Preventative Maintenance - Napa 791-6402 A Operating Manual & Parts List

SETUP
PLEASE REFER TO THE EXPLODED VIEW DRAWING IN THIS MANUAL IN ORDER TO IDENTIFY PARTS.
1. Insert the #41 upper handle in the #39 lower handle aligning the cross holes so the handle halves can be secured together using the #40
bolt. Do not overtighten or you will strip the threads.
2. Remove the #38 handle bolt from the #35 handle socket. Install the assembled handle into the #35 handle socket making sure the
bottom of the handle engages the release valve u-joint #32
3. Install the #38 handle bolt in the #35 handle socket and tighten the screw to secure the handle in the yoke.
4. Air may become trapped in the hydraulic system during shipping and handling. Trapped air will affect the pumping performance of the
jack. If this occurs, follow the air purging procedure below:
a) Remove the four screws that secure the cover plate #20 to the jack frame #4 so the oil fill screw #33
removed from the hydraulic power unit reservoir tube #41
b) With the lift arm #25 in its down position, look inside the oil fill screw hole. You should be able to see the top of the power unit's
cylinder #6 (Power Unit Parts List).
it is not at the proper height. See PREVENTATIVE MAINTENANCE for proper fluid specification.
c) Pump the jack against a load that is at least 500 lbs. (225 Kgs). After the load is raised, slightly turn the pump handle in a
counterclockwise rotation so the load is very slowly lowered. While the lift arm is lowering, quickly pump the handle 5 or 6 full
incremental pump strokes. After pumping, lower the lift arm to its full rest position.
d) Install the oil fill screw #33 (Power Unit Parts List). Rotate the handle in a clockwise rotation until tight and pump the lift arm to
maximum height. Repeat steps "a" through "d" until all of the air has been purged from the system.
e) Install the cover plate #20 with the four screws.
OPERATING INSTRUCTIONS
This is the safety alert symbol used for the OPERATING INSTRUCTIONS section of this manual to alert you to potential personal
injury hazards. Obey all instructions to avoid possible injury or death.
IMPORTANT: Before attempting to raise any vehicle, check vehicle service manual for recommended lifting surfaces.
OPERATION:
1. To raise load: Turn the handle in a clockwise direction until tight. Position the jack under the load. Proceed to pump the handle in order
to raise the lift arm to the load. As the saddle at the end of the lift arm gets closer to the load, reposition the jack so the saddle will
contact the load firmly and the load is centered on the saddle. Make sure the saddle is correctly positioned. Raise the load to the desired
work height. Place jack stands of appropriate capacity at the vehicle manufacturers's recommended support areas that provide stable
support for the raised vehicle. DO NOT CRAWL UNDER VEHICLE WHILE LIFTING VEHICLE OR PLACING OR REMOVING THE
JACK STANDS! Once jack stands are positioned, turn the handle VERY SLOWLY. Lower the load to rest on the jack stands. Inspect the
relationship between the jack stands and load to make sure the setup is stable and safe. If the setup is not stable or safe, follow the
preceding steps until corrected.
2. To lower load: Follow the procedures mentioned in "To raise load" section of the OPERATING INSTRUCTIONS in order to raise the
load off the jack stands. DO NOT CRAWL UNDER VEHICLE WHILE LIFTING VEHICLE OR PLACING OR REMOVING THE JACK
STANDS! Once the load has cleared the jack stands, remove the stands from under the load and away from the work area. Turn
handle very slowly in a counterclockwise direction until the load is completely lowered to the ground. Once the jack's lifting saddle has
cleared the load, remove the jack from under the load. CAUTION: Keep hands and feet away from the hinge mechanism of the jack.

PREVENTATIVE MAINTENANCE

This is the safety alert symbol used for the PREVENTATIVE MAINTENANCE section of this manual to alert you to potential personal
injury hazards. Obey all instructions to avoid possible injury or death.
1. Always store the jack in a well protected area where it will not be exposed to inclement weather, corrosive vapors, abrasive dust, or any
other harmful elements. The jack must be cleaned of water, snow, sand, grit, oil, grease or other foreign matter before using.
2. The jack must be lubricated periodically in order to prevent premature wearing of parts. A general purpose grease must be applied to all
zerk grease fittings, caster wheels, front axle, elevator arm, handle base pivot bolts, release mechanism and all other bearing surfaces.
Worn parts resulting from inadequate or no lubrication are not eligible for warranty consideration. See page 5 for lubrication instructions.
3. It should not be necessary to refill or top off the reservoir with hydraulic fluid unless there is an external leak. An external leak requires
immediate repair which must be performed in a dirt-free environment by an authorized service center.
IMPORTANT: In order to prevent seal damage and jack failure, never use alcohol, hydraulic brake fluid, or transmission oil in the jack. Use
NAPA Hydraulic Jack Oil #765-1541.
4. Every jack owner is responsible for keeping the jack labels clean and readable. Use a mild soap solution to wash external surfaces of the
jack but not any moving hydraulic components.
5. Inspect the jack before each use. Do not use the jack if any component is cracked, broken, bent, shows sign of damage or leaks
hydraulic fluid. Do not use the jack if it has loose or missing hardware or components, or is modified in any way. Take corrective
action before using the jack again.
6. Any hydraulic repairs within the warranty period must be performed by an authorized service center.
791-6402 A
OPERATING MANUAL & PARTS LIST FOR 791-6402 A
The hydraulic fluid level should be no higher than the top of the cylinder. Correct the fluid level if
(Power Unit Parts List).
(Power Unit Parts List).
3
(Power Unit Parts List). can be
03/07/17