POWER FIST 9096652 Ton Flat Bottom Long Ram Hydraulic Jack Instruction Manual

POWER FIST 9096652 Ton Flat Bottom Long Ram Hydraulic Jack

Please read and understand all instructions before use. Retain this manual for future reference.

SPECIFICATIONS

INTRODUCTION
The long ram hydraulic jack is ideal for lifting heavy objects. Use it on hydraulic equipment that requires an extended lift range.

SAFETY

WARNING! Read and understand all instructions before using this tool. The operator must follow basic precautions to reduce the risk of personal injury and/or damage to the equipment.

HAZARD DEFINITIONS
Please familiarize yourself with the hazard notices found in this manual. A notice is an alert that there is a possibility of property damage, injury or death if certain instructions are not followed.

  DANGER!| This notice indicates an immediate and specific hazard that will result in severe personal injury or death if the proper precautions are not taken.
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  WARNING!| This notice indicates a specific hazard or unsafe practice that could result in a serious injury if the proper precautions are not taken.
  CAUTION!| This notice indicates a potentially hazardous situation that may result in minor or moderate injury if proper practices are not taken.
  NOTICE!| This notice indicates that a specific hazard or unsafe practice will result in equipment or property damage, but not personal injury.

WORK AREA

1. Operate in a safe work environment. Keep your work area clean, well-lit and free of distractions. Place lights so you are not working in a shadow.
2. Keep anyone not wearing the appropriate safety equipment away from the work area.
3. Store unused tools properly in a dry, safe and secure location to prevent rust, damage or misuse.

PERSONAL SAFETY
WARNING! Wear personal protective equipment approved by the Canadian Standards Association (CSA) or American National Standards Institute (ANSI).

PERSONAL PROTECTIVE EQUIPMENT

1. Always wear impact safety goggles that provide front and side protection for the eyes. Eye protection equipment should comply with CSA Z94.3-07 or ANSI Z87.1 standards based on the type of work performed.
2. Wear protective clothing and gloves designed for the work environment, materials and tools.
3. Wear steel toe footwear or steel toe caps to prevent a foot injury from falling objects.

PERSONAL PRECAUTIONS
Control the tool, personal movement and the work environment to avoid personal injury or damage to tool.

1. Do not operate any tool when tired or under the influence of drugs, alcohol or medications.
2. Avoid wearing clothes or jewelry that can become entangled with the moving parts of a tool. Keep long hair covered or bound.

SPECIFIC SAFETY
WARNING! DO NOT let comfort or familiarity with product (gained from repeated use) replace strict adherence to the tool safety rules. If you use this tool unsafely or incorrectly, you can suffer serious personal injury.

1. Use the correct tool for the job. This tool was designed for a specific function. Do not modify or alter this tool or use it for an unintended purpose.
2. Do not use a handle extension for the jack handle.
3. Make sure the load is stable, so it does not shift when lifting or lowering.
4. Once the load is lifted to the desired height, support the load with jack stands to prevent injury should the long ram hydraulic jack fail. Do not work under a load that is supported only by a jack.
5. Do not attempt to move the load while on the long ram hydraulic jack. The jack must only be used in a static position for lifting and lowering loads. Ensure that the load remains stable at all times.
6. Do not push a load off the long ram hydraulic jack; lower carefully.
7. Ensure that there are no obstructions under the load and that the area is clear before lowering the device.
8. Lower the load in a slow and controlled manner to prevent shock loading. Shock loading may cause the device to fail and lead to property damage and/or severe personal injuries.

LIFTING PRECAUTIONS
WARNING! Ensure that the load is secure and centered on the device. Do not allow the load to move or tilt as the device may kick out causing injury to the operator and/or cause the load to fall.

