JET AHJ-12, AHJ-20 Operating Instructions and Parts Manual

Operating Instructions and Parts Manual

Air/Hydraulic Bottle Jack

Models AH J- 12 an d AH J- 20

WMH TOOL GROUP

This manual has been prepared for the owner and operators of a JET AHJ-Series Bottle Jack. Its purpose, aside from tool operation, is to promote safety using accepted operating and maintenance procedures. To obtain maximum life and efficiency from your bottle jack and to aid in using it safely, please read this manual thoroughly and follow the i nstruct ions carefully.

Warranty and Service

WMH Tool Gr oup warrants ever y product it sell s. If one of our tools needs s ervice or repai r, one of our Authorized Repair St ations located throughout the United States can provide quic k service or information.

In most cases, a WM H Tool Group Repair Station can assist in authorizing repair work, obtaining part s, or perform routi ne or m ajor maintenance repair on your JET produc t.

For the nam e of an A uthoriz ed Repair St ation in your area, pl ease call 1-800-274-6848, or v isit our web site at www.wmhtoolgroup.com

More Information

Remember, WMH Tool Group i s consistently adding new products to the li ne. For complete, up-to-dat e product information, check with your local WMH Tool Group distributor, or visit our web site at www.wmhtoolgroup.com

WMH Tool Group Warranty

WMH Tool Group makes every effort to assure that it s products meet high quali ty and durability standards and warrants to the original retail consumer/purchaser of our products that each product be free from defects in mat erials and workmanship as foll ows: 1 YE AR LIMITED WARRANTY ON ALL PRODUCTS UNLESS SPECIFIED OTHERWISE. This Warranty does not apply to defects due directly or i ndirectly to misuse, abuse, negl igence or acc idents, norm al wear-and-tear , repair or alterati ons outside our f aciliti es, or to a lack of maintenanc e.

WMH TOOL GROUP LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD SPECIFIED ABOVE, BEGINNING FROM THE DATE THE PRODUCT WAS PURCHASED AT RETAIL. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. IN NO EVENT SHALL WMH TOOL GROUP BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL, CONTINGENT, SPECIAL, OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR PRODUCTS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

To take advantage of this warranty, the product or part must be returned for examination, postage prepaid, to an Authorized Repair Station designated by our office. Proof of purchase date and an explanati on of the complaint m ust accompany the merchandi se. If our inspecti on discloses a defec t, we will either repair or replace the product at our discreti on, or ref und the pur chase pric e if we cannot readi ly and quickly provide a repai r or replac ement. We will return the repai red product or replacem ent at WMH Tool Group’s ex pense, but if it is determ ined there i s no defect, or that the def ect resulted f rom causes not within the scope of WMH Tool Group’s warranty, then the user must bear the cost of storing and returning t he product . This warranty gives you specif ic legal ri ghts; you m ay also hav e other ri ghts, whic h vary from state t o state.

WMH Tool Group sells through distribut ors only. Members of the WMH Tool Group reserve the right to effect at any time, wit hout prior notice, alter ations to parts, fittings and accessory equi pment, which they may deem necessary for any reason whatsoever.

Warning

1. Read and understand all warnings and operating instruc tions before attempting to use this jack.

2. Do not exceed rated capacity. Overloading can c ause damage t o and/or failure of the jack.

3. If jack is damaged and/or oper ates abnormally, remove from service until repaired.

4. Support load by appropriate means after lifti ng.

5. Always center load on the jack.

6. Use this jack as a lifti ng dev ic e only .

7. Use only on a hard, l evel surf ace capable of sustaini ng the load. Usi ng the bot tle j ack on other t han hard, level surf ac es can resul t in jack instabilit y and possible loss of load.

8. Lift only on areas of t he v ehicl e specif ied by the vehicle manufac turer.

9. Always replace damaged, missing or worn labels and use only genuine factory replacement parts when replacement is necessary.

10. Only use attachments and/or adapters supplied with, or sold specifically for, t he j ac k.

11. No alterations shall be made to this product.

12. Failure to comply with all of these warnings may result in loss of load, damage to jack, and/or personal inj ur y or property damage.

Specifications

Model Number.................................................................AHJ-12.................................................. AHJ-20

Stock Number..................................................................456612..................................................456620

Rated Capacity (ton)............................................................... 12..........................................................20

Minimum Height (in.).............................................................9.65.......................................................9.65

Maximum Height (in.)..........................................................18.70..................................................... 18.70

Air Pressure Required (psi)...........................................90 to 145...............................................90 to 145

Base Size (L x W)(in.) ............................................... 8.27 x 6.30.............................................8.66 x 6.89

Net Weigh t (lb s)..................................................................26.46..................................................... 30.86

Shipping Weigh t (lbs)..........................................................30.86.....................................................39.68

The above specifications were current at the tim e this manual was publi shed, but because of our policy of continuous im provement, WMH Tool Group reserv es the right to change specif ications at any tim e and without pri or notic e, without incurring obligations.

