rev 3-7-16 mm-2000 mm-2000s mm-2000 ah mm-2000ahs …

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Professional Service

Equipment

3501 S. Leonard Rd.

St. Joseph, Missouri 64503 U.S.A.

800-821-7320

FAX (816) 233-7251

www.grayusa.com

REV 3-7-16

MM-2000 – MM-2000S – MM-2000 AH – MM-2000AHS 2,206 lb. Capacity (MM stands for MULTI-MATIC)

TCHS - TRUCK COMPONENT HANDLING SYSTEM OPTIONAL ADAPTERS – CLUTCH, DIFFERENTIAL, FLY WHEEL, BRAKE DRUM, 1 ¾” SPLINE, 14 TOOTH SPLINE & EF-10

Power system

The self-contained sealed system hydraulic unit incorporates a modular design and is easily serviceable and replaceable. The unit features urethane seals, hard chrome plated plunger, ram, stainless steel ball bearings and springs. The hydraulic unit contains a high-grade low viscosity hydraulic fluid that operates under very severe conditions. The hydraulic system was designed, tested and proven by the Gray engineering staff and all manufacturing processes are performed within Gray to insure quality and consistency.

It is also available with an air driven motor that powers the hydraulic system. The system is designed to combine speed and precise control when making fine adjustments and eliminates manual pumping process, which on a large component can require 70 lbs. of force to operate the pump. **This can only be used with an airline connected to the jack. There is no manual pump on the air/hyd model.

Transmission brackets

The jack comes complete with four 75 degree uniquely designed ratcheting brackets. The brackets slide in freely and automatically ratchet and lock into place and release using individual spring loaded adjustment levers…no tools needed.

Tilt controls. Designed for ease of operation. Roller thrust bearings reduce effort to

operate tilt controls. The design provides 10 degrees of fore and aft tilt and side-to side tilt. Both tilt shafts incorporate a hand adjustment knob and also a hex head designed end for optional wrench adjustment.

Truck component handling adapters. (See page 4)

The system comes complete with a Heavy-Duty tool box that contains: set of universal adapters, which can be assembled, in a modular fashion to stabilize and support heavy-duty truck driveline components to include: power dividers, differentials, axle assemblies and a variety of transmissions.

This combined lift and adapter system provides the heavy-duty truck technician with four separate support mechanisms. 1. A flat steel head platform with tilt controls. 2. Four 90° Transmission Brackets 3. Four independently adjustable vertical brackets. 4. Chain slings. 5. Two bolt/stud circle adapters.

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Unique frame design.

Designed in a “wedge” shape, the jack combines an open front, narrow rear and low profile, which maximizes accessibility, convenience and stability. The jack is shipped fully assembled and ready to use using welded steel frame construction.

Cycle and load testing procedures.

Testing is a standard operating procedure with all Gray products. Each MM-2000 hydraulic unit is individually tested using two separate procedures. Each individual hydraulic unit must pass a “full rated load” test before it packaged for shipment. This will ensure that it meets or exceeds all specifications and the customer will receive a product that is “ready to go to work”.

The original design of the hydraulic unit has been laboratory tested at Gray’s facility to insure that it will hold up to years of heavy shop use.

Time proven design.

The Gray MM-2000 jack has been continually manufactured since the mid 1970’s and quickly became the industries most desired choice for heavy-duty truck component installation and removal.

Easily portable.

Four large 4” swiveling casters with ball bearing mounts allow smooth movement under the vehicle for exact spotting and easy movement throughout the shop.

GRAY MM-2000S / MM-2000SA/H SPECIFICATIONS

Capacity 2,206 lbs Minimum starting height 8 inches Maximum lift height 34 inches Power Manual/Hydraulic - Air/Hydraulic Air pressure required 90 – 200 psi Ram power travel 26 inches

Head Plate size (Before 7/2004) 10” x 15” Head Plate size (After 7/2004) 11-1/2” x 17”

Tilt forward 10 degrees

Tilt rear 10 degrees

Tilt side-to-side 10 degrees

Frame width 28-1/4 inches Handle length 44-1/2 inches Caster wheel diameter 4 inches Shipping weight 305 lbs

The warranty of the MM-2000S / MM-2000A/HS is 1 year.

