FORM 2
THE PATENTS ACT-1970
(39 of 1970)
and
The Patent Rules, 2006
COMPLETE SPECIFICATION
(See Section 10 and Rule 13)
1. TITLE OF THE INVENTION UNIVERSAL TROLLEY JACK
2. APPLICANT

a) Name VE Commercia! Vehicles Ltd.
b) Nationality INDIAN
c) Address VE Commercial Vehicles Ltd.,
102, Industrial Area No.1,
Pithampur-454775
Dist. Dhar (Madhya Pradesh), India
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF INVENTION:
The present invention relates to a universal trolley jack. More particularly, it relates to a multi-purpose, user-friendly and ergonomic trolley jack for removal and installation of bulky assemblies on commercial vehicles as well as for on-site repairs. Still more particularly, the present invention relates to a universal trolley jack capable of removing and installing transmission assemblies weighing from 100 Kg to 500 Kg, drive-head assemblies and lifting light duty trucks.
BACKGROUND OF THE INVENTION
A Commercial vehicle is utilized to carry heavy loads from one place to another. To carry these loads, the vehicle is equipped with a large engine, transmission, driveline and other bulky components. All of these sub-assemblies require maintenance which may be either preventive or upon breakdown. With increase in engineering/packaging complexity in vehicle design, it has become very difficult to service the vehicles.
Developing a tool to reduce time and efforts in service of vehicles is the need of the hour. These tools must be reliable, highly productive (fast in operation), user-friendly (easy to operate) and ergonomic. There are various conventional tools and trollies available in market but with limitations with respect to operations, ergonomics, complexity and cost. Especially for removal of heavy assemblies from vehicle, the conventional tools prove unsuccessful because of reasons like limited space available under the vehicle, mechanical lifting system which makes them cumbersome to operate and requirement of manual intervention for removal of assemblies to ground as conventional trolleys cannot bring the assemblies to the ground level.
The related arts describe a variety of concepts related to automobile jacking system:

The patent document US20010062401A1 discloses a combination mechanism of jib, link rods and connecting plates which is used for lifting purpose. However, this invention suffers from the drawbacks of a complicated design which is difficult to manufacturing and use. The disclosed invention also uses expensive hydraulic unit which increases the tool cost. One more major drawback of this kind of design is that mechanical setting and adjustment is required to achieve proper height adjustment of tool. This requires additional time of operation and a skilled technician. This increases the chances of improper tightening of setting bolts leading to falling of assembly from trolley and injury to the technician. Secondly, such adjustments are not possible with a loaded trolley. Another limitation of this design is the limited area of contact with the load which may be suitable for jacking purposes but if used for lifting bulky assemblies, it leads to improper balancing during operation. Also, there is no provision of angular tilting which leads to misalignment of one aggregate/assembly with respect to another.
One more comparative art is described in patent document US20120223281A1. According to this invention, a raising arm is connected with hydraulic cylinder at one end and top plate at another. This top plate is equipped with the provision of mounting upper frame of different heights which helps in achieving required height. Major drawbacks of this concept are same as that of previous concept as it also requires additional frame and column system to attain the required height, and this will too add more time in operation and need for skilled technician for operation. In this concept also, different attachments are required to attain different heights. There is no provision of angular tilting which leads to misalignment of one aggregate/assembly with respect to another. Another major limitation which makes it completely unsuitable for use is the foot operated jacking system which is difficult and uncomfortable to operate while sitting under the vehicle.
Thus, the need was felt to develop a multi-purpose trolley jack which is less complex and more versatile in application. In all the existing prior arts, some major problems were found, which are still unaddressed, i.e. not considered while

