1 Model # 791-6402. 2 Ton CapaCiTy LOW pRoFiLE . sERviCE jack This operating manual contains important safety information. Read carefully and understand all information before operating tool. Save this manual for future use. Owner/User Responsibility The owner and/or user must have a thorough understanding of the man u fac tur er's operating in struc tions and warn ings be fore using this sERviCE jack . Personnel involved in the use and op er a tion of equip ment shall be careful, com pe tent, trained, and qual i fied in the safe operation of the equip ment and its proper use when servicing motor vehicles and their com po nents. Warning in for ma tion should be em pha sized and un der stood. If the operator is not fluent in English, the man u fac tur er's in struc tions and warn ings shall be read to and dis.
2 Cussed with the op er a tor in the op er a tor's native language by the pur chas er/own er, mak ing sure that the op er a tor com pre hends its con tents. Owner and/or user must study and maintain for future ref er ence the manufacturer's instructions. Owner and/or user is responsible for keeping all warning labels and instruction manuals legible This is a Lifting Device ONLY. Do NOT Move or and intact. Replacement labels and literature are Dolly the Vehicle While on the jack . IMMEDIATELY. AFTER LIFTING, SUPPORT THE VEHICLE WITH APPROPRIATE. available from the manufacturer. MEANS. Do NOT Overload. Overloading can Cause Damage To or Failure of the jack . Lift Only on Areas of the Vehicle as Specified by the Vehicle Manufacturer. CENTER LOAD ON SADDLE PRIOR TO LIFTING.
3 OFF-CENTER. LOADS MAY CAUSE DAMAGE TO jack , LOSS OF LOAD, PROPERTY DAMAGE, PERSONAL OR FATAL INJURY. This jack is Designed for Use Only on Hard Level FOR YOUR SAFETY AND TO PREVENT INJURY: Surfaces Capable of Sustaining the Load. Use on Other than Hard Level Surfaces Can Result in jack Use sERviCE jack for Instability and Possible Loss of Load. lifting purposes No Alterations to the jack Shall be Made. ONLY. Read, Study and Understand the Operating manual Packed with this jack Before Operating. Always support Failure to Heed These Warnings May Result in Loss vehicle with of Load, Damage to jack , and/or Failure Resulting jack stands. in PROPERTY DAMAGE, PERSONAL OR FATAL INJURY. 791-6402 09/12/05. OPERATING manual & PARTS LIST FOR 791-6402.
4 Breather Operating Instructions IMPORTANT: Before attempting to raise a vehicle, check vehicle sERviCE manual for recommended lifting surfaces. 1. To raise load: Close release valve tightly (by turning handle clockwise). DO NOT. OVERTIGHTEN. Position jack under load so that saddle will contact load firmly and load is centered so it cannot slip. Operate jack handle until saddle approaches the load. Once again check to see that saddle is correctly positioned. Raise load to desired height. Place jack stands of appropriate CapaCiTy under the vehicle. DO NOT. Before Use CRAWL UNDER VEHICLE WHILE LIFTING VEHICLE OR. IMPORTANT! BEFORE USING THIS jack : PLACING/ REMOVING jack STANDS! Place jack stands at The breather located below hole in cross plate must be opened.
5 Insert vehicle manufacturer's recommended lift areas that provide stable support for the slotted screw driver through hole and turn breather screw counter clockwise until it stops raised vehicle. turning. Do not force screw past stopping point. 2. To lower load: Open release valve VERY SLOWLY (by turning handle Air may become trapped in the hydraulic system during transit. To purge air: counterclockwise). When release valve is opened, saddle and load will be lowered. 1. Open release valve by turning handle counterclockwise. Lower the vehicle slowly, so as not to shock load the jack stands. Once repairs are 2. Pump handle rapidly 4 full strokes. This will expel air that may have entered completed, raise vehicle enough to remove jack stands.
