MAHLE ATJ-1000H User manual

MAHLE ATJ-1000H
EN
Operation Manual
Hi-Rise Transmission jack

en
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EVERY PERSON WHO OPERATES THIS
EQUIPMENT NEEDS TO KNOW AND
UNDERSTAND ALL OF THE INFORMATION IN
THIS MANUAL – FAILURE TO DO SO COULD
RESULT IN SERIOUS INJURY OR DEATH.
READ THIS MANUAL
CAREFULLY AND
RETAIN FOR YOUR
RECORDS

ATJ-1000H |3|en
Contents
Contents
1. Safety Regulations ...............................................4
1.1 Warnings......................................................4
2. Foreword ..............................................................5
2.1 From the manufacturer.................................5
3. Symbols Use.........................................................5
3.1 Signal words................................................5
4. Responsibilities ....................................................6
4.1 Receiving inspection ....................................6
4.2 Owner and/or operator responsibilities.........6
5. Specifications.......................................................6
5.1 ATJ-1000H...................................................6
6. Product Description.............................................7
6.1 Component identification .............................7
7. Operation..............................................................8
7.1 Removing transmission................................8
7.2 Priming instructions......................................9
8. Maintenance and Inspection..............................10
8.1 Inspection – before each use......................10
8.2 Maintenance instructions............................10
8.3 Replenish oil supply ...................................10
8.4 Air valve cleaning instructions.....................11
9. Troubleshooting .................................................12
10. Optional Adapters ..............................................13
#45 Adapter kit...........................................13
#90 Adapter kit...........................................13
4T80E Adapter...........................................13
All purpose adapter kit ...............................13
11. Maintenance Chart.............................................14

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Safety Regulations
1. Safety Regulations
1.1 Warnings
The transmission jack was designed only to assist in the
removal and installation of automotive and light truck
transmissions/transfer cases weighing up to 1,000 lbs.
Special factory made adapters are available to help
stabilize some transmissions.
To avoid serious injury or death, read this manual
carefully before operating this unit. Contact the
manufacturer using the contact information on the
back cover of this manual if you have any questions.
Failure to understandandobey safetyinstructions may
result in unsafe or improper use of this product.
Before using this jack, be sure you have read and
understood all of the instructions and warnings on the
on product labeling and in this owner’smanual.See the
section entitled “OWNER AND/OR OPERATOR
RESPONSIBILITIES” on page 6 of this manual for more
information.
Inspect the jack before each use. The jack must be
removed from service if damage is detected or if the
jack is subjected to an abnormal shock or load. See
page 10 of this manual for proper “INSPECTION –
BEFORE EACH USE.”
Inspect the work area before each use. Make sure
vehicle is appropriately supported before starting
repairs. Use the jack only on hard, level surfaces
capable of sustaining the load.
Make sure air stage of lift is fully raised or fully
lowered prior to transferring load. If a load is
transferred to the lift when the air cylinder is only
partially raised, the lift will drop suddenly. Do not allow
any part of your body under the load while jack is
supporting a load..
Make sure the load does not exceed the rated
capacity of the jack. The maximum lifting capacity of
the ATJ-1000H is 1,000 lb. /455 kg.
Use the jack only as a lift, not as a workstand. Lift
only by means of the head assembly; never use any
other part of the jack as a lifting surface.
Do not tow loaded jack by hydraulic pump handle.
Keep transmission in the lowest position when rolling
jackacrossfloor. Keep straptightly secureduntilr e ady
to remove transmission from jack.
Do not use this jack to remove and/or install
gas/fuel tanks.
Use only the factory supplied adapters. Do not use
any adapters that are not supplied by the
manufacturer.
Always use the jack as intended. Never modify or
alter the jack.
Failure to understand and obey these warnings may
result in personal injury and / or property damage.

ATJ-1000H |5|en
Foreword
2. Foreword
2.1 From the manufacturer
Thank you for your purchase. To complement the offering
of A/C, fluid and nitrogen service equipment, MAHLE
Service Solutions has partnered with GrayManufacturing
to provide the highest quality hydraulic and pneumatic
equipment available for the professional service
technician. This equipment adheres to high standards
promised in the MAHLE guarantee including the
assuranceof innovation andreliability that comeswith the
Gray Manufacturing name. Please contact MAHLE
Service Solutions’ customer service at [phone] or
[e-mail] with any comments or questions.
3. Symbols Use
3.1 Signal words
Signal words call attention to a safety message or
messages, or a property damage message or messages,
and designate a degree or level of hazard seriousness.
Signal words used in this manual include:
Keyword Probability of
occurrence
Severity of danger if
instructions not
observed
DANGER Immediate
impending danger
Death or severe injury.
WARNING
Possible impending
danger
Death or severe injury
CAUTION Possible dangerous
situation
Minor injury
NOTICE
Possible damage to
property
Possible property
damage

