulic Caravan Bottle
Jack & Levelling Aid
User Manual
KJ4000S/T-UM-0910
®
Suitable For:
Single-Axle Caravans (KJ4000S)
Twin-Axle Caravans (KJ4000T)

KJ4000S/T User Manual Page 2
KJ4000S/T User Manual Page 3
This jack is designed for
lifting purposes only.
After jacking, always use safety stands to
support load before making any repairs. For
your safety, do not overload beyond rated
capacity and do not adjust safety valve.
1. The chassis brackets are suitable for
AL-KO caravan chassis manufactured
after 1992 that have pre-drilled mounting
holes already on the chassis.
2. The chassis brackets should be mounted,
behind the axles on both sides. The
brackets are marked ‘OFF-SIDE’ for
installation on the ‘driver’s’ side of
the caravan when hitched and
‘NEAR-SIDE’ for installation on the door
side (UK) of the caravan. The brackets can
be installed onto continental caravans by
reversing the brackets.
3. 2 sets of bolts, washers and nylock
nuts are supplied for xing the
brackets onto both sides of the caravan.
4. Please refer to Diagram A.
Working on the outside of the chassis
face, line-up the holes on one of the
outer brackets (6) with the pre-drilled
chassis holes and insert the bolts with
washers through the apertures. For
KJ4000T only: Locate one of the inner
brackets (7) over the ends of the bolts
onto the inside face of the chassis.
Note: The bolt heads and washers
must be on the outside of the chassis
with the nylock nuts on the inside.
5. Screw on the nylock nuts and tighten
securely. Ensure that the brackets
are, as close as possible, at 90° degrees
to the horizontal oor of the caravan.
Careful tting at this stage, ensures that
the spirit levels will give a true reading to
aid accurate levelling.
6. Repeat the procedure to t the remaining
bracket(s) to the opposite side.
Ensure that the bolts are sufciently
tightened up to 86Nm.
1. The inclusion of 2 spirit level vials per
bracket (one for the length of the
caravan and one for width) provides
the caravanner with accurate guidance
in determining and adjusting the level
of the caravan.
2. With the aid of the easy to use hydraulic
jack, the level of the caravan can be
adjusted simply and chocked accordingly
with suitable platforms.
1. Before jacking, the caravan must be
attached to the towing vehicle and the
handbrake must be applied on both
the caravan and the vehicle.
2. Chock the caravan wheels (back & front)
on the opposite side to the wheels to
be lifted/changed. Place the jack
in-line with the bracket on the side of the
caravan to be raised. If the ground
surface is soft, a board, plank or similar
should be placed underneath the jack.
Only use the jack on a at, hard
surface.
Gloves should be used to avoid
hand injury.
3. Tighten release valve on base of jack
by turning the valve (4) clockwise,
do not overtighten.
4. Insert the operating handle (5) into the
handle socket (1) and pump the handle
up and down until the slotted saddle (2)
is aligned with the base of the chassis
bracket (6).
5. Once correctly aligned, continue to pump
handle to raise the caravan to the
required height. Use smooth, full strokes
for best results.
6. To lower the caravan, remove the handle
(5) from the handle socket (1), then use the
notched end of the handle to turn the
release valve (4), carefully and slowly,
anti-clockwise - no more than one full
turn.
Chassis Bracket Installation
General Safety
1. Read ALL of this User manual and
become familiar with the product’s
application, limitations and possible
hazards.
2.
These symbols identify important safety
precautions. They mean CAUTION!
WARNING! SAFETY FIRST!
3. Keep work area clean and free from
obstruction.
4. Keep children at a safe distance of
apparatus whilst in operation.
5. Only use adapters and accessories that
are supplied or recommended by the
manufacturer.
6. Keep the apparatus clean and in good
operating condition.
7. Inspect the bottle jack each time you
use it. Ensure that there are no loose,
bent or missing parts. Never attempt to
use the jack if it is in any way defective.
8. Do not operate the jack if you are under
the inuence of drugs, alcohol or any
medication that could impair your ability to
use the equipment safely.
Important Safety Instructions
Read this User Manual carefully before use. Failure to comply with
these rules could result in serious injury or damage to property.
Installation & Operation
Product Identication
Hydraulic Jack Operation
1. Handle Socket
2. Slotted Saddle
3. Oil Filler Plug
4. Release Valve
5. 3-Piece Handle
6. Outer Brackets x 2
7. Inner Brackets x 2
(KJ4000T only)
8. Bracket Fixings
9. Spirit Levels
10. Lifting Arm
11. Pump
Levelling Aid
Diagram A.
Inner Bracket
(KJ4000T only)
Outer Bracket
Chassis
Note: The KJ4000S is only supplied with one pair of
Outer Brackets (6).
1
2
4
5
7
6
8
9
10
11
3
Oil ller plug on
rear of bottle jack

KJ4000S/T User Manual Page 4
Do not raise the caravan more than necessary; only raise until the
wheel is sufciently clear of the ground.
Do not lie underneath the caravan whilst it is jacked up as this could result
in serious injury.
1. Do not totally unscrew and remove the Release Valve (4) as this may unseat the rubber seal
from the bottom of the housing.
2. When not in use the lifting arm (10) and pump (11) should be in the lowest position.
3. Keep pivot points well lubricated.
4. Store handle with jack, in the supplied carry case, to avoid loss.
5. Change hydraulic oil at least once a year.
6. To check oil level:
a. With the lifting arm (10) in the lowest position, remove oil ller plug (3) on rear of body.
b. With jack upright, the oil should be level with the bottom of the ll hole.
c. If necessary, ll reservoir until level with the oil ller plug hole. Fill with high quality
hydraulic jack oil only. DO NOT use brake uid, transmission oil or turbine oil.
d. Reinstall the oil ller plug (3).
7. To purge trapped air:
a. Open release valve (4) one full turn.
b. Hold down the lifting arm (10) and
c. Operate pump handle (5) for eight full strokes.
d. Close release valve.
e. Pump handle until the jack reaches maximum height and continue to pump several times
to remove any trapped air.
f. Depress the rubber oil ller plug (3) just enough for any air to escape.
g. Open release valve counterclockwise one full turn and lower jack piston to its lowest
position. Use force if necessary.
h. Close release valve and check for proper pump action. Repeat as necessary.
8. Clean the jack with a soft cloth and mild detergent or solvent.
Product Specication
© Copyright 2010. Purple Line Limited, Peninsula Business Centre, Wherstead, Suffolk, IP9 2BB, England
www.purpleline.co.uk
Photographs for illustration purposes only. Actual product may differ slightly.
Purple Line Limited reserve the right to alter product specication without prior notice.
Specications
SWL (Kg) Minimum
Height (mm)
Maximum
Height (mm)
Overall
dimension
(retracted) (mm)
Net Weight (Kg)
2000 170 390 170 x 125 x 132 4.5
Care and Maintenance
design...innovate...improve