Sealey 500TTJ.V2 User manual

TRANSMISSION JACK 0.5 TONNE
MODEL NO: 500TTJ.V2
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these
instructions, and properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE
THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR
PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
1. SAFETY
WARNING: The warnings, cautions and instructions discussed in this instruction manual cannot cover all possible conditions
and situations that may occur. It must be understood that common sense and caution are factors which cannot be built into this
product, but must be applied by the operator.
WARNING! Ensure all preliminary checks are carefully carried out before use of jack. Immediately repair or replace damaged
parts (use authorised service agent). Ensure use of genuine parts only. Unauthorised parts may be dangerous and will invalidate
the warranty.
WARNING! Use jack on level, solid ground, preferably concrete. Ensure the floor over which the jack will be transported is swept clean.
▲DANGER! DO NOT use on tarmacadam, or any other soft surface as jack may sink or topple. Serious injury may result if ignored.
▲DANGER! If jack tips or leans STOP WHAT YOUR ARE DOING. MOVE QUICKLY TO A SAFE DISTANCE. DO NOT TRY TO HOLD
OR STEADY JACK.
9Use jack in a suitable work area. Keep the area clean and tidy and free from unrelated materials. Ensure there is adequate lighting.
9Before use ensure the gearbox weight and size does not exceed the capacity of the jack.
9Ensure the vehicle is raised and stabilised at the correct height before attempting to move the jack under the vehicle.
9Ensure the jack saddle is fully lowered and is clean, dry, and oil free before attempting to transport the jack with or without a load.
9Keep all unauthorised persons away from the jack during lifting and lowering and when in transit.
9Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
9Remove ill fitting clothing. Remove ties, watches, rings and other loose jewellery, and contain and/or tie back long hair.
9WARNING! Ensure that the load is placed level and centrally on the jack saddle and that it is fixed in place before attempting to lift,
lower or transport the load.
9The lowering speed will vary according to the weight of the load and the release valve setting.
9Diligence is required in ensuring that you continually monitor the operation until completed.
9Should the jack make any abnormal sounds during use, STOP IMMEDIATELY and contact your local service agent.
8DO NOT operate the jack if any parts are damaged or missing.
8DO NOT exceed the rated capacity of the jack.
8DO NOT raise/lower vehicle lifting platform whilst the transmission jack is being used.
8DO NOT transport the jack with/without a load, with the saddle in the raised position.
8DO NOT get the jack wet, or use it in damp or wet locations or areas where there is condensation.
8DO NOT operate the jack when you are tired or under the influence of alcohol, drugs or intoxicating medication.
8DO NOT lift or support vehicles with the jack and DO NOT use the jack as a load sustaining device.
8DO NOT use the jack for any purpose other than removal, transportation and the installation of transmissions.
8DO NOT make any modifications to the jack.
8DO NOT adjust, or tamper with, the safety valve.
8DO NOT remove any labels from the jack. If the labels are damaged or unclear, replace them.
8DO NOT use brake fluid to top up the hydraulic unit.
9Use Sealey hydraulic oil only.
9Use a qualified person to to lubricate and maintain the jack.
9Before storing the jack in a safe area, ensure that all parts, especially the saddle are clean and free of grease and oil.
2. INTRODUCTION
Telescopic 2-stage model for reduced clearance lifts. Featuring high speed lift to gearbox - just lift piston. Foot pedal operation
keeps hands free. Spring loaded dead man’s safety release control reduces the risk of inadvertent lowering. Highly manoeuvrable on
castors.
Original Language Version
© Jack Sealey Limited
Refer to
instructions
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safety
footwear
500TTJ.V2 | Issue 1 28/02/19

3. SPECIFICATION
Model No.......................................................500TTJ.V2
Capacity............................................................... 500kg
Ram Extensions...........................................................2
Minimum Saddle Height ..................................... 962mm
Maximum Saddle Height .................................. 1933mm
Base Size..............................................1000 x 1000mm
Saddle Tilt - Forward .................................................28°
Saddle Tilt - Backward ..............................................22°
Saddle Tilt - Left to Right...................................... 65mm
Weight................................................................. 72.5kg
4. ASSEMBLY
4.1. Assemble 4 x castors as shown in fig.2 using a washer and domed nut on each.
4.2. Bolt the two halves of the legs together as fig.1 using bolts, washers and nuts x 3.
4.3. Fit the main jack body to the leg platform, align the three bolt holes and secure bolts & washers x 3.
4.4. Remove the transportation oil plug and replace it with the Air Vent Valve in fig.1 & fig.2.
5. PRE-USE CHECK LIST
5.1. Before each use, check jack is in sound working order, use following list to form a habitual pre-check procedure. Check items are not:
damaged, broken, cracked,bent, malfunctioning, distorted, worn, loose, damage to welds, leaking, dirty, noisy or missing.
WARNING! DO NOT use jack if any suspect part is found, or if believed to have been subjected to abnormal load or shock.
Immediately remove from service and contact an authorised service agent.
5.2. PURGE THE AIR FROM THE HYDRAULIC CYLINDER
5.2.1. Before using your transmission jack for the first time, remove the Transportation Bolt and Seal from the side of the reservoir.
5.2.2. Replace with Air Vent Valve Assembly and its O-ring seal.
5.2.3. Using the Pump Pedal, slowly pump the cylinder. You will observe trapped air escaping from the valve in the Air Vent Valve assembly.
Continue to pump until all air is purged.
6. OPERATION
WARNING! The warnings, cautions and instructions discussed in this instruction manual cannot cover all possible conditions
and situations that may occur. It must be understood that common sense and caution are factors which cannot be built into this
product, but must be applied by the operator.
WARNING! Before use, ensure that you read, understand and apply the Safety Instructions in Section 1.
WARNING! Ensure you prepare the vehicle correctly before attempting to use the Hydraulic Transmission Jack.
6.1. POSITIONING THE JACK BENEATH THE LOAD
NOTE: Before use, ensure that the transmission weight and size does not exceed the capacity of the jack.
6.1.1. Ensure the vehicle from which the gearbox or transmission is to be removed is correctly positioned, raised and locked on an
appropriate lift system.
6.1.2. Ensure that there are no other persons around, or under, the vehicle.
6.1.3. Ensure the saddle is in the lowest position. Use the handle to transport and centrally position the jack beneath the transmission.
g.1
g.2
Original Language Version
© Jack Sealey Limited 500TTJ.V2 | Issue 1 28/02/19