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Responsibilities
4. Responsibilities
4.1 Receiving inspection
Before attempting to operate this equipment, thoroughly
read and understand this manual. Completely remove all
tape and packaging. Inspect the equipment immediately
upon delivery. If shipping damage is evident, inform the
delivering carrier immediately and contact the
manufacturer using the contact information on the back
cover of this manual.
4.2 Owner and/or operator responsibilities
The owner of this equipment must read these instructions
and maintain them for future reference and for instructing
any other users of the equipment. The owner is
responsible for keeping all warning labels and instruction
manuals legible and intact. Replacement labels and
literature are available from the manufacturer. The owner
must never authorize or allow anyone to use this
equipmentuntil the operator hasreadandunderstoodthe
information in this manual and on the accompanying
labeling on the equipment itself.
If this equipment is being used in an occupational setting
(or workplace), the employer should ensure that all
personnel working with and around the equipment know
of the risks associated with its use. Personnel involved in
the use and operation of this equipment shall be careful,
competent, trained, and qualified in the safe operation of
the equipment and its proper use when servicing motor
vehicles and their components. Safety information
provided with this equipment should be emphasized by
the employer and understood by each employee. The
employer mustmake this manualavailable toallpersonnel
using this equipment and all personnel must read and
understand the contents of this manual. If the operator is
not fluent in English, the manufacturer’s instructions and
warnings shallbe readto and discussed with the operator
in the operator’snative language bythe employer,making
sure that the operator comprehends its contents and
observes the proper procedures for use ofthisequipment.
5. Specifications
5.1 ATJ-1000H
Model ATJ-1000H US units Metric units
Capacity 1,000 lb each 453.6 kg each
Start Height 34.5 in 87.6 cm
Lift Height 72 in 182.9 cm
Width 41 in 104.1 cm
Length 41 in 104.1 cm
4 Swivel Casters 4 in 10.2 cm
Air pressure 90-160 psi 6.2-11.0 bar
Weight 125 lb 56.8 kg
Tilt Forward 50° 50°
Tilt Rear 20° 20°
Tilt Side 10° 10°

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Product Description
6. Product Description
6.1 Component identification
Fig. 1: Component identification
1. Downfootpedal
2. Casters
3. Air valve
4. Lockingpawl
5. Air stage
6. Foreand aft crank
7. Sidetosidecrank
8. Hookring
9. Ratchet brackets
10. Strap
11. Head assembly
12. Release knob
13. Pump handle
14. Hydraulic stage
15. Air inlet
16. Casters
17. Up footpedal

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Operation
7. Operation
WARNING - This section discusses the appropriate and
safe methods for using the jack to raise and lower a
transmission from a vehicle. Safe operation is not limited
to simply raising and lowering the transmission - it also
includes adequate preparation before removing
transmission. Failure to follow all of the steps outlined in
this section could result in serious injury and/or pr operty
damage.
7.1 Removing transmission
1. With vehicle elevated on lift, position the jack near
transmission to be removed.
2. Attach air hose. Depress foot pedal marked “UP” and
raise air stage to its fully extended and locked position.
The locking pawl will automatically engage when the air
stage is at full height. Air hose may be removed.
3. Close the hydraulic release valve by turning
CLOCKWISE. Pump the handle to raise head assembly
close to transmissionto be removed. If hydraulic stage
does not lift, see “PRIMING INSTRUCTIONS” located in
Section 7.2 of thismanual.
4. Roll head assembly side to side and tilt forward or back
as needed to firmly contact bottom of transmission.
5. With short strokes of the pump handle, jack may be
raised slowly to contact transmission.
6. Unlock pawls to pull out ratchet brackets (Fig. 2). Then
push in the 4 ratchet brackets on head assembly firmly to
contact sidesof transmission.
Fig. 2: Unlock pawls
7. Secure transmission to the jack by placing the strap over
the transmission, hook it in the hook ring, and then pull
the strap tight (Fig. 3).
Fig. 3: Strap transmission
8. Before unbolting transmission from engine, support
engine with stand, or other appropriate device (Fig. 4).
Fig. 4: Support engine
9. When component is free, lower hydraulic stage slowly by
turning hydraulic release valve COUNTERCLOCKWISE.
Then lower air stage by depressing foot pedal marked
“DOWN”.
If load is restingon the lockingpawl, attach air hose and
depress “UP” foot pedal briefly so locking pawl will
release. Air stage should then lower when “DOWN” foot
pedal is depressed.
WARNING -Never prylockingpawlto release the load,
the load will drop. Failure to heed this warning may
result in personal injury and/or property damage.
CAUTION! Moving parts of the jack can cause
personal injury. Keep hands and all other body parts
free of pinch points while lowering. Lowering the
hydraulic stage first minimizes the number of exposed
pinch points

