Harbor Freight 8 Ton Long Ram Air Hydraulic Jack Product Manual

Manual for the 94562 8 Ton Long Ram Air/Hydraulic Jack 94562 8 Ton Long Ram Air / Hydraulic Jack

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8 TON

AIR/HYDRAULIC LONG RAM JACK

Model

94562

SET UP AND OPERATING INSTRUCTIONS

Visit our website at: http://www.harborfreight.com

Read this material before using this product.

Failure to do so can result in serious injury.

SAVE THIS MANUAL.

Copyright© 2006 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. Diagrams within this manual may not be drawn proportionally. Due to continuing improve-

ments, actual product may differ slightly from the product described herein. Tools required for assembly

and service may not be included.

For technical questions or replacement parts, please call 1-800-444-3353.

Revised Manual 10d

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 2

SPECIFICATIONS

Lifting Capacity 8 Tons (16,000 Pounds)

Required Air Pressure 110 ~ 120 PSI

Air Flow Required 7 CFM

Air Inlet Size 1/4” – 18 NPT

Minimum Height 24-1/4”

Maximum Height 42-7/8”

Ram Diameter 1.33”

Stroke 18-5/8”

Ram Mounting Holes 5/8” Diameter

Handle Length 20”

Hose Length 48”

Unit Weight 36 Pounds

Save This Manual

You will need this manual for the safety warnings and precautions, assembly, operat-

ing, inspection, maintenance and cleaning procedures, parts list and assembly diagram.

Keep your invoice with this manual. Write the invoice number on the inside of the front

cover. Keep this manual and invoice in a safe and dry place for future reference.

UNPACKING

When unpacking, check to make sure all the parts shown in the Parts Lists on pages

11 and 12 are included. If any parts are missing or broken, please call Harbor Freight Tools

at the number shown on the front cover of this manual as soon as possible.

GENERAL SAFETY RULES

IMPORTANT SAFETY INSTRUCTIONS

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions detailed in this manual may

result in serious personal injury.

SAVE THESE INSTRUCTIONS

Work Area

Keep your work area clean and well lit. 1. Cluttered and dark work areas invite

accidents.

Keep bystanders, children, and visitors away while using the Long Ram 2.

Jack. Distractions can cause you to lose control.

Personal Safety

Stay alert. 1. Watch what you are doing, and use common sense during use. Do

not use the Long Ram Jack while tired or under the influence of drugs, alcohol,

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 3

or medication. A moment of inattention while operating power tools may result in

serious personal injury.

Dress properly. 2. Do not wear loose clothing or jewelry. Contain long hair. Keep

your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or

long hair can be caught in moving parts.

Do not overreach. 3. Keep proper footing and balance at all times. Proper footing

and balance enables better control in unexpected situations.

Always wear eye and hand protection. 4. Wear ANSI-approved safety impact gog-

gles, non-skid safety shoes, and heavy duty work gloves when using this product.

Tool Use and Care

Store idle tools and equipment out of reach of children and other untrained 1.

people. Tools and equipment are dangerous in the hands of untrained users.

Maintain the Long Ram Jack with care. 2. Keep this product clean. A properly

maintained tool is easier to control. Do not use damaged tools and equipment. Tag

damaged tools and equipment “Do not use” until repaired.

Check for misalignment or binding of moving parts, loose or broken parts, and 3.

any other condition that may affect the Long Ram Jack’s operation. If dam-

aged, have the tool serviced before using. Many accidents are caused by poorly

maintained tools and equipment.

Use only accessories that are recommended by the manufacturer for your 4.

model. Accessories that may be suitable for one product may become hazardous

when used on another product.

Service

Tool service must be performed only by qualified service technician. 1. Service

or maintenance performed by unqualified personnel could result in a risk ofinjury.

When servicing the Long Ram Jack, use only identical replacement parts. 2.

Follow instructions in the “Inspection, Maintenance, And Cleaning” section of this

manual. Use of unauthorized parts or failure to follow maintenance instructions may

create a risk of electric shock or injury.

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 4

SPECIFIC SAFETY RULES

Prior to assembling the Long Ram Jack onto a shop crane, make sure to read 1.

and understand all instructions and safety precautions as outlined in the shop

crane manufacturer’s manual. Make sure the Long Ram Jack is fully compatible

with the shop crane.

WARNING! Do not exceed the maximum lifting capacity of this Long Ram 2.

Jack (8 tons / 16,000 pounds). Exceeding the maximum lifting capacity could

cause personal injury and/or property damage.

Maintain labels and nameplates on the Long Ram Jack. 3. These carry important

information. If unreadable or missing, contact Harbor Freight Tools for a replace-

ment.