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Other Specifications:

Head Plate Adjustments –The head plate can be adjusted to accommodate a variety of components, front to rear and side-to-side. Gray utilizes a combination of “ACME” threaded rod, hex head nut and turning knob for head plate adjustments. This will allow for hand and wrench adjustments. With a heavy component on the head plate, the wrench adjustment control is very necessary due to the weight of the component sitting on top of the head plate. The head plate was 15” long x 10” wide. *After July 2004 the new size is 17” x

11-1/2”. This was changed to accommodate the larger transmission casings that are available today.

JACK SPECIFICATIONS: Outside Leg Spread – 28” Inside Leg Spread – 21” (Distance past the caster bracket) Width at back of jack with wheels facing out – 20” Casters: 4” Steel swivel casters with grease zerk -

Pump handle rotates 360 to allow for easy positioning while under the vehicle. Ratcheting Brackets – allow for easy adjustment when working with a variety of different components. Other style jacks typically use threaded capscrews to adjust the head plate that require a wrench or tools. Release Stem Guard – the jack has a round guard located at the back of the jack that protects the release knob from being damaged.

The old style MM-2000 was designed with the release knob on the left side and pump handle on the right side of the jack. It was also only 2,000 lbs. capacity. This was discontinued in 1985 and was replaced by a 2,206 lb. Capacity (1 Metric Ton).

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TRUCK COMPONENT HANDLING SYSTEM:

TCHS KIT AS SEEN WITH THE JACK Much more than a transmission jack, the MM-2000S is a handling system for differentials, power dividers, auxiliary boxes, and the entire axle assemblies. It’s the sure and easy way to grip awkward truck components. The unique patented features of the MM-2000S make the most difficult jobs a simple one-man operation. The MM-2000S sets up quickly, cradles components securely. The truck component adapters adjust to the shape and size of the load, so you can remove and install the tough ones with confidence. Suggested configurations and set ups are available in the owners manual that is provided with each kit and jack purchased.

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Below are a few examples of different configurations that can be set up using the TCHS kit:

TRANSMISSIONS DIFFERENTIALS POWER DIVIDERS

Transmissions

Configuration 1 Configuration 1A

No. Description Qty No. Description Qty

11 75° Tramsmission Bracket 4 3 90° Transmission Bracket 4



5 Adjustable Vertical Support 4 3 90° Transmission Bracket 4

11 75° Transmission Bracket 4 5 Adjustable Vertical Support 4

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7 Coil Chain 2 5 Adjustable Vertical Support 4

11 75° Transmission Bracket 4 7 Coil Chain 2



1Universal Adapter Support Bar, Long2 1 Universal Adapter Support Bar, Long 2



8 Cap Screws 4 7 Coil Chain 2

9 Short Support Bar, R.H. 1 8 Cap Screws 4

10 Long Support Bar, L.H. 1 9 Short Support Bar, R.H. 1

11 75° Transmission Bracket 4 10 Long Support Bar, L.H. 1

The technique for applying configuration 4A is to

position the lift platform so the lower part of the

differential housing and the tie rod both rest directly

on the lifting platform. Spread transmission

brackets (3) to the left and right of the differential

housing. Slide adjustable vertical supports (5) along

the universal support bars (9) or (10) until the upper

portions come into contact with the axle housing.

Use vertical supports (5) to tighten the chain slings

(7) so they firmly cradle the axle housing. This

provides lateral stability for the axle assembly. Use

the tie down strap (4) to secure the drive shaft lift

platform.