ATJ-1000H |9|en
Operation
7.2 Priming instructions
1. Tilt entire jack over on two casters with the pump
handle down as show in Fig. 5.
Fig. 5: Tilt jack
1. Downfootpedal
2. Casters
2. Open hydraulic release valve by turning release knob
and operate the pump handle until resistance is felt.
3. Close hydraulic release valve and continue pumping
handle while restoring jack to upright position.

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Maintenance and Inspection
8. Maintenance and Inspection
WARNING - The jack must be inspected accordingto
the requirements of this section. Failure to properly
inspect the jack could lead to severe injury or death.
The jack must be removed from service and inspected
immediately if it is subjected to an abnormal load or a
shock load. If any irregularities or problems are
detected during an inspection, the jack must be
removed from service immediately and repaired.
Contact the manufacturer at the numbers and address
printed on the back cover of this manual.
8.1 Inspection – before each use
The jack owner (or a knowledgeable person appointed by
the owner) must give the jack a more thorough inspection
weekly (if it is used on a daily basis) or monthly (if used
less frequently). In addition to a visual inspection (as
described above), the inspector should also operate and
move the jack to assist in identifying any problems that
might exist. The jack must be removed from service and
repaired if the jack appears damaged, if it is badly worn,
or if it operates abnormally.
Visual inspection of the jack must be made before each
use of the jack. The jack should be immediately removed
fromservice ifanyofthe followingconditions are detected
or observed:
Visually inspect the jack for signs of cracking,
chipping, or excessive wear, including all welds.
Visually inspect all four casters for cracking, chipping
or excessive wear.
Visually inspect the power unit for oil leaks.
Any abnormal condition or sign of damage that
suggests the jack will not work properly.
If any irregularities or problems are detected during an
inspection or during operation, the unit must be
removed from service immediately and repaired.
Contact the manufacturer using the contact
information on the back cover of this manual.
8.2 Maintenance instructions
WARNING - All inspection and maintenance procedures
must be performed after the jack has been removed from
service. Failure to do this may result in personal injury
and/or property damage.
Lower unit completely and exhaust all air from the air
cylinder before servicing the air cylinder. Failure to
exhaust all air from the air cylinder can cause rapid
separation of the piston rod from the air cylinder.
Failure to heed this warning may result in serious
personal injury and / or property damage.
Apply light machine oil at all portions of movement to
the jack monthly.
All warning and capacitylabels should be readable and
complete. Wash external surfaces of jack, labels, and
decals with a mild soap solution.
8.3 Replenish oil supply
With all four casters of the jack resting on the floor,
lower the hydraulic stage fully and remove the head
assembly by extracting the four head mounting bolts.
See Fig. 6. Carefullyclean the top of the jackto remove
all dirt, especially in the vicinity of the fill plug. Remove
the release knob by turningcounterclockwise. Remove
the fill plug and using a squirt-oil can, slowly add Tellus
T22 oil (or equivalent) until reservoir overflows.
Note: The release knobopeningserves asreservoirvent
during filling. Be sure to reinstall release knob and fill
plug, and then remount the head assembly.
Fig. 6: Replenish oil
Fill Plug Release
Knob
Head Mounting
Bolts