designing. These tools require the use of additional systems to attain the desired height. Also, the lifting plate travel is not up to ground level which needs human intervention. The complexity of design increases the cost of the tool to an undesirable extent. The major limitation is that there is no provision for angular tilting of assemblies on jack which will obstruct correct alignment of one assembly with respect to another.
"Universal Trolley" is designed after keeping in mind the above limitations. The invention employs a novel approach for removal and installation of bulky assemblies on commercial vehicles like trucks and buses, specifically entire range of transmission assemblies weighing from 100 Kg to 500 Kg, installation of Drive Head assemblies and also lifting of light duty trucks for various other service operations. Due to its moderate weight and handy size, this tool can prove helpful for on-site repairs as well.
Hydraulic lifting technology is used for the Universal Trolley Jack for favourable user ergonomics. For ease of handling, caster wheels are fitted and the weight of tool assembly is kept optimal.
The specific advantage of this trolley is that it can be used in limited spaces like in low floor height vehicles where other commercial trolleys are not reachable. Also the tray travel is close to the ground surface which provides easy landing of the assembly to the floor and avoid manual shifting of heavy load from trolley to shop floor. One of the unique features of universal transmission trolley is its ability to tilt the assembly angularly through a hinged plate and adjusting bolt mechanism. Due to this feature trolley the trolley is capable of aligning transmission assembly or drive head assembly to the required angle of fitment with respect to their mating assemblies.
The present invention thus offers several advantages over prior art by using simplified link and arm arrangement which will avoid usage of additional bracket/arrangement to attain maximum height. Secondly, the lowest travel height of lifting tray is up to ground level, so that mechanical/human intervention is not

required to move heavy assemblies from trolley. Innovative angular tilting arrangement is also provided, which helps in proper alignment of transmission, drive head and other assemblies relative to other parts. Additionally, this tool works equally well in both light commercial vehicles with low chassis height and heavy duty vehicles with high chassis height.
OBJECT OF THE INVENTION
• The primary object of the invention is to provide a universal trolley jack which enables user-friendly and ergonomic removal/installation of bulky assemblies on commercial vehicles.
• Another object of the invention is to provide a reliable and durable design of a universal trolley jack tool, which is capable of working with a wide range of vehicles i.e. from 5 tonner to 49 tonner vehicles.
• Still another object of the present invention is to provide a universal trolley jack which is capable of reaching aggregates (eg. In low floor height vehicles) which are inaccessible for the tools currently available in the market.
• Yet another object of the invention is to provide a universal trolley jack which does not require human or mechanical intervention to attain maximum required height or for any other mechanical setting before use.
STATEMENT OF THE INVENTION
Accordingly, the present invention provides a reliable, durable, ergonomic and user-friendly universal trolley jack for removal and installation of bulky assemblies on commercial vehicles as well as for lifting light-duty trucks for various other service operations. The universal trolley jack assembly is capable of reaching limited space/ground-level heights in low floor vehicles without any human or mechanical intervention. The universal trolley jack also has the ability

to tilt the assembly angularly through a hinged plate and adjusting bolt mechanism, for aligning the transmission assembly or the drive-head assembly to the required angle of fitment.
SUMMARY OF THE INVENTION
The present invention relates to a universal trolley jack assembly which is capable of removal and installation of bulky assemblies on commercial vehicles, specifically entire range of transmission assemblies weighing from 100 Kg to 500 Kg and drive head assemblies. The universal trolley jack assembly may also be utilized for lifting light duty trucks. The universal trolley jack assembly is capable of reaching limited space/ground-level heights in low floor vehicles without any human or mechanical intervention. The universal trolley jack also has the ability to tilt the assembly angularly through a hinged plate and adjusting bolt mechanism, for aligning the transmission assembly or the drive-head assembly to the required angle of fitment
The universal jack assembly comprises of a base frame, castor wheels, a hydraulic jack, a lifting plate, a tilting plate, a handle, a connecting arm and a connecting bracket.
Another aspect of the present invention discloses the method of assembling and using the universal trolley jack.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and/or other objects, features and advantages, of the invention will become more apparent from the following description of the preferred embodiment with reference to the accompanying drawings in which reference numerals designate the elements of the invention and wherein -
Fig. 1 shows the side view of the universal trolley jack showing all the parts of the assembly