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Configuration 4B

No. Description Qty

2 Bolt Circle Adapter 1

3 90° Transmission Bracket 4

5 Adjustable Vertical Support 4

7 Coil Chain 2

8 Cap Screws 4

9 Short Support Bar, R.H. 1

10 Long Support Bar, L.H. 1

The technique for using configuration 4B is to

position the axle assembly so the bottom of the

differential housing rests directly on the lift

platform. Spread transmission brackets (3) so they

are approximately 18 inches wide and so the chains

(7) are located to left and right of the differential

housing. Slide adjustable vertical supports (5)

along the universal support bars (9) and (10) until

the upper portions come into contact with the axle

housing. Use vertical supports (5) to tighten the

chain slings (7) so they firmly cradle the axle

housing on each side of the differential. This

provides lateral stability for the axle assembly.

Secure the bolt circle adapter (2) to the end yoke or

the housing by removing a bolt directly from the

flange which supports the input shaft bearing. On

the bolt circle adapter, tighten the elbow bolt and

component mounting bolt sufficiently to secure the

load. This support mechanism will prevent the

assembly from tending to rotate and will hold the

axle assembly firmly in place.






8 Cap Screws 4 7 Coil Chain 2

9 Short Support Bar, R.H. 1 8 Cap Screws 4


11 75° Transmission Bracket 4

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2 Bolt Circle Adapter 2 2 Bolt Circle Adapter 2

3 90° Transmission Bracket 4 3 90° Transmission Bracket 4

8 Cap Screws 4 5 Adjustable Vertical Support 4

9 Short Support Bar, R.H. 1 7 Coil Chain 2

10 Long Support Bar, L.H. 1 8 Cap Screws 4

9 Short Support Bar, R.H. 1


Configuration 6B Configuration 6C


1Universal Adapter Support Bar, Long2 3 90° Transmission Bracket 4

2 Bolt Circle Adapter 2 5 Adjustable Vertical Support 4

3 90° Transmission Bracket 4 7 Coil Chain 2

8 Cap Screws 4 8 Cap Screws 4

9 Short Support Bar, R.H. 1 9 Short Support Bar, R.H. 1

10 Long Support Bar, L.H. 1 10 Long Support Bar, L.H. 1

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Operating Instructions

After unpacking the hand powered model, use a flat bladed screwdriver to open the hydraulic reservoir vent

screw. Turn counterclockwise. This vent screw is located on the left side of the pump block which is mounted

on top of the reservoir at the rear of the jack. Always close this vent screw to prevent hydraulic fluid loss

during shipment or if stored in an upended position.

After unpacking the air / hydraulic powered model, install a quick coupler into the hand air valve. The jack is

now ready for use. The following chart is for reference only. The exact air pressure required may vary slightly.

Typical Air Motor Operating Pressures

Component Weight Air Pressure Required

500 lbs. ................................ 40 psi

1000 lbs. ............................... 70 psi

1500 lbs. .............................. 100 psi

2000 lbs. .............................. 135 psi

2206 lbs. .............................. 145 psi

When using the tow handle, position hose as shown in the photo to the right.

Removing Components 1. Place jack under component on a hard level surface free of obstacles.

2. Use the pump handle or hand air valve to raise hydraulic portion of jack to make contact with the

component.

3. Secure component firmly using manufacturer supplied brackets and adapters. When possible, the

component should rest directly on the lift platform.

4. Secure component to jack using tie down strap and ratchet. Refer to “Tie Down Ratchet Operating

Instructions” section of this manual.

5. When removing a driveline component do not lower the jack until the component is completely free of

the vehicle. All bolts, control connections, etc. must be disconnected and the housing interface seal

must first be broken free. Remove component mounting bolts. Lower the hydraulic portion of the jack

by slowly turning the release knob.

Note: The area around the jack must be clear for the jack to move and accommodate the swinging movement of

the lift arm.

6. Use the tow handle or pump handle to transport a component.

Installing Components 1. Once the component is secure using the tie down strap, place jack under component’s installation

position.

2. Use the pump handle or hand air valve to raise hydraulic portion of jack into position for installation.

Note: The area around the jack must be clear for the jack to move and accommodate the swinging movement of

the lift arm.