(NOTE: Numbers in parentheses refer to item numbers on the breakdown, page 5.)

Inspection Before Use

Prior to each use, visually inspect for leaking hydraulic oil , dam aged, loose or mi ssing part s. If jack becomes worn or dam aged in any way, or operates abnorm all y, remove it fr om service and contact your nearest service center for repair.

2. Turn the jack 90° to its horizontal position. Be sure that the air m otor is underneath t he ram assembly (37).

3. Connect the ai r valve (29) to an air supply, and press the lev er on the air valv e (29) for 20 seconds to operate the jack.

4. Close the release valve (49) by turning it clockwise while the jack remains at its horizontal position. If the r am assembly ( 37) doesn’t extend, r epeat steps 1 through 4.

Purging the Hydraulic System

During transit, the jack’s hydraulic system may become filled with air, causing a spongy ram action. The air should be purged from the system before operating.

1. To purge air from the hydraulic system, open the release valve (49) by turning it counterclockwise for 2 to 3 turns.

Operation

Jack operation is controlled either manually or by external air pressure. To operate manually, insert the handle (61) into the handle socket (60). To operat e by air pressure, connect the air valve (29) to an external air pressure source. Clean the air connections and lubr icate air mot or prior to as sembly.

To raise the jack, turn the release valve (49) clockwise until it is tight, and either manually pump with t he handle, or press the lev er on the air valve (29) if c onnec ted to an air supply.

To lower the jack, turn the release valve (49) counterclockwise slightly and very slowly. Do not turn valve too quic kl y or more than t wi c e.

1. With the j ack in an upright positi on and the ram completely retracted, open the release valve (49) by tur ning it counterclockwise.

2. Unscrew and rem ov e the filler plug (31) . The oil level shoul d be just up to the hole.

3. If necessary, fill with clean hydraulic jac k oil .

4. Re-install the filler plug (31).

When lowering the jack, do

not turn rel ease valve too quickly or tu rn the valve more than twice. This can cause the load to descend too rapidly creating a dangerous situation.

With the release valve (49) open, manually pump the handle six times. This will keep internal com ponents lubricated.

To prevent corrosion, occasionall y lubri cate the handle socket pivot point (60), release valve

Maintenance

screw thread (49), and ai r v alve (29), with a light coat of oil.

Maintain oil at full level. To check the oil, proceed as follows:

Troubleshooting the AHJ Bottle Jack

Trouble Probable Cause Remedy

Erratic Action.

Ram does not advance.

Ram does not extend or only partially.

Ram advances slowly.

Air i n hydraulic system.

Viscosity of oil is too high. Change to a lower viscosity oil.

Internal leakage in ram (37).

Release valve (49) is open. Close release valve (49).

Low or no oil in reservoir.

Air locked in syste m.

Load is above capacity. Use correct equipment rated for that load.

Low oil level in reservoir.

Pump plunger (57) is binding.

Low air pressure. Adjust ai r pressure to 90 to 14 5 psi. Leaking seals. Replace seals.

Bleed air by opening release valve (49). Pump for 20 seconds.

Replace worn packing. Look for excessive contamination or wear.

Fill reservoir with oil and bleed air from system.

Bleed air by opening release valve (49). Pump for 20 seconds.

Fill reservoir with oil and bleed air from system.

Look for dirt, gummy deposits, leaks, misalignment, worn parts, or defective packing.

Ram advances but does not hold load.

Ram will not retract, or retracts slowly.

Release valve (49) is open. Close release valve (49). Ram seals are leaking. Replace seals. Release valve (4 9) is c l osed. Open releas e valve (49). Reservoir is too full. Drain o il to correct le vel.

Ram damaged internally.

Take jack to authorized service center for repair.

AHJ-12 and AHJ-20 Bottle Jacks

Replacement Parts

Replacement part s are li sted on the f ollowing page s. To order par ts or reac h our servi ce depar tment, call 1-800-274-6848 between 7:30 a.m. and 6:00 p.m. (CST), Monday through Friday. Having the Model Number and Serial Number of your product avail able when you call will allow us to serve you quickly and accurately.

Parts List: AHJ-12 Bottle Jack

Index No. Part No. Description Size Qty

1...............AHJ12-1..................Pump Cylinder............................................. .........................................1

2...............AHJ12-2..................Y-Seal*........................................................5.8x12x5.2mm.................. 1

3...............AHJ12-3..................Nylon Gaske t*..............................................5.8x12x1.2 5mm................1

4...............AHJ12-4..................Copper Washer ........................................... .........................................1

5...............AHJ12-5..................Nut .............................................................. .........................................1

6...............AHJ12-6..................O-Ring.........................................................18x2.65mm.......................1

7...............TS-1503051............ Socket Head Cap Screw..............................M6x20............................... 8

8...............AHJ12-8..................Base Cover.................................................. .........................................1

9...............SB-3........................Steel Ball.....................................................Ø 3mm..............................4

10.............AHJ12-10................ Air Motor Housing........................................ .........................................1

