Harbor Freight Tools Automobile Parts 41487 User Manual

AIR/OVER HYDRAULIC JACK  
20 TON  
41487  
ASSEMBLY AND OPERATING  
INSTRUCTIONS  
3491 Mission Oaks Blvd., Camarillo, CA 93011  
Copyright © 1999 by Harbor Freight Tools. All rights reserved. No portion of this  
manual or any artwork contained herein may be reproduced in any shape or  
form without the express written consent of Harbor Freight Tools.  
For technical questions and replacement parts, please call 1-800-444-3353  
 
9. Store idle equipment. When not in use, tools must be stored in a dry location to inhibit  
rust. Always lock up tools and keep out of reach of children.  
10. Do not force tool. It will do the job better and more safely at the rate for which it was  
intended. Do not use inappropriate attachments in an attempt to exceed the tool  
capacity.  
11. Use the right tool for the job. Do not attempt to force a small tool or attachment to do  
the work of a larger industrial tool. Do not use a tool for a purpose for which it was not  
intended.  
12. Dress properly. Do not wear loose clothing or jewelry as they can be caught in  
moving parts. Protective, electrically non-conductive clothes and non-skid footwear  
are recommended when working. Wear restrictive hair covering to contain long hair.  
13. Use eye and ear protection. Always wear ANSI approved impact safety goggles.  
Wear a full face shield if you are producing metal filings or wood chips. Wear an ANSI  
approved dust mask or respirator when working around metal, wood, and chemical  
dusts and mists.  
14. Do not overreach. Keep proper footing and balance at all times. Do not reach over or  
across running machines.  
15. Maintain tools with care. Keep tools sharp and clean for better and safer  
performance. Follow instructions for lubricating and changing accessories. Inspect tool  
cords periodically and, if damaged, have them repaired by an authorized technician.  
The handles must be kept clean, dry, and free from oil and grease at all times.  
16. Remove adjusting keys and wrenches. Check that keys and adjusting wrenches  
are removed from the tool or machine work surface before plugging it in.  
17. Stay alert. Watch what you are doing, use common sense. Do not operate any tool  
when you are tired.  
18. Check for damaged parts. Before using any tool, any part that appears damaged  
should be carefully checked to determine that it will operate properly and perform its  
intended function. Check for alignment and binding of moving parts; any broken parts  
or mounting fixtures; and any other condition that may affect proper operation. Any part  
that is damaged should be properly repaired or replaced by a qualified technician. Do  
not use the tool if any switch does not turn On and Off properly.  
19. Replacement parts and accessories. When servicing, use only identical  
replacement parts. Use of any other parts will void the warranty. Only use accessories  
intended for use with this tool. Approved accessories are available from Harbor Freight  
Tools.  
20. Do not operate tool if under the influence of alcohol or drugs. Read warning  
labels on prescriptions to determine if your judgment or reflexes are impaired while  
taking drugs. If there is any doubt, do not operate the tool.  
21. Not to be used for any aircraft purposes.  
REV 02/04  
SKU 41487  
Page 3  
 
Warning: The warnings, cautions, and instructions discussed in this in-  
struction manual cannot cover all possible conditions and situations that  
may occur.It must be understood by the operator that common sense and  
caution are factors which cannot be built into this product, but must be  
supplied by the operator.  
Unpacking  
When unpacking, check to make sure the following parts are included. If any parts are  
missing or broken, please call Harbor Freight Tools at the number on the cover of this  
manual as soon as possible.  
Jack  
Two-piece Handle  
Hose and Fittings Air Inlet Fitting  
Assembly  
1. Screw the Connector (3) into the Air Pump (4) and tighten.  
2. Connect the Air Hose (2) to the Connector (3).  
Tighten the Air Hose to prevent air loss.  
3. Connect the other end of the Air Hose to the Valve Body (1.6).  
4. Connect the two pipe Handles (5, 6) together.  
Operation  
Lifting  
1. Place the slotted end of the Lower Handle (6) over the Release Valve (18, 21).  
Refer to the photo on the next page and the Assembly Drawing on the last page of this  
manual.  
2. Turn the Valve Release screw clockwise until snug.  
3. Place the Jack into position under the load.  
Caution: Follow all Safety and Precautions listed on pages 2 and 3.  
4. Adjust the Extension Screw (44) as needed.  
Turn Counterclockwise to raise, clockwise to lower.  
5. Insert the big end of the Handle assembly into the Handle Sleeve (7).  
6. Connect the air supply hose lock fitting into the Air Inlet Fitting.  
The Lever (1.13) should be Off (not in the locked position).  
REV 05/04  
SKU 41487  
Page 4  
 