3. Install component.

4. Loosen the component securing brackets on lift platform which support the component.

5. Remove the tie down strap. Refer to “Tie Down Ratchet Operating Instructions” section of this manual.

6. Lower the hydraulic portion of the jack by slowly turning the release knob.

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Specifications

Gray

Model Number MM-2000 MM-2000 A/H

Capacity 2206 lbs

Starting Height 8-1/4”

Max Lift Platform

Height 34-1/2”

Power source Hyd or Air/Hyd

Overall Length 44”

Overall Width 28”

Caster Diameter 4”

Forward Tilt 10

Rearward Tilt 10

Sideways Tilt 10

Handle Length

Head plate size

After July 2004

10” x 15”

11-1/2” x 17”

Shipping Weight 314 lbs

Manufactured in USA

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TCHS KIT used to stabilize a Mack Transmission TCHS Kit used to handle a rear-rear differential

Supporting auxiliary, (rear box) No TCHS kit used on this flat pan transmission.

Supporting Inter-Axle Differential Carrier

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Optional Adapters:

Differential Adapter – This is a dedicated adapter for the removal of truck differentials. The customer can use the Truck Component Handling System adapters for removing differentials, but this dedicated adapter saves the customer time if they are removing differentials frequently. The adapter includes (1) differential adapter plate, (1) one long differential support tube, (1) short differential support tube, (1) support pin adjustment bracket, (2) adjustable differential adapter collars, and the necessary components to bolt the adapter to the Gray 2000 Series head plate. To install or remove the truck differential, either the short or long differential support tube must

be inserted through the differential’s yolk (See picture). Then the differential must be supported by one adapter collar being secured to the support tube above the yolk and the other adapter collar being secured to the support tube below the yolk (See picture).

Clutch Adapter – This adapter bolts to the existing head plate of the Gray 2000 Series transmission jacks. It allows the technician to remove the clutch and transmission with the same jack. The clutch adapter includes the adapter mounting plate, 2” spline shaft, and the vertical support. The 2” spline shaft allows the technician to remove both 14” and 15 ½” clutch assemblies. Similar to the TCJ-500, the adapter rotates 360 degrees allowing the technician to lay the clutch down horizontally, and has fore/aft & side tilt adjustments. 1 ¾” Spline – This adapter can be purchased once the customer has the above clutch adapter for the Gray 2000

series transmissions jacks. This 1 ¾” spline adapter is used for 1” or .983” hub pilot sizes.

NEW ADAPTER:

Optional 14 tooth spline for EATON ULTRASHIFT PLUS transmissions.

The 10 tooth spline is currently the norm for HD transmissions. Eaton Fuller has come out with a

new design that has a 14 tooth spline. Picture below.14 Tooth Spline on left, 10 tooth on right.This adapter can be purchased once the customer has the above clutch adapter

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Flywheel Adapter – This adapter can be purchased if the customer already has the clutch adapter or they can purchase the flywheel adapter separately and then order the adapter mounting plate through customer service. Brake Drum Adapter – This adapter can be purchased if the customer already has the clutch adapter or they can purchase the brake drum adapter separately and then order the adapter mounting plate through customer service.

EF-10 Adapter – This adapter has been designed specifically for use on the FR Series Eaton Fuller RoadRanger transmissions. These transmissions have an irregular shaped bottom which the adapter accommodates. The EF-10 adapter is designed to quickly mount to the head plate of all the Gray 2000 series transmission jacks.

NEW

King Pin Adapter – This adapter has been designed to handle complete hub and or

disc brake assembly removal. Utilized for king pin removal, bearing, seal replacement,

pulling hubs, along with hydraulic, airbrake and disc brake work. Eliminates taking

assembly apart piece by piece.

Eliminates lifting heavy components by hand.

rev 3-7-16 mm-2000 mm-2000s mm-2000 ah mm-2000ahs …

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