Hijacker - Installation

Servicing Instructions

1. LINKAGE ASSEMBLY REPLACEMENT ( drwg A )

(A) Remove cotter pin (6) and pull out clevis pin (4).

(B) Take hold of linkage assembly (5) and gently pull out from the pump assembly cartridge (9).

(C) If the O-ring at the end of cartridge where the plunger goes in is damaged, it is easy to remove by stabbing it with a needle and lifting it out. Replace it with O-ring (13). The replacement plunger O-ring is (22).

(D) Insert plunger into cartridge SLOWLY so as not to damage O-ring(s). Fasten clevis and cotter pins.

2. RELEASE VALVE REPLACEMENT ( drwg A & C )

(A) Open release valve (14) 1 1/2 to 2 turns, unhook the safety catch (24) and push inner tube (25) to the ground.

(B) Remove release valve completely by turning it out all the way. Plug hole with a clean rag in order to prevent undo loss of oil.

(C) New or repaired release valve should be cleaned and is then ready to be installed.

3. PUMP ASSEMBLY CARTRIDGE REPLACEMENT (P.A.C.) ( drwg A, B & C )

(A) Remove cotter pin (6) and pull out clevis pin (4).

(B) Remove release valve (14) as per 2(A) above.

(C) Insert cartridge blank in release valve hole immediately. Remove retaining ring (16) and slide it up to the end of the cartridge blank.

(D) Tap blank lightly to start it in and push SLOWLY but firmly with one hand and rotate the cartridge SLOWLY back and forth with pliers as you remove it. (The slow rotating action is to prevent damage to the O-rings). This is VERY IMPORTANT

(E) If replacing O-rings on the cartridge, maximum care is needed to prevent any damage.

(F) Fit P.A. cartridge (9) to end of blank and squirt some oil on cartridge to assist ease of entry and protection of O-rings. Begin pushing it back into the chamber. Again rotate the cartridge back and forth SLOWLY as you push it into place.
Once in place, replace retaing ring (16), release valve (14) and linkage assembly (5).

NOTE: Sometimes the cartridge (9) will turn in the head chamber when you open and/or close the release valve (14). This is by design and for ease of servicing. If the release valve has seated firmly, simply hold the cartridge with the other hand when opening/closing it.

4. PRIMING A JACK
(See "Before Installation" instructions).

(A) Close release valve and while standing on the leg pad, raise jack up to its full extension.

(B) Open release valve 3 full turns and let jack stand in full extension position for approximately 3 minutes.

(C) Bring jack to down position, close the release valve. Using the handle, pump jack up approximately 1 foot to ensure working. Let jack down again by opening the release valve. The jack should now be ready for installation.

5. PACKING NUT REPLACEMENTS (drwg A & C)

(A) Open release valve 1 1/2 to 2 full turns.

(B) Turn jack on a 45 degree angle, upside down, and place it in a vice, leg pad (25) sticking up. (This is so hydraulic oil will not spill).

(C) Unfasten leg pad bolt (27) and remove inner tube (25).

(D) Using special tool (available at dealer/distributor) remove packing nut (19) from inside cylinder. Replace the aluminum sealing washer (20) and/or O-rings (21) if necessary.

(E) Ensure aluminum sealing washer is securely flat inside packing nut before installation. Torque packing nut on approximately 90 pounds, no more.

(F) Replace inner tube (25) and fasten bolt (27) and lock washer (26). (If you have difficulty lining up the ram (18) with the leg pad hole, turn inner tube (25) slowly until holes line up). Tighten securely.