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 [e-mail] www.sealey.co.uk
ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to
a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely
unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids
according to local regulations.
Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior
notice.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
6.1.4. Raise the saddle by pumping the jack foot pedal.
6.1.5. When the saddle is just beneath the transmission, re-adjust the alignment if necessary to centralise the saddle.
6.2. LOWERING THE LOAD
WARNING! Ensure the load is central and stable on the jack saddle and that it is fixed securely.
Before you loosen the mounting bolts, wrap the chains over the top of the transmission, and attach them using the Hook Pins before
attempting to lift, lower, or transport it. Tighten the chains by tightening the Wing Nuts on the Hook Pins.
6.2.1. SLOWLY press the Release Valve Pedal to gently lower saddle as far as possible before attempting to transport the load.
WARNING! Speed of lowering is controlled by Release Valve Pedal . The further you depress it the more rapid the jack’s
descent.
6.2.2. Ensure the jack’s descent is slow and controlled to avoid the risk of sudden dropping which would be very dangerous.
6.3. TRANSPORTING THE LOAD
WARNING! Ensure you read, understand and apply the safety instructions in Section 1.
6.3.1. Ensure the jack saddle is fully lowered and the load is fixed in place before attempting to lift, lower, or transport the load.
6.3.2. Transport the load over level and solid ground, preferably concrete, and ensure that the floor is swept clean beforehand.
6.3.3. Be diligent in continually monitoring the load in transit.
6.3.4. Keep all other personnel at a safe distance.
▲DANGER! DO NOT use on tarmacadam, or any soft surface as jack may sink or topple. Serious injury or death may result.
▲DANGER! If the jack tips or leans, STOP WHAT YOUR ARE DOING AND MOVE QUICKLY TO A SAFE DISTANCE. DO NOT TRY
TO HOLD OR STEADY THE JACK. Serious injury or death may result.
6.4. RE-INSTALLING A GEARBOX
6.4.1. To transport, reposition beneath a vehicle, and raise a load up, reverse the procedures outlined above.
7. MAINTENANCE
NOTE: Only fully qualied personnel should attempt maintenance or repair.
7.1. When the jack is not in use, the saddle must be in the lowest position to minimise ram and piston corrosion.
7.2. Keep the jack clean and wipe off any oil or grease. Lubricate all moving parts with acid free oil.
7.3. The oil cylinder is a sealed unit and must not be accessed. For service contact your authorised dealer.
WARNING! Only a good quality Jack oil, such as SEALEY HYDRAULIC JACK OIL must be used. DO NOT use brake fluid.
7.4. Before each use, follow the pre-check list to ensure components are not damaged, broken, cracked, bent, malfunctioning, distorted,
worn or loose.
7.5. Ensure there is no visible damage to welds. If any suspect item is found, remove the jack from service and take the necessary action
to remedy the problem.
8DO NOT use the jack if you believe it to have been subjected to abnormal load or shock.
7.6. Periodically check the pump piston and piston rod for signs of corrosion.
7.7. Clean exposed areas with a clean oiled cloth.
NOTE!: NO RESPONSIBILITY IS ACCEPTED FOR INCORRECT USE OF THE JACK.
Hydraulic products are only repaired by local service agents. We have service/repair agents in all parts of the UK.
8DO NOT Return the jack to us. Please telephone [phone] to obtain the address and ‘phone number of your local agent. If the jack
is under guarantee, please contact your local stockist.
8. TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Jack will not lift. No hydraulic oil, or defective suction valve or
delivery valve. Release valve is open.
Contact authorised service agent.
Close release valve.
Jack will only lift halfway. Hydraulic oil low or excess of hydraulic oil. Contact authorised service agent
Raised load will not hold. Defective valves, or defective piston packing. Contact authorised service agent
Poor Lifting Defective plunger packing Contact authorised service agent
Original Language Version
© Jack Sealey Limited 500TTJ.V2 | Issue 1 28/02/19