Parts List and Operating Instructions Form No. 102620
ASSE BLY OF THE JACK
Assembly of the Cylinder
1. Replace o-ring (14) and U-cup (16) on the toe (17).
2. Grease the bore of the toe (17) with a non-silicone lubricant.
3. Mount the toe (17) on the cylinder rod (9).
4. Tighten the guide (8) on the cylinder rod using a thread locking compound. Clean away any excess compound.
5. Grease the exterior machined portion of the toe (17) with a non-silicone lubricant.
6. Assemble the cylinder rod/base plate assembly (9), the toe (17), and the guide (8) into the body of the jack.
7. Drive the spring stock (15), round end first, into the hole at the base of the jack body using a pliers to guide the
spring.
Assembly of the Pump
1. Install o-ring (26), U-cup (25), and wiper (30) on the piston cartridge (29). Grease the pump barrel with a suitable
lubricant.
2. Seat the piston cartridge into its housing in the pump barrel (28) using a small press or mallet and a piece of soft
metal.
3. Replace the inlet check valve into the pump body (21) by installing the ball (13), spring (18) and perforated screw
(12).
NOTE:
●●The inlet check valve may be reconditioned by coining the ball into its seat with a hammer and soft
punch.
●●Springs (11 & 18) look very much alike and must not be confused. Spring (18) is a lighter rate than
spring (11).
4. Replace o-ring (22) on the inlet check valve body. Thread the valve body onto the pump barrel (29).
5. Reassemble the outlet check valve into the pump barrel (28) by installing the ball (13), spring (11) and screw
(12) respectively.
6. Reinstall the breather valve into the top of the pump barrel (28) by first installing the spring (3), then the ball (4)
and last the screw (2).
7. Coat the inside of the jack body with a suitable lubricant to accept the pump body.
Assembly of the Release Valve
1. Reassemble the spring (6), ball follower (7), ball (8), and seat (9).
2. Grease and replace o-ring (1).
3. Install the release valve in the pump body.
4. Install the retaining ring (2).
Assembly of the Lever
1. Using two pins (4), attach the connecting link (5) and the piston (23) to the lever (2). I PORTANT: Do NOT
damage the piston.
Final Assembly of the Jack
1. Place the bladder (20) in the reservoir of the jack body.
2. Mount the pump into its housing on the jack body. Tap the pump into place with a mallet, while protecting the top
of the pump with a piece of wood. Secure with four screws (27).
3. Position the jack vertically and hold it in the extended position by wedging the toe on the base.
4. Open the release valve.
5. Using a funnel with a filter, fill the jack with Power Team hydraulic fluid through the cylinder cap hole while holding
the breather valve ball off its seat with a pin or punch. Fill until fluid comes out of the breather valve. Allow the
breather valve ball to reseat.
6. Close the release valve and continue to fill the jack with oil until oil comes out of the top of the cylinder.
7. Replace the cylinder plug (6) and the o-ring (7).
8. Fill the piston cavity with oil.
9. Install the lever assembly (2) with pin (7), nut (8) and washer (6).
10. Turn the jack upside down for a few seconds.
11. Push the breather valve ball off of its seat until oil stops
coming out of the screw.
12. Install protective screw (1).
Sheet No. 2 of 3
Rev. 4 Date: 13 June 2008