11.............AHJ12-11................ Nut .............................................................. .........................................1

12.............AHJ12-12................ Spring.......................................................... .........................................1

13.............AHJ12-13................ Washer........................................................ .........................................1

14.............AHJ12-14................ Air Pump Plunger......................................... .........................................1

15.............AHJ12-15................ Air Piston Base............................................ .........................................1

16.............AHJ12-16................ O-Ring.........................................................20.3x2.65mm....................2

17.............AHJ12-17................ Air Shuttle Valve.......................................... .........................................1

18.............AHJ12-18................ O-Ring.........................................................43x3.55mm.......................2

19.............AHJ12-19................ Air Piston..................................................... .........................................1

20.............TS-1502021............ Socket Head Cap Screw..............................M5x10...............................3

21.............AHJ12-21................ Shuttle Valve Seal....................................... .........................................1

22.............AHJ12-22................ O-Ring.........................................................57x5.3mm.........................2

23.............AHJ12-23................ O-Ring.........................................................67x2.4mm.........................1

24.............AHJ12-24................ Top Cover.................................................... .........................................1

25.............AHJ12-25................ Snap Ring....................................................Ø 14mm............................1

26.............AHJ12-26................ O-Ring.........................................................11.5x1.5mm......................2

27.............AHJ12-27................ Coupler........................................................ .........................................1

28.............AHJ12-28................ Air Hose Assembly ...................................... .........................................1

29.............AHJ12-29................ Air Valve Assembly...................................... .........................................1

30.............AHJ12-30................ Oil Tank Assembly....................................... .........................................1

31.............AHJ12-31................ Oil Filler Plug............................................... .........................................1

32.............AHJ12-32................ Snap Ring....................................................Ø 36mm............................1

33.............AHJ12-33................ O-Ring Retainer........................................... .........................................1

34.............AHJ12-34................ O-Ring* .......................................................36x4.6mm.........................1

35.............AHJ12-3 5................ Seal Washer *............................................... .........................................1

36.............AHJ12-36................ Piston Ring.................................................. .........................................1

37.............AHJ12-3 7................ Ram Assembly ............................................ .........................................1

38.............AHJ12-38................ Bushing....................................................... .........................................2

39.............AHJ12-39................ O-Ring* .......................................................43x3.55mm.......................1

40.............AHJ12-40................ Snap Ring.................................................... .........................................1

41.............SB-4........................Steel Ball.....................................................Ø 4mm..............................1

42.............AHJ12-4 2................ Safety Va l ve Bal l Se a t................................. .........................................1

43.............AHJ12-4 3................ Safety Va l ve Spr ing..................................... .........................................1

44.............AHJ12-44................ Safety Valve Adjusting Screw...................... .........................................1

45.............AHJ12-45................ O-Ring* .......................................................7.5x2.65mm......................2

46.............AHJ12-46................ Screw.......................................................... .........................................1

47.............AHJ12-47................ Copper Washer ........................................... .........................................4

48.............AHJ12-48................ Valve Block Assembly.................................. .........................................2

49.............AHJ12-49................ Release Valve Assembly ............................. .........................................1

50.............SB-6........................Steel Ball.....................................................Ø 6mm..............................1

51.............AHJ12-51................ Link Pin ....................................................... .........................................2

52.............AHJ12-52................ Pin............................................................... .........................................3

53.............AHJ12-53................ Pump Cylinder............................................. .........................................1

54.............AHJ12-54................ O-Ring* .......................................................7x3mm..............................1

55.............AHJ12-5 5................ Nylon Gasket*..............................................7x12x1.5mm.....................1

56.............AHJ12-56................ Dustproof Ring.............................................12.5x18.5x6mm................ 1

57.............AHJ12-57................ Pump Plunger.............................................. .........................................1

58.............AHJ12-58................ Pump Plunger Pin........................................ .........................................1

59.............AHJ12-59................ Link ............................................................. .........................................1

60.............AHJ12-60................ Handl e Socket............................................. .........................................1

61.............AHJ12-61................ Front Handle................................................ .........................................1

62.............AHJ12-62................ Rear Handle ................................................ .........................................1

63.............TS-1540031............ Hex Nut.......................................................M5....................................1

64.............TS-2361051............ Lock Was h e r................................................M5....................................1

65.............TS-1550031............ Flat Washe r.................................................M5....................................1

66.............TS-2285302............ Phillips Pan Head Machine Screw................M5x30...............................1

67.............AHJ12-67................ Hex Nut (Thin).............................................M10..................................2

68.............AHJ12-68................ Return Spring.............................................. .........................................2

69.............AHJ12-69................ Screw ......................................................... .........................................2

70.............AHJ12-70................ Spring Lid.................................................... .........................................1

................. AHJ12-RK............... Repair Kit for AHJ-12 *................................. ...........................................

Items marked wit h an asteri sk (*) ar e included in the Repair Kit.

Parts List: AHJ-20 Bottle Jack