1. Do not exceed the maximum capacity to prevent equipment failure or damage.
2. Inspect the device before each use. Do not use if it is bent, cracked, damaged or has been subjected to a sudden or unexpected (shock) load.
3. Ensure that all applicable pins, bolts and nuts are firmly tightened before using.
4. Use only with accessories rated to handle the forces exerted by the device during operation. Other accessories may break and forcefully launch pieces.
5. Do not place your hands between moving components.

HYDRAULIC PRECAUTIONS
DANGER! Seek immediate medical attention if hydraulic fluid under pressure penetrates your skin. See Injection Injury precautions for instructions before using a pressurized hydraulic system.

1. Do not touch or handle, hydraulic hoses or components while under pressure. Hydraulic fluid escaping under pressure has sufficient force to penetrate your clothing and skin. A pinpoint hole may inject hydraulic fluid into your body. Seek immediate medical attention if this occurs (see Injection Injury).
2. Never exceed the hydraulic system’s load capacity (see Specifications).
3. Do not adjust the hydraulic system’s relief setting. The settings are preset by the factory.
4. Hydraulic oil under pressure is hot and can cause a burn injury if touched, sprayed or spilled. Allow the hydraulic system to cool before conducting maintenance.
5. Hydraulic components require regular inspection. Release all pressure from the system before you inspect it. Replace damaged hydraulic parts with identical manufacturer’s components.
6. Do not attempt makeshift repairs to a hydraulic system. Such repairs can fail suddenly and create a hazardous condition.
7. A damaged or disconnected hydraulic hose under pressure may whip around and inflict personal injury or damage the work area. Secure the hose to a fixed or permanent structure with clamps or cable ties.
8. Hydraulic fluid has a combustible flash point of 200°F (93°F). Do not expose the fluid to an ignition source.
9. Change your clothing immediately if sprayed with hydraulic fluid. Store clothing or rags contaminated with hydraulic fluid in an approved metal safety can with a spring-closing lid and venting designed to contain a fire.
10. Only use hydraulic fluid in the pump. Do not substitute or mix brake fluid, or any other fluid, with the hydraulic fluid. This can result in a pump failure and injure the user or bystander. It may also damage the pump.

INJECTION INJURY
DANGER! Seek immediate, professional medical treatment if fluid penetrates your skin. It may feel like a pricking or sting. Do not wait for the appearance of symptoms. A toxic reaction can occur from the exposure. Delay in treatment can lead to amputation or death.

Inform the medical staff that you have a fluid penetration injury as soon as you arrive at the medical facility. The severity of the symptoms will depend on the type of fluid injected. Bring the Safety Data Sheet for the fluid with you to the medical facility if possible.

INJECTION PRECAUTIONS
Fluid can penetrate the skin at 100 PSI pressure. Fluid escaping under pressure from the tool has sufficient force to penetrate your clothing and skin. Follow the precautions below to avoid an injection injury.

1. Always check for leaks wearing a face shield, safety goggles, rubberized gloves and protective clothes.
2. Release all pressure from the system before you inspect it.
3. Do not use your hands to detect a leak. Use a large piece of wood, cardboard or paper and watch for discolouration.
4. Replace damaged parts with identical manufacturer’s components to ensure it is rated to handle the pressure.

UNPACKING

• WARNING! Do not operate the tool if any part is missing. Replace the missing part before operating. Failure to do so could result in a malfunction and personal injury.
• Remove the parts and accessories from the packaging and inspect for damage.

CONTENTS
Make sure that all items in the contents are included.

• Long Ram Hydraulic Jack
• Handle

IDENTIFICATION KEY

• A. Rod End Opening
• B. Ram
• C. Oil Plug
• D. Handle
• E. Housing
• F. Handle Receiver
• G. Pump
• H. Release Valve

ASSEMBLY & INSTALLATION

WARNING! Ensure that the pins are capable of supporting the load and are properly secured to prevent equipment failure and/or personal injuries.