Fig. 2 shows the top view of the universal trolley jack showing all the parts of the assembly
Fig. 3 shows the perspective view of the linkage bracket and the jack mounting plate
Fig. 4 shows the base sub-assembly, comprising of the base frame, the front and rear wheels, linkage bracket and the handle
Fig. 5 shows the perspective view of the connecting arm as used in the universal trolley jack assembly
Fig. 6 shows the perspective view of the hydraulic jack as used in the universal trolley jack assembly
Fig. 7 shows the perspective view of the lifting plate sub assembly as used in the universal trolley jack assembly
Fig. 8 shows the top and bottom views of the lifting plate assembly as used in the universal trolley jack
Fig. 9 shows the perspective view of the connecting bracket sub assembly as used in the universal trolley jack
Fig. 10 shows the perspective view of the connecting arm sub assembly as used in the universal trolley jack
DETAILED DESCRIPTION OF THE DRAWINGS
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practised and carried out in various ways. Also, it is to be understood that the phraseology and terminology

herein as well as the abstract are for the purpose of description and should not be regarded as limiting.
The universal trolley jack assembly will now be described with reference to the accompanying drawings. The description below does not limit the scope and ambit of the disclosure.
Referring to Fig. 1 and Fig. 2, the main parts constituting the universal trolley jack are clearly displayed. Base frame (1) of the universal trolley jack provides rigidity to the assembly and the shape of the base frame helps to avoid toppling of load on the trolley. On both ends of the base frame (1) are the heavy duty castor wheels. The front wheels (2) and the rear wheels (3) help in the free movement of the trolley. The front wheels (2) are fixed type wheels mounted on open ends of structure. The rear wheels (3) are swivelling wheels which helps in turning of trolley and are also equipped with brakes which help to fix trolley to a particular position. The universal trolley jack uses hydraulic elevation technology. Hydraulic jack (4) is a hydraulic assisted mechanical jack mounted on the mounting plate. This jack is a telescopic jack specifically used for loading and unloading of heavy assemblies. The top end of jack is modified to link the same with connecting bracket (6). Connecting bracket (6) is fixed with upper arm which connects the jack with the linkage unit of the lifting plate sub assembly, through the connecting arm. This connecting bracket (6) serves for parallel movement of trolley jack and also acts as a load transferring agent as entire load from the lifting tray is transmitted to the jack through this connecting bracket. Connecting arm (7) connects the hydraulic jack (4) and the connecting bracket (6) to the linkage bracket mounted on the structure. This unit plays an important role in lifting the transmission up and down. Two connecting arms (7) are used to lift the transmission parallel to the ground. The linkage bracket (10) is mounted on the base frame structure as shown in Fig. 4, on which the connecting arms (7) are mounted with the help of a linkage pin. This linkage unit is reinforced with ribs which enhance the rigidity and performance life of the unit and also show better compliance with the CAE test requirements. The lifting plate (8) is connected to

the other end of the connecting arm. Load is placed over the lifting plate (8) and the height is adjusted by changing the inclination of the connecting arms (7). The handle (5) is installed on the rear end of the universal trolley jack assembly to facilitate the driving of the trolley. The handle (5) is also connected to the linked arrangement so that it can be moved vertically or from the ground level based on the requirement of the application.
Referring to Fig. 4, the different parts of the base frame sub-assembly are illustrated. The base frame (1) is constructed using standard extrusion pipes and metal plates which make it rigid and strong. More particularly, the structure is made of square extrusion pipes of IS4923 material and welded plates supported by caster wheels. The "A-Frame" structure helps in correct static and dynamic balancing of the trolley which avoids toppling during working. The hollow section of extrusion also helps in keeping the weight of trolley low. Base frame supports the entire load which is applied on the trolley. The base frame sub-assembly further comprises of front wheels (2), rear wheels (3) and the linkage bracket (10). The front wheels (2) and the rear wheels (3) facilitate the movement of the trolley. These wheels are constructed using heavy duty cast iron, and are wear resistant. The rear wheels (3) are integrated with swivelling attachments and locking brakes which help in maintaining the correct position during working under the vehicle. The linkage bracket (10) is also mounted on the base frame structure to increase the strength and performance life of the linkage unit. This linkage unit is supported by the ribs and is welded all around which helps to resist deflection when load is applied through the lifting units and links.
Referring to Fig. 5, the connecting arm (7) as displayed, is made of square extrusion pipes of IS4923 material and welded plates with eye-joint for insertion of connecting pin. Square extrusion helps the connecting arm to be rigid and capable of resisting the load applied by the weight of transmission and the lifting unit and further transferring the load to the base structure through connecting bracket and hydraulic jack. Square shape of arm also improves the weld ability of connecting bracket with arm.