6 Lower vehicle very slowly. hydraulic fluid passages during transit. CAUTION: Keep hands or feet away from the hinge mechanism of the jack . 3. Close release valve by rotating handle clockwise and pump handle. Lubrication 4. If lift arm raises to full height, jack is ready for use. If not, repeat this procedure or All moving joints require lubrication on a regular maintance schedule. Remove handle follow trouble shooting instructions provided. and grease the lower end of handle where it rotates in the handle socket. Using a grease gun, lubricate the lift arm pivot shaft grease fitting until grease appears at the end of the shaft. Grease all lift arm linkages, front wheels and rear casters. Inspection Visual inspection should be made before each use of the jack , checking for leaking specifications hydraulic fluid and damaged, loose or missing parts.
7 Each jack must be inspected by a manufacturer's repair facility immediately, if subjected to an abnormal load or Model 791-6402. shock. Any jack which appears to be damaged in any way, found to be badly worn, or operates abnormally MUST BE REMOVED FROM sERviCE . 2 ton until necessary repairs are made by a manufacturer's authorized repair facility. It is Low ". recommended that an annual inspection of the jack be made by a manufacturer's Raised ". authorized repair facility and that any defective parts, decals or warning labels be replaced with manufacturer's specified parts. Handle 50". A list of authorized repair facilities is available from the manufacturer. Net 90 lbs. Maintenance IMPORTANT: When adding or replacing hydraulic fluid, always use a quality hydraulic fluid (NAPA 765-1541 or equivalent).
8 DO NOT use brake fluid, alcohol, glycerine, detergent motor oil, or dirty oil as improper fluid can cause serious internal damage to jack . To add hydraulic fluid: With saddle fully lowered and jack on level ground, remove breather. The hydraulic fluid should just cover the surface of the internal cylinder visible through the hole. Do not overfill. Replace breather. If low, add hydraulic fluid as needed. Maintenance and Inspection: The owner and/or user must maintain and inspect the jack in accordance with the manufacturer's instructions. 791-6402 12/13/06. OPERATING manual & PARTS LIST FOR 791-6402. Ref. Part Ref. Part No. No. Description Qty. No. No. Description Qty. 1 RS3501 Retaining Ring 2 23 Inspection Plate 1. 2 RS3501-1 Washer 2 24 Hex Nut 24 2.
9 3 RS640203 Wheel 2 25 Shaft Arm 1. 4 Side Plate Assembly 1 26 Bolt 2. 5 Washer 16 2 27 Retaining Ring 25 2. 6 Hex Nut M16 2 28 Long Linkage 2. 7 RS640207 Caster Assembly 2 29 RS640229 Block Linkage (including #27 (2), #41) 1. 8 Hex Bolt M12 x 20 2 30 Retaining Ring 10 2. 9 Spring Washer 2 31 Saddle Block 1. 10 RS640210 Bolt 2 32 RS640232 Saddle 1. 11 Spring Washer 2 33 Linkage Axle 1. 12 RS3510N Nut M18 2 34 Washer 24 2. 13 Spring Washer 18 2 35 RS35BA Breather 1. 14 Screws 4 36 Pull Rod 1. 15 RS640215 Torsion Spring 2 37 Washer 12 2. 16 RS640216 Handle Socket 1 38 Nut M12 2. 17 RS3526 Bolt 1 39 Lift Arm Assembly 1. 18 RS3536Y Handle Upper 1 40 RS3544N Handle Bumper 1. 19 RS3534 Hex Bolt M6 x 35 1 41 Split Pin 4 x 25 1. 20 RS640220 Handle Lower 1 42 RS640242 Rubber Saddle Pad 1.
10 21 RS640221 Power Unit Assembly 1 43 RS3527 Release Assembly 1. RS640221SK Seal Kit for Power Unit Assembly 44 RS3524-1 Cap for Pump Plunger 1. 22 Spring 1 45 RS3524-2 Pin for Pump Plunger 1. Only those items listed with part numbers are available as sERviCE parts for this jack . 791-6402 12/13/06. OPERATING manual & PARTS LIST FOR 791-6402. PROPER STORAGE. It is recommended that this jack be stored in a dry location with all wheels touching the ground on a relatively level surface. TROUBLESHOOTING. Important: sERviCE jacks are self-contained devices used for lifting, but not sustaining, a partial vehicular load. In accordance with ASME-PALD standard, section Load Sustaining Test: A load not less than the rated CapaCiTy shall not lower more than 1/8 ( ) in the first minute, nor a total of.