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MODEL 804
4 TON BODY AND FRAME
REPAIR KIT
USER'S MANUAL
Jackco Transnational Inc. © 2009
South El Monte, CA
888-452-2526 www.jackco.com
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FOR YOUR SAFETY
Read all instructions, warnings and cautions carefully. Follow all safety precautions to avoid personal injury
or property damage during system operation. Jackco cannot be responsible for damage or injury resulting
from unsafe product use, lack of maintenance or incorrect product and/or system operation. Contact Jackco
when in doubt as to the safety precautions and operations.
Failure to comply with the following cautions and warnings could cause equipment damage and personal
injury.
Ram Load
Never lift a load that exceeds the capacity of the ram.
Do not over extend the ram, because it is possible to
force the plunger out of the top of the ram.
Dust Caps
When coupler valves are disconnected screw in dust
cap to keep the oil line clean.
Off-center loads
Be careful when load is not centered on ram plunger.
Pump carefully- IF YOU FEEL THAT YOU HAVE TO
PUMP UNUSUALLY HARD-STOP. Adjust set-up to
the off center load is reduced.
Protect your hose
Do not drop heavy objects on your hose and avoid
sharp kinks. Provide proper clearance to avoid
damage to the hose and couplers.
Heat and re
Always keep your equipment away from excessive
heat or re.
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INSTRUCTION
How to operate
Release Valve
Tur n knob C L O C K W ISE and pump han d l e for
applying pressure.
Turn knob counterclockwise to release pressure.
Pump Position
It is possible to hold pump in any possible from horizonal to vertical but always keep the
hose end of the pump down when above the horizontal position
Oil Level
Retract the ram that is connected to the pump. Place pump in an upright position as
shown. Remove ller plug and add hydraulic oil until it is level with the full mark on the dip
stick.
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Set Up
Possible congurations for the 4 ton ram and attachments.
Rubber
Head
Spreader
Ram
Extension
Pump
Flat
Base
Rubber
Head
Rubber
Head
Ram
Ram
Flat
Base
Flat
Base
Rubber
Head
Pump
Ram
Serrated
Saddle
Spoon
Ram
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Load Capacities
The capacity of this equipment is signicant affected by the number of attachments used and
the type of load supplied several typical hook-ups are illustrated below. The approximate load
capacity if each set up is noted with illustration. When using two or more extension tubes
together, always position the shortest tube farthest away from the ram.
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Parts List
Part No. Description Q'ty
804-01 Blow Mold Case 1
804-A02 19 1/2" Extension Tube 1
804-A03 16 1/2" Extension Tube 1
804-A04 8 1/2" Extension Tube 1
804-A05 5 " Extension Tube 1
804-A06 3 1/4" Extension Tube 1
804-07 Serrated Saddle 1
804-11 Spreader Ram 1
804-12 2 3/4" Rubber Head 1
804-13 Flat Base 1
804-14 Spreader Ram Toe 1
804-15 Spreader Plunger Toe 1
804-16 Wedge Head 1
804-17 90° V-Base 1
804-18 Connector 1
804-40 4Ton Hydraulic Unit 1
804-41 4 Ton, 6" Stroke Ram 1
87006 6 ft. Hose With Half Coulping 1
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Hydraulic Spreader Assembly 1/2 Ton Capacity
Part No. Description
04-S01 Lower Duck Bill
04-S02 Spring
04-S03 Upper Duck Bill
04-S04 Pivoting Pin
04-S05 Cir Clips
04-S06 Piston
04-S07 Cup Seal
04-S08 Washer
04-S09 End Cap
04-S10 Coupling Ring
04-S15 Couping Bolt
04-S16 Bolt O-Ring
04-S17 Dust Cap
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Hydraulic Ram Assembly 4 Ton Capacity
Part No. Description
4-R01ASSN Cylinder
4-R04SSN Ram
4-R05N Bearing
4-R06N Bushing
4-R07N Back-up Ring
4-R08N "U" Seal
4-R09N Washer
4-R10N Cir Clip
4-R13 Spring
4-R14 Scerw
4-R15 Ring
4-R16 Protector
86140 1 1/4" hydraulic coupler
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Hydraulic Body&Frame Pump 4 Ton Capacity
Part No. Description Part No. Description
4-P01B Pump Housing 4-P27 Plunger
4-P02 Filter 4-P28 Pump Pivot Brm Arm
4-P04 Seal 4-P29 Pivot Arm Pin
11-P05 Pump Reservoir 4-P30 Pivot Arm Pin
4-P06 Reservoir End Cap 4-P31 Cir Clip
4-P07 Pump Foot 4-P32 Pump Handle Assy
4-P08 Nut-Housing 4-P33 Grip
4-P09 O-Ring 4-P36 Hose
4-P10A Dip Stick(Oil Level Check) 4-P42A Coupling
4-P12 Ball Valve 4-P43 Dust Cap
4-P13 Ball Valve 4-P44 Back-up Ring
4-P14 Spring 4-P45 Back-up Ring
4-P15 Overload Stem 4-P46 Steel Ball
4-P18 Spacer 4-P47 Spring Plunger
4-P22 Seals (Complete Set) 4-P48 Spring
4-P23 Seal 4-P49 O-Ring
4-P24 Lower Spanner Nut 4-P50 Screw (Safety Valve)
4-P25 Seal 4-P51 Plastic Cap
4-P26 Upper Spanner Nut 4-P55A Release Valve Stem
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LIMITED ONE YEAR WARRANTY
Jackco Transnational Inc. warrants all Jackco equipment and tools to the original purchaser against any manufacturing defect in material or
workmanship for a period of one (1) year from the original date of purchase. If the defective equipment or tool is determined to be covered under
this warranty, it shall be repaired or replaced at manufacturer's discretion without charge, provided that the equipment or tool must be returned
with proof of purchase to the dealer and freight prepaid, if returned to the manufacturer. This warranty shall not apply to damage due to accident,
negligent use, and lack of maintenance, abuse or applications other than the specic function the equipment or tool is designed for.
No other warranties, expressed or implied, including those of merchantability or tness for particular purpose shall be applicable to Jackco
except as specifically stated herein. In no event shall Jackco be liable to any party for any special, direct, indirect, consequential, punitive
damage of any nature caused by the sale or use of the equipment or tool.
Note: This warranty gives the original purchaser specic legal rights which may very from state to state.
Jackco Transnational Inc. © 2009
South El Monte, CA
888-452-2526 www.jackco.com
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