Use the right product for the job. 4. There are certain applications for which this

product was designed. Do not use this product for a purpose for which it was not

intended.

WARNING! 5. The Long Ram Jack mounting holes are 5/8” diameter. Do not at-

tempt to drill or alter the mounting holes.

WARNING! 6. The two 5/8” diameter Pins (not included) used to attach the Long Ram

Jack to a shop crane must be rated to support at least 8 tons (16,000 pounds) of

pressure and must have R-Pins (not included) to lock the two Pins in place.

Do not use the Long Ram Jack in an unsupported application. 7. Twisting or

sideways forces could cause the Jack to unexpectedly fail.

The Long Ram Jack is designed for short-term lifting of loads. 8. Do not use for

extended lifting of loads.

Stay clear of a shop crane. 9. Never go under an object being lifted by the crane. It

is possible for an object to fall, possibly resulting in serious injury and/or property

damage.

Immediately after lifting, support the load with appropriate supporting equip-10.

ment such as jack stands (not included) of adequate capacity. DO NOT work

under a load which is supported only by the Long Ram Jack.

Use the Long Ram Jack with a shop crane only on a flat, level, solid surface 11.

capable of supporting the weight of the Jack, crane and the weight of the

object being lifted.

Industrial applications must follow OSHA requirements.12.

Always monitor the object being lifted so it does not rock back and forth.13.

Before lowering a load, make sure there are no obstructions underneath and 14.

that all other personnel are standing clear.

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 5

Do not attempt to move a load while it is supported by the Long Ram Jack. 15.

The Jack must only be used in a static position for lifting and lowering loads.

Compressed air only. 16. Use clean, dry, regulated, compressed air between 110

and 120 PSI. Never use oxygen, carbon dioxide, combustible gases, or any other

bottled gas as a power source for this product.

This Jack is intended for use on a shop crane (not included), properly at-17.

tached. The shop crane to which the Long Ram Jack will be installed must

be designed to use an 8 ton (16,000 pound) capacity Long Ram Jack.

The Long Ram Jack is designed for vertical, or near vertical, use only. 18. Do not

use in a horizontal or upside down position.

NEVER attempt to adjust the factory pre-set Safety Valve on the Long Ram 19.

Jack.

Not to be used for aircraft purposes.20.

WARNING! 21. The warnings and cautions discussed in this 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.

SAVE THESE INSTRUCTIONS

ASSEMBLY INSTRUCTIONS

NOTE: 1. To attach the Long Ram Jack onto a shop crane you will need two 5/8”

diameter Pins of appropriate length and two R-Pins (neither included).

PIN

R-PIN

5/8” DIAMETER

FIGURE A

WARNING! The Pins must be rated to support at least 8 tons

(16,000 pounds) of pressure. (See Figure A.)

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 6

FIGURE B

RAM

(13)

HANDLE

(21)

RELEASE VALVE

(4)

BASE

(1)

2. Place the end of the Handle (21) over the Release Valve (4), and turn the Handle

counterclockwise to fully lower the Ram (13). Then, remove the Handle.

(See Figure B.)

PILLAR

BOOM

INSERT PIN & R-PIN HERE

INSERT PIN & R-PIN HERE

RESERVOIR

(16)

SHOP CRANE

(NOT INCLUDED)

FIGURE C

oFILLER PLUG

(17)

3. Lower the Boom on the shop crane (not included). (See Figure C.)

With assistance, align the mounting hole in the Ram (13) with the mounting hole 4.

located in the Boom of the shop crane. Insert one Pin completely through both

mounting holes. Then, secure the Pin in place with one R-Pin.

(See Figures B and C.)

Align the two mounting holes in the Base (1) of the Long Ram Jack with the mount-5.

ing hole located in the Pillar of the shop crane. Insert the remaining Pin completely

through the mounting holes in the Base and the Pillar. Then, secure the Pin in place

with the remaining R-Pin. (See Figures B and C.)

IMPORTANT: 6. The Long Ram Jack already contains some hydraulic oil in its Res-

ervoir (16). Even so, it is recommended that you check the oil level in the Reservoir

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 7

prior to the shop crane’s first use and, if necessary, top off the Reservoir with the

proper amount of hydraulic oil. To do so, remove the Filler Plug (17) located on the

Reservoir. Top off the Reservoir with hydraulic oil. Make sure the Release Valve

(4) is closed. Insert the Handle (21) in the Handle Bracket (31) and slowly pump

the Handle until a slight amount of oil begins to leak out of the oil fill hole. Then,

replace the Filler Plug. Make sure to test the shop crane’s performance several

times before attempting to lift an object with the crane.