1. Align the ram’s bolt hole with the bolt hole on the equipment’s attachment point. The attachment point location will vary depending on the equipment and application.
2. Insert a pin or bolt through the mounting points and the ram’s bolt hole.
3. Secure the pin with the appropriate clip or a hardened cotter pin.
4. Secure the bolt with a washer, lock washer and nut.
5. Mount the flat base onto the appropriate location of the equipment, following the equipment’s installation instructions.
   Secure the base with bolts, washers, lock washers and nuts, if possible. The hardware is not included.

OPERATIONS

RAISING A LOAD
Once the load is lifted to the desired height, support the load with jack stands to prevent injury should the long ram hydraulic jack fail. Do not work under a load that is supported only by a jack.

1. Close the release valve. Insert the slotted end of the handle over the valve and twist to the right.
2. Insert the handle into the bottle jack’s receiver.
3. Pump the handle until the load reaches the desired height.
4. Position supports, like jack stands, if the load will remain above ground for an extended period. Consult the support device’s manual for proper placement.
5. Twist the valve to the left slowly to allow the ram to retract. Gradually lower the load onto the supports.
6. Once the supports are carrying the load, open the valve to allow the ram to retract fully.

LOWERING A LOAD
WARNING! Dynamic shock loads are created by quick opening and closing of the release valve when lowering the load. The resulting overload may cause the hydraulic system to failure, which could result in severe personal injury and/or property damage.
WARNING! Before lowering the load, ensure that there are no obstructions underneath and that all people are standing clear.

1. When the work is done, raise the load enough with the jack to carefully remove the supports.
2. Open the release valve by slowly rotating the handle counterclockwise. The load will descend as pressure is released from the jack’s system. Control the speed by rotating the handle.
3. Rotate the handle counterclockwise to increase the speed.
4. Rotate the handle clockwise to decrease the speed.

CARE & MAINTENANCE

1. Maintain the tool with care. A tool in good condition is efficient, easier to control and will have fewer problems.
2. Inspect the tool components periodically. Repair or replace damaged or worn components. Only use identical replacement parts when servicing.
3. Keep the tool handles or gripping surfaces clean and dry.
4. Maintain the tool’s labels and name plates. These carry important information. If unreadable or missing, contact Princess Auto Ltd. for replacements.
5. Have a qualified technician inspect the jack:
6. Once a year.
7. After receiving a shock load. Take the jack out of service until the technician certifies that it is safe to use.

WARNING! Only qualified service personnel should repair the tool. An improperly repaired tool may present a hazard to the user and/or others.

HYDRAULIC MAINTENANCE

HYDRAULIC RAM MAINTENANCE
Monthly maintenance is recommended for the hydraulic ram. Any restrictions due to dirt, rust, etc. can cause the either slow movement or extremely rapid jerks, damaging the internal components. The following steps are designed to keep the pump maintained and operational.

1. Lubricate the cylinder and the pumping mechanism with light oil.
2. Visually inspect for cracked welds, bent, loose, missing parts or hydraulic oil leaks.
3. Inspect the hydraulic ram immediately if it was subjected to an abnormal load or shock load.
4. Remove any hydraulic jack pump from service that is damaged, worn down or operates abnormally, until repaired by an authorized service technician.
5. Check and maintain the ram oil level.
6. Always store the hydraulic ram in the fully retracted position. This will help protect critical areas from corrosion.
7. Do not use brake or transmission fluids or regular motor oil as they can damage the seals. Always purchase and use products labeled Hydraulic Oil.

REFILL THE HYDRAULIC JACK PUMP
The pump may become less efficient when the hydraulic oil level is too low or contaminated by metal particulate through normal wear-and-tear.

1. Retract the ram and remove the oil filler plug.
2. Check and maintain the ram oil level.
3. Check the oil level with the oil dip stick. Use a long plastic cable tie as a substitute if the unit does not have a dipstick.
4. Fill the cylinder with a high quality hydraulic jack oil, up to the oil plug opening.
5. Place a funnel into the oil fill neck. The funnel opening should be wide enough to prevent the oil from collecting in the funnel’s cone.
6. Pour oil into the funnel. Allow the oil to settle for one minute and recheck the level. Repeat until the desired level is reached.
7. Follow the steps in Bleeding the Hydraulic System.
8. Insert the oil filler plug and hand tighten.
9. Wipe up any spilled oil. Dispose of oil soaked rags in a proper hazardous waste container.