7. Press the Lever (1.13) to the On position and lock using the Lock Lever (1.17)  
This provides a continuous air supply to the Air Pump (4).  
8. Raise the Jack by alternately lifting and lowering the Handle assembly.  
Extension Screw (44)  
Connector (3)  
Air Hose (2)  
Handle fits in  
Handle Sleeve  
(7)  
Air Pump  
(4)  
ReleaseValve (18, 21)  
Lever (1.13) and  
Lever Lock (1.17)  
Handle (5, 6)  
Hose Connector (1.1)  
Lowering  
Caution: Avoid rapid descent of the load.Turn the Release Valve slowly.  
1. Release the Lock Lever (1.17) to stop air flow to the Air Pump (2).  
2. Remove air supply hose from the Air Inlet Fitting.  
3. Place the slotted end of the Handle (5, 6) assembly over the Release Valve (18, 21).  
4. Slowly and carefully lower the load by turning the Release Valve counterclockwise in  
extremely small increments using only the Handle assembly (never your hand).  
5. Lower the Extension Screw (44) as needed by turning clockwise.  
6. Remove the Jack.  
Maintenance  
General Care  
1. Periodically lubricate the joints and Extension Screw (44) with a light oil as needed.  
2. Clean the outside of the Jack with a dry, clean cloth.  
3. If the Jack is exposed to moisture, wipe dry with a clean cloth and lubricate as noted  
above.  
4. Store jack with Extension Screw (44) and Ram (48) fully collapsed.  
REV 05/04  
SKU 41487  
Page 5  
 
Purging Air from the Hydraulic System  
Air bubbles can become trapped inside the hydraulic system thereby reducing the efficiency  
of the Jack. Purge the air from the system if lift efficiency drops.  
1. Place the slotted end of the Handle (5, 6) assembly over the Valve Release screw (18,  
21) and turn 1-1/2 turns counterclockwise.  
2. Remove the oil Filler Plug (23) on the side of the jack Reservoir (37) by gently pulling  
and turning it.  
3. Rapidly pump the Handle assembly several times to purge the air from the hydraulic  
system.  
4. Turn the Release Valve screw clockwise until snug using the Handle assembly.  
5. Top off jack Reservoir (37) as described below.  
5. Replace the Filler Plug (23).  
Oil Replacement  
1. Place Jack in an upright position.  
2. Completely lower the Ram (48).  
3. Remove the Filler Plug (23).  
4. Fill with high-quality hydraulic jack oil to the lower rim of the fill hole.  
5. Purge air from the hydraulic system as previously described.  
6. Top off with more hydraulic oil.  
7. Replace Filler Plug (23).  
PLEASE READ THE FOLLOWING CAREFULLY  
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS  
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANU-  
FACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY  
OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY RE-  
PAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY  
PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR  
EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD  
BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE  
BUYER.THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR  
HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO,  
OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS  
THERETO.  
REV 05/04  
SKU 41487  
Page 6  
 
Parts List  
Part  
1.1  
1.2  
1.3  
1.4  
1.5  
1.6  
1.7  
1.8  
1.9  
1.10  
1.11  
1.12  
1.13  
1.14  
1.15  
1.16  
1.17  
2
Description  
Hose Connector  
Connecting Nut  
Air Filter  
Qty.  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
3
3
1
1
1
1
1
1
6
1
Part  
Description  
Rlease Valve Screw  
Release Valve Seal  
Steel Ball 6.35  
Pin  
Qty.  
1
1
1
1
2
1
2
1
1
1
1
1
2
2
2
2
1
4
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
O-ring 18 X 2.4  
Connector  
Valve Spring  
Filler Plug  
Valve Body  
Spring  
Screw  
Packing  
Plug Screw  
Throttle  
Plunge Washer  
Overload Valve Screw  
Safety Valve Spring  
Tapering Overload Valve  
Filter Net  
O-ring 3 X 1.6  
O-ring 18 X 2.4  
Nut  
Lever  
Lever Ring  
Spring Washer 8  
Nut 8  
Hose Connector  
Hose Band  
Bolt M8 X 3.5  
Base  
Lock Lever  
Air Hose  
Plug Screw  
3
Connector  
Cylinder Bottom Seal  
Reservoir  
4
Air Pump  
5
Handle, Upper  
Handle, Lower  
Handle Sleeve  
Shaft Pin  
Packing  
6
Cylinder  
7
Steel Ball Retainer  
Cylinder Top Seal  
0-ring  
8
9
Cotter Pin  
10  
Pump Plunger  
Pump Plunger Retainer  
O-ring  
Top Nut  
11  
Extension Screw  
0-ring  
12  
13  
Dust-Resistant Ring  
Pump Reservoir  
Copper Washer  
Steel Ball 6  
Plunger Connecting Rod  
0-ring Returner  
Ram Header  
Ram  
14  
15  
16  
Spring  
17  
Spring Plate  
REV 05/04  
SKU 41487  
Page 7  
 
Assembly Drawing  
REV 05/04  
SKU 41487  
Page 8  
 

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