Once satisfied that the crane is operating properly, then the crane is ready to

lift an object. (See Figure C.)

OPERATING INSTRUCTIONS

MANUAL OPERATION

FIGURE D

HANDLE

(21)

To Operate Manually:

Position the shop crane so that its Hook is directly above the object you wish to lift. 1.

(See Figure D, next page.)

WARNING! Stay clear of the shop crane. 2. Never go under an object being lifted

by the crane. It is possible for its Hook to slip, causing an object to fall, possibly

resulting in serious injury and/or property damage.

Use the Handle (21) of the Long Ram Jack to open the Release Valve (4) and lower 3.

the Hook. Attach the Hook to the object you are lifting. Then close the Release

Valve, and pump the Handle to raise the object. Carefully move the engine crane

to the location where you wish to lower the object, i.e., an engine stand, proper

support, floor surface, etc. Then lower the object by opening the Release Valve

slightly. Once the object is fully lowered, disconnect the Hook from the object.

(See Figures B and D.)

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 8

CONNECT

TO

AIR

SUPPLY

AIR VALVE

(32)

COMPRESSED AIR OPERATION

FIGURE F

To Operate, Using Compressed Air:

For best service, you should incorporate an oiler, regulator, and in-line filter, as 1.

shown in the diagram below. Hoses, couplers, oilers, regulators, and filters are all

available at Harbor Freight Tools. NOTE: If an automatic oiler is not used, put 3-5

drops of pneumatic Tool Oil (not included) in the Long Ram Jack’s Quick Coupler

(A41) before each use. (See Figure E.)

TO

LONG

RAM

JACK

FILTER

OILER FIGURE E

REGULATOR

2. Use the Handle (21) of the Long Ram Jack to open the Release Valve (4) and lower

the Hook. Attach the Hook to the object you are lifting. Then close the Release

Valve and remove the Handle. (See Figures B, and F, next page.)

Connect an air supply hose to the Quick Connector (A41) on the Air Valve (32) of 3.

the Long Ram Jack. (See Figure F.)

Turn on the air compressor, and set its regulator at 110 to 120 PSI. 4. Do not exceed

120 PSI.

Squeeze the Lever of the Air Valve (32) to raise the object. Once raised, release 5.

pressure on the Lever. Carefully move the engine crane to the location where you

wish to lower the object, making sure not to damage the air supply hose of the

compressor. Then lower the object by opening the Release Valve slightly with the

Handle (21) of the Long Ram Jack. Once the object is fully lowered, disconnect the

Hook from the object. Turn off the air compressor. Then squeeze the Lever of the

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 9

Air Valve once again to release any remaining air pressure from the system. (See

Figures B and F.)

When finished using the Long Ram Jack and shop crane, store the equipment in a 6.

clean, dry, safe location out of reach of children and other unauthorized people.

INSPECTION, MAINTENANCE, AND CLEANING

Before each use,1. inspect the general condition of the Long Ram Jack. Check for

cracked, worn or damaged parts, loose or missing parts, low or no hydraulic oil, and

any other condition that may affect the tool’s safe operation. If a problem occurs,

have the problem corrected before further use.

Do not use damaged equipment.

To clean, 2. use a damp cloth and a mild detergent. Do not use solvents or other

flammable agents.

If lifting performance of the Long Ram Jack begins to diminish, 3. check the

hydraulic oil level in the Reservoir (16). If necessary, top off the Reservoir with

hydraulic oil. (See Step #6, page 6-7.)

Drain and replace the hydraulic fluid at least once a year.4. If you are uncertain

how to do this, have the service performed by a qualified technician.

To bleed the Long Ram Jack, 5. remove the Filler Plug (17) located on the Reser-

voir (16). Make sure the Release Valve (4) is closed. Insert the Handle (21) in the

Handle Bracket (31) and slowly pump the Handle until a slight amount of oil begins

to leak out of the oil fill hole. Top off the Reservoir with hydraulic oil. Then, replace

the Filler Plug. Make sure to test the Long Ram Jack’s performance several

times before attempting to lift an object with the shop crane.

Once satisfied that the shop crane is operating properly, then the crane is

ready to lift an object. (See Figure D.)

When storing, 6. keep the Long Ram Jack and shop crane in a clean, dry, safe loca-

tion out of reach of children and other unauthorized people.

CAUTION! 7. All maintenance, service, and repairs not discussed in this manual

should only be performed by a qualified service technician.

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 10

TROUBLESHOOTING

Problem Possible Causes Possible Solution

Jack will not lift load. Release Valve not tightly closed.1.

Overload condition.2.

Air supply inadequate.3.

Air trapped in system.4.

Close Release Valve firmly.1.

Do not exceed 8 ton lifting capacity.2.