Referring to Fig. 6, the hydraulic jack illustrated has a loading capacity of 10 T with 240 mm stroke length. The durable jack is mounted on tilt able plate which is connected to base frame via connecting steel pin, which allows angular movement of the jack and helps in keeping ground clearance to the minimum.
Fig. 7 and Fig. 8 explain in detail the parts of the lifting plate assembly. This unit contains the linking unit (16) which is linked to the connecting arm (7). Connecting arm (7) drives the lifting plate to load and unload the assembly with the help of the jack and linkage mechanism. The load rests on base plate (12) which is a rectangular plate with 2 slots for fixing the L Plate (13). The L plates (13) are adjustable in accordance with the width of load to be carried. On L plate (13), special arrangement for mounting of support chain is provided. This chain ensures proper mounting of load of any shape on the lifting plate assembly. The lifting plate assembly is also equipped with L shaped stiffener (15) which provides support to the loading tray where the transmission is rested, and also holds the connecting unit which is connected to the connecting arm for actuation of the lifting unit. As the transmission or most of the bulky assemblies is installed in vehicle at a specific angle to the connecting part, the tilting plate (9) helps the transmission to achieve the required angle for the ease of installation. This tilting action is achieved by bolts from the bottom side. These bolts are round-ended to avoid rubbing on the plate thereby avoiding damage of the plate by the bolt.
Fig. 9 shows the connecting bracket sub-assembly. It comprises of an L plate (21), a rib (19) and a connector (20). The rib (19) and connector (20) are welded on top and bottom of the L plate (21) respectively.
Fig. 10 illustrates the connecting arm sub-assembly, which comprises of the connecting arm (7) and the connecting bracket (6). The connecting bracket (6) is welded on to the upper part of the connecting arm (7).
The universal trolley jack assembly is assembled by following the steps as mentioned below -

1. To the base-frame (1), the jack mounting plate (11) and the hydraulic jack (4) are attached through a steel pin attachment.
2. To the linkage bracket (10), the connecting arms (7) are attached, wherein the arm containing the connecting bracket (6) should be assembled on the top.
3. The jack mounting plate (11) is connected to the connecting bracket (6) through the pin attachment which gives a swivel action to the link.
4. The lifting plate (8) and the handle (5) are connected the connecting arms (7) to complete the universal trolley jack assembly.
METHOD OF OPERATION
The universal trolley jack assembly does not require any pre-operational setting or a skilled/literate technician. It is ergonomic in use and does not require any mechanical intervention for loading and unloading of assemblies. The usage of universal trolley jack involves two steps - Transmission Removal and Transmission Re-fitment.
For transmission removal,
- The propeller shaft and other attaching components like booster connection, sensor electrical connection must be disconnected from transmission side.
- Further the rear mounts and gear shifting linkage connection need to be disconnected.
- The universal trolley jack assembly is moved below the vehicle, keeping the lifting tray at lowered position.
- The trolley is aligned to the proper position below the transmission, and jacked-up to the transmission assembly, adjusting the position according to the width of the transmission, and locking the trolley with wheel brakes.