ATJ-1000H |11 |en
Maintenance and Inspection
8.4 Air valve cleaning instructions
Occasionally pieces of scale or rust from the airline will
become lodged under the rubber seats of the air valve
causing air leakage.This leakage is easily detected since
lift will rise slowly when you connect the airline to the
quick coupler inlet even though the valve lever has not
been touched. If this occurs, the Inlet Side of the valve
needs cleaning. The lift may also lower slowly when you
disconnect the airline from the quick coupler even though
the valve lever has not been touched. If this occurs, either
the Inlet Side or both sides of the valve needs cleaning.
To clean, refer to Fig. 7 and follow these instructions: A.
Remove the adapter (2) from the Inlet Side of the air
control valve. Inspect screen (1) for foreign particles and
clean as required. B. Remove the spool (7) from the body
by pushing on spool (7) (from center towardthe outside of
valve)with a piece ofstiff wire or nail. C. Carefullyexamine
the valve seal (6) for any scale, dirt or foreign matter. If
foreign matter is embedded in the valve seal (6), remove
the screw (4) and cup (5) from the end of spool (7) and
clean the seal (6), turn over the seal and reassemble. D.
Lubricate the spool (7) with light chassis grease. E.
Reassemble the valve in this order: First, insert the spool
(7). Make sure that the spool with the O-Ring (8) is
reassembled on the Inlet Side. Second, insert spring (3).
Third, assemble adapter (2) into inlet side and plug (10)
into exhaust side of body (9). The valve should now
operate like new.
Fig. 7: Air valve exploded view
# P/N Description Qty
1 1-312-91004 Screen 1
2 1-274-12001 Adapter 1
3 1-233-12001 Spring 2
4 0-202-10601 Screw 2
5 1-312-91003 Cup 2
6 1-390-10006 Seal 2
7 1-312-91002 Spool 2
8 0-390-00005 O-Ring 1
9 4-312-91001 Body 1
10 1-275-21004 Plug 1
11 0235-21009 Roll Pin 1
12 Note2 Handle 1
Notes:
1. CompleteValve Assembly,withHandle:
2-312-01005 ValveAssembly,TeeHandle
2-312-01006 ValveAssembly,Long Handle
2-312-01007 ValveAssembly,WingedHandle
2. Handlepartnumbers:
12A 1-232-20053 TeeHandle
12B 1-232-20034 LongHandle
12C 1-232-20052 WingedHandle
Inlet Side
Exhaust Side

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Troubleshooting
9. Troubleshooting
This section is a list of potential problems and solutions.
If the solution listed fails to correct the problem, call the
manufacturer at the numbers and address printed on the
back cover of this manual. Please have the model
number, and serial number of your jack available. The
serial number is permanently stamped on the left front
caster bracket.
Problem Cause/Solution
Hydraulic stage fails
to lift load
•Out of prime: See “Priming Instructions ”
on decal fastened to the jack and also
found in the “Operating Instructions ”
section of this manual
•Low oil level, see the “REPLENISH OIL
SUPPLY” section of manual.
•
Release open, turn control knob
clockwise until tight.
Air stage fails to lift
load
•Inadequate air pressure; requires 90 –
160 psi required
Hydraulic stage fails
to hold load
•
Release open, turn control knob
clockwise until tight.
Air stage fails to hold
load
•Air leak. Remove jack from service and
repair leak. Possible dirty air valve seals.
Follow simple directions on cleaning the
air valve located in the “Maintenance
Instructions” section of this manual
Locking pawl cannot
be released with light
foot pressure on the
down foot pedal
•Attach air hose and depress up foot pedal
to pressurize air cylinder. The air stage
will extend completely and now the down
foot pedal will pull the locking pawl back
so the air stage will lower. Do not attemp t
to pry the pawl loose.

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Optional Adapters
10. Optional Adapters
The following adapters are available for purchase to
allow better support at the bottom of the transmission.
#45 Adapter kit
Fig. 8: #45 adapter kit
Set of 4 ratcheting adapters stabilizes the irregular-
shaped transmission pans allowing one-person removal
and installation.
#90 Adapter kit
Fig. 9: #90 adapter kit - For use with 4L80E units
Designed for the vehicles where the exhaust passes right
next to the transmission pan prohibiting easy removal of
this transmission.
4T80E Adapter
Fig. 10: 4T80E adapter - Northstar® adapter
Stabilizes 4T80E transmissions with only one technician
by connecting to the side of the transmission in the
provided bolt hole pattern.
All purpose adapter kit
Fig. 11: All purpose adapter kit
Enables easy removal of transmission and transfer case
as one unit. Also allows easy removal of front wheel drive
transaxles

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Maintenance Chart
11. Maintenance Chart
Action Date Details Person
responsible
Receiving inspection

ATJ-1000H |15 |en
Maintenance Chart
Action Date Details Person
responsible

MAHLE Aftermarket Inc.
916A West State Street
St. Johns, Michigan 48879 U
.S.A.
Phone: (800) 468
-2321
E
-mail: [e-mail]
www.servicesolutions.mahle.com
670-90727_A