Ensure adequate air supply.3.

Purge air from system.4.

Jack will lift, but will not maintain

pressure.

Release Valve not tightly closed.1.

Overload condition.2.

Hydraulic unit malfunction or defective 3.

seals.

Close Release Valve firmly.1.

Do not exceed 8 ton lifting capacity.2.

Have a qualified service technician 3.

check the hydraulic unit.

Jack will not lower after it is raised. Reservoir overfilled.1.

Linkages binding.2.

Drain oil to proper level.1.

Clean and lubricate moving parts.2.

Poor lift performance. Hydraulic oil level low.1.

Air trapped in system.2.

Add oil to proper level.1.

Purge air from system.2.

Will not lift to maximum height. Hydraulic oil level low. Add oil to proper level.

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY

DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR

DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER 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 RISKS 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.

PLEASE READ THE FOLLOWING CAREFULLY

LIMITED 90 DAY WARRANTY

Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and

durability standards, and warrants to the original purchaser that this product is free from defects in

materials and workmanship for the period of 90 days from the date of purchase. This warranty does

not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs

or alterations outside our facilities, criminal activity, improper installation, normal wear and tear, or

to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or

for incidental, contingent, special or consequential damages arising from the use of our product.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so

the above limitation of exclusion may not apply to you. THIS WARRANTY IS EXPRESSLY IN LIEU

OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF

MERCHANTABILITY AND FITNESS.

To take advantage of this warranty, the product or part must be returned to us with transportation

charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the

merchandise. If our inspection verifies the defect, we will either repair or replace the product at our

election or we may elect to refund the purchase price if we cannot readily and quickly provide you

with a replacement. We will return repaired products at our expense, but if we determine there is

no defect, or that the defect resulted from causes not within the scope of our warranty, then you

must bear the cost of returning the product.

This warranty gives you specific legal rights and you may also have other rights which vary

from state to state.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 11

PARTS LIST & ASSEMBLY DIAGRAM

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Part Description Qty.

1 Base 1

2 Ball 6

3 Seal 1

4 Release Valve 1

5 Ball Cup 2

6 Spring 1

7 Spring 1

8 Screw 2

9 Nylon Ring 1

10 Cylinder 1

11 O-Ring 1

12 Cup Seal 1

13 Ram 1

14 Ring 1

Part Description Qty.

15 Packing 1

16 Reservoir 1

17 Filler Plug 1

18 Nylon Ring 1

19 Top Nut 1

20 O-Ring 1

21 Handle 1

22 Copper Washer 2

23 Pump Cylinder 1

24 O-Ring 1

25 Nylon Ring 1

26 Back-Up Ring 1

27 Piston 1

28 Pin 3

Part Description Qty.

29 R-Pin 3

30 Connector 1

31 Handle Bracket 1

32 Air Valve 1

33 Air Hose 1

34 Air Motor 1

35 Ball 1

36 Ball Cup 1

37 Spring 1

38 Screw 1

39 O-Ring 1

40 Screw 1

41 Plastic Cap 1

REV 10d

SKU 94562 For technical questions, please call 1-800-444-3353 PAGE 12

PARTS LIST & ASSEMBLY DIAGRAM A - AIR MOTOR

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Part Description Qty.

A01 Air pump cylinder 1

A02 Nut 1

A03 Sealing Ring 1

A04 Nylon Ring 1

A05 Copper Ring 1

A06 Air Cylinder Seat 1

A07 Nut 1

A08 Spring 1

A09 Air Pump Piston 1

A10 O-Ring 2

A12 Large Piston 1

A13 O-Ring 1

A14 Small Piston 1

A15 O-Ring 1

A17 Sealing Ring 1

A18 Nylon Ring 1

A19 Air Cylinder 1

Part Description Qty.

A20 Air Cylinder Cap 1

A21 Bolt 3

A22 Coupler Seat 1

A23 Retaining Ring 1

A24 O-Ring 2

A25 Coupler 1

A26 Air Hose 1

A27 Lock Lever 1

A28 Lever 1

A29 Nut 1

A30 O-Ring 1

A31 O-Ring 1

A32 Packing 1

A33 Throttle 1

A34 Spring 1

A35 Lock Nut 1

A36 Bolt 1

Part Description Qty.

A37 Valve Body 1

A38 Screw 1

A39 Screen 1

A40 O-Ring 1

A41 Quick Coupler-male 1

A42 Bolt 3

A43 O-Ring 2

A44 O-Ring 1

A45 Coupler Seat 1

A46 Screw 2

A47 Lock Washer 2

A48 Safety Cover 1

A49 Filter 1

A50 Silencing pad 1

REV 10d