- The transmission housing mounting bolts, which are mounted with flywheel housing, are removed.
- The transmission is then locked up using a locking chain.
- The jack is then lowered and pulled back to disconnect the main shaft from clutch assembly. Finally the transmission assembly is taken out from the vehicle.
insmission re-fitment -
- The transmission assembly is placed on the lifting tray (8), the sliding arms are adjusted as per the transmission width and the transmission is locked by using locking chain.
- The loaded trolley is moved under the vehicle and aligned to the correct position.
- The jack is lifted up to the required height of mating assembly
- The transmission is tilted to the required angle from front with the help of tilting arrangement provided at front of the trolley to align the main shaft with clutch assembly.
- The transmission assembly is pushed towards clutch assembly until it is aligned properly and there is minimal gap between transmission housing and flywheel housing.
- The jack is lifted up as per the requirement.
- The flywheel housing mounting bolts and rear mount bolts are inserted and tightened to get the required torque.
- The trolley is then lowered down and taken out from the vehicle.
- The gear shifting linkage connection and other attaching components like booster connection, sensor electrical connection on transmission side, are connected.

- Propeller shaft connection is made to complete the re-fitment.
TESTS FOR VALIDATION
Both Hard and soft validation of the invention were performed for the universal trolley using physical trial and CAE tools to evaluate its characteristics and the strength of the trolley under cyclic loads and different operating conditions. Based on the results of tests and analysis done, modifications, have been incorporated in the final product.
The result indicates that the loads and stresses on this trolley are within the target band. Factor of safety (FOS) on the brackets was also found to be in the acceptable range for loads.
Soft validation was followed by hard validation on physical vehicles under actual aftermarket conditions to validate ergonomics, application, usage, cyclic loading and various other factors.
ADVANTAGES:
1. The present invention has compact size and is capable of performing service operations in inaccessible parts of the vehicle (especially with low floor height).
2. This universal trolley jack assembly is ergonomically suitable and easy to use due to the presence of the hydraulic lifting system.
3. The present invention improves the productivity of workshops as it requires very less effort and time for removal and installation of bulky assemblies.

4. The universal trolley jack is modular throughout the vehicle platform as it can be operated from ground level to more than 650 mm height without using any additional tools.
5. This universal trolley serves as single equipment solution for the entire range of trucks and buses which optimizes the dealers' investments.
6. The present invention meets CAE (Computer Aided Engineering) criteria required for deployment in workshops.
7. The present invention does not require any manual intervention to attain the maximum required height or any mechanical setting before work.
8. The present invention minimizes user level intervention for heavy load shifting and during alignment due to innovative angular tilting arrangement.
9. The present invention has better serviceability and easy to manufacture due to simple design.

CLAIMS
We claim,
1. A universal trolley jack assembly comprising: a base sub-assembly for providing rigidity and support to the invention and to avoid toppling of load from the trolley; a lifting sub-assembly for placing the load to be carried by the universal trolley jack; a connecting arm sub-assembly for connecting together the base sub-assembly and the lifting subassembly; a hydraulic jack (4) for facilitating the elevation of the lifting plate sub-assembly; a connecting bracket sub-assembly; and a handle to propel the universal trolley jack assembly.
2. The universal trolley jack assembly as defined in claim 1, wherein the said assembly comprises of a base sub-assembly which further comprises of a base frame (1), front wheels (2), rear wheels (3), s handle (5) and a linkage bracket (10).
3. The universal trolley jack assembly as defined in claim 1, wherein the said assembly comprises of a connecting bracket sub-assembly which further comprises of an L plate (21), a rib (19) and a connector (20) such that the rib (19) and the connector (20) are welded on top and bottom of the L plate (21) respectively.
4. The universal trolley jack assembly as defined in claim 1, wherein the said assembly comprises of a lifting plate sub-assembly which further comprises of a linking unit (16) linked to the connecting arm (7), a base plate (12), two L plates (13), two L-shaped stiffeners (15) and a tilting plate (9).
5. The universal trolley jack assembly as defined in claim 1, wherein the said assembly is capable of reaching ground-level heights in low floor vehicles without any human or mechanical intervention

6. The universal trolley jack assembly as defined in claim 1, wherein the said assembly is capable of tilting angularly through a hinged plate and adjusting bolt mechanism for aligning the transmission assembly or the drive-head assembly to the required angle of fitment.