REPLACE THE HYDRAULIC OIL
Replace the hydraulic oil annually.

1. Relieve pressure from the system by opening the release valve, then loosening the oil filler plug.
2. Remove the oil fill plug.
3. Lay the jack on its side and drain the oil into a suitable container. Dispose of used hydraulic oil in accordance with local by-laws.
4. Stand the jack on its base and wipe off any excess oil.
5. Follow the instructions for Refill the Hydraulic Jack.

BLEEDING THE HYDRAULIC SYSTEM
Bleed excess air from the hydraulic system as follows:

1. Open the release valve by turning it counterclockwise.
2. Remove the oil filler screw and fill the hydraulic jack pump with hydraulic fluid.
3. Wait 5 minutes for trapped air to rise to the surface.
4. Pump the handle for several strokes to eliminate any air in the system.
5. Check the oil filler hole and if necessary, top off with more hydraulic oil.
6. Restore the oil filler screw. Close the release valve by turning clockwise.
7. Test the ram several times for proper operation before putting it into use. Do not use the ram if it still does not appear to be working properly. Have a qualified service technician service or repair the hydraulic system.

FLUSHING THE VALVE
Contaminants may block the release valve, causing issues when attempting to lower a load. Clear the valve with the following steps.

1. Lower the saddle and securely close the release valve.
2. Manually lift the saddle several inches.
3. Open the release valve and force the saddle down as quickly as possible.

LUBRICATION
Inspect and lubricate the tool when required. Only use light oil to lubricate the tool. Other lubricants may not be suitable and could damage the tool or cause a malfunction during use.
Clean and lubricate all moving parts.

DISPOSAL

• Recycle a tool damaged beyond repair at the appropriate facility.
• Contact your local municipality for a list of disposal facilities or by-laws for electronic devices, batteries, oil or other toxic liquids.
• DO NOT pollute the environment by allowing uncontrolled discharge of waste oil.

HYDRAULIC FLUID DISPOSAL
Do not drain hydraulic oil into the sewer system or dispose in an uncontrolled location. Hydraulic fluid may take more than a year to breakdown in the environment and the ingredients may still be toxic. Contact your local municipality for proper disposal instructions or locations.

TROUBLESHOOTING

Visit a Princess Auto Ltd. location for a solution if the tool does not function properly or parts are missing. If unable to do so, have a qualified technician service the tool.

TROUBLESHOOTING A JACK

1. The release valve is not closed tightly.
2. Overloaded the jack.
3. Air is trapped in the hydraulic system.
4. Hydraulic oil level is low.

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1. Close the release valve firmly.
2. Reduce load or use a jack with a greater lift capacity.
3. Bleed air from the system.
4. Check the oil filler hole and if necessary, top off with more hydraulic oil.

Jack will lift, but will not maintain pressure.|

1. The release valve is not closed tightly.
2. Overloaded the jack.
3. Hydraulic unit is malfunctioning.

|

1. Close the release valve firmly.
2. Reduce load or use a jack with a greater lift capacity.
3. Malfunctions:
4. Replace the seals.
5. Have a qualified technician service the tool.

Will not lower after loading.|

1. Reservoir is overfilled.
2. Linkages are binding.
3. Contaminated release valve.

|

1. Drain oil to the proper level.
2. Clean and lubricate all moving parts.
3. See Care & Maintenance – Flushing the Valve.

Poor lift performance.|

1. Hydraulic oil level is low.
2. Air is trapped in the hydraulic system.

|

1. Add oil to the proper level.
2. Bleed air from the system.

Or|
Will not lift to the max. height.|

PARTS BREAKDOWN

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