Polaris 800 INDY Offroad Vehicle User Manual
Contents
1. m m NIO I m m O ja U W 2 Q Ww 1 12 1 14 145 1 17 1 21 1 22 1 24 Oo NIN gt L YW NINN SKU 66242 PARTS LIST Part 3 2 14 2 15 2 16 Description Screw Washer Bolt Washer S Washer 3 Spring Steel Ball Valve Core 5 Steel Ball 8 Cylinder Base Steel Ball Spring w i j NX Ww N Ww iN NIOJ Ww 0 1 3 4 5 6 7 8 9 0 1 S O Ring S Pump Body Washer O Ring Release Valve Body Steel Ball O Ring W N 252 fe 9 D lt BE m w NININJ eje N EE 3 4 5 6 Release Valve Screw Washer Stop Ring Fork Axle With Hole 7 Steel Wire 8 Connecting Block 3 29 Spring Pin 3 30 Spring Pin 3 31 Fork Axle 3 32 Pin 3 33 NIN A Ww Ww NINININ N CG 2 et For technical questions please call 1 800 444 3353 34 Steel Wire 3 36 Fork Axle With Hole 3 37 38 39 40 022 85888500 4 4 1 Packing 35 Rubber Hose 36 5 Air Valve Assembly 2 Filter Nozzle ed 3 Lock Lever eV Handle Control Rod 10 1 Knob 5 Handle Cap 3 6 U Bolt 12 7 12 82. EICENTRAL HYDRAULICS 22 TON AIR HYDRAULIC BOTTLE JACK SET UP AND OPERATING INSTRUCTIONS Diagrams within this manual may not be drawn proportionally Due to continuing improvements actual product may differ slightly from the product described herein Distributed exclusively by Harbor Freight Tools 3491 Mission Oaks Blvd Camarillo CA 93011 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 2008 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 or replacement parts please call 1 800 444 3353 SAVE THIS MANUAL Keep this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference IMPORTANT SAFETY INFORMATION In this manual on the labeling and all other information provided with this product This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbo
3. a Hitch Pin 12 9 See Fig 1 Page 5 Set Screw 2 5 Fig 2 4 Put the Handle Assembly into Handle Socket and secure with Set Screw See Fig 2 OPERATING INSTRUCTIONS SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product TO PREVENT AWARNING serious INJURY FROM ACCIDENTAL OPERATION Disconnect the Bottle Jack from its compressed air supply source and release any compressed air from the Read the ENTIRE IMPORTANT tool before performing any set 3 up and operating procedures SKU 66242 For technical questions please call 1 800 444 3353 Tool Set Up Male Male Connector Connector 2 I Quick Coupler 1 Nair Hose Compressor Coupler Regulator with Pressure Gauge Recommended Air Line Components Fig 3 This Jack comes in two boxes and easily connects to an air compressor For proper Jack Air compressor con nection see Fig 3 Incorporate an in line oiler shut off valve regulator with pressure gauge and filter for best service as shown in the diagram above An in line shut off valve is an important safety device because it controls the air supply even if the air hose is rup tured Note If an automatic oiler system is not used add a few drops of Pneumatic Tool Oil to the airline connection be fore operation Add a few more drops after each hour of conti
4. transmission in PARK if automatic or in it lowest gear if manual Set the emergency brake Then chock the wheels that are not being lifted Check to make sure the Bottle Jack is fully lowered If not turn the Knob 6 11 counterclockwise to lower the Jack Once the Jack s ram is fully lowered turn the Knob clockwise to close the Release Valve 3 23 See Assembly Diagram Carefully position the Saddle 1 2 of the Bottle Jack under the vehicle manufacturer s recommended lifting point See vehicle manufacturer s manual for location of seam lifting point when lifting only one wheel and frame lifting points when lifting the entire front or rear end of the vehicle See Assembly Diagram To raise the vehicle manually Pump the Handle Assembly until the top of the Bottle Jack s Saddle 1 2 has nearly reached the vehicle lifting point The Jack should be positioned at 90 to the vehicle s lifting point to ensure the Bottle Jack s Saddle and vehicle lifting point are in alignment If not remove and reposition the Jack before lifting To lift the vehicle pump the Handle assembly using smooth full strokes See Assembly Diagram To raise the vehicle using compressed air Check to make sure the Knob 6 11 assembly is in its locked position fully turned clockwise Then con nect an air hose not included to the Air Valve Assembly 5 See Assem bly Diagram For technical questions pl
5. Nut 12 9 Hitch Pin 8 ae fs 6 5 6 3 oO ul OV p m pi N m N m NIN N Page 13 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
6. T 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 TROUBLESHOOTING Bottle Jack will not raise the Bottle Jack ram 1 Turn the Lock Lever clockwise until snug when pumping the Handle manually 2 Bleed the Air Bottle Jack of excess air Bottle Jack will not raise the Bottle Jack ram Turn the Lock Lever clockwise until snug when using the pneumatic function Check to make sure the regulator of the air compressor is set at 90 145 PSI 3 Check for loose air connections and damaged air hoses Bleed the Bottle Jack of excess air SKU 66242 For technical questions please call 1 800 444 3353 Page 11 ASSEMBLY DIAGRAM 1 1 12 9 12 3 12 1 SKU 66242 For technical questions please call 1 800 444 3353 Page 12 over addle xtension Screw pring Pin ead Nut iston Rod 1 10 1 11 1 12 lt Head 1 13 Stop Ring 1 14 Cylinder 1 15 Spring Li 1 17 Screw i 1 19 1 20 Screw 1 21 1 22 1 23 1 24 1 25 Base ide Plate ngle Bracket andle Fork et Screw Q e 0 m 1 3a W m
7. ared to stand clear of the vehicle as the vehicle can fall off the jack stand s causing personal injury and or property damage 8 When the repair work to the vehicle is completed and prior to lowering the vehicle Make sure to remove all tools old vehicle parts etc from under the vehicle To lower the vehicle manually 1 sure the Knob 6 11 assem bly is turned completely clockwise to close the Release Valve Screw 3 23 Pump the Handle assembly to raise the vehicle slightly above the saddle s of the jack stand s Then remove the jack stand s from under the vehicle 2 Slowly turn the Knob 6 11 assembly counterclockwise never more than one full turns to lower the vehicle to the ground See Assembly Dia gram To lower the vehicle using compressed air 1 sure the Knob 6 11 assembly is turned completely clockwise clos ing the Release Valve Screw 3 21 Release the Lock Lever on the Air Valve Assembly 5 Depress the Lever on the Air Valve Assembly 5 to raise the vehicle slightly above the saddle s of the jack stand s Place the Lock Lever in its locked position Then remove the jack stand s from under the vehicle See Assembly Diagrams 2 Slowly turn the Knob 6 11 assembly counterclockwise never more than one full turns to lower the vehicle For technical questions please call 1 800 444 3353 Page 8 SKU 66242 onto the ground See Assembly Diagram Lower
8. d caution are factors which cannot be built into this product but must be supplied by the operator A SAVE THESE INSTRUCTIONS SPECIFICATIONS 22 Tons 44 000 Ib Required Air Pressure 90 145 PSI 1 4 18 NPT 13 without saddle Air Inlet Fitting Minimum 17 1 2 without saddle 4 1 2 85 Ibs Maximum Lift Height Ram Travel Net Weight Air Hose Length Jack Handle UNPACKING When unpacking check to make sure that the item is intact and undamaged If any parts are missing or broken please call Harbor Freight Tools at the number shown on the cover of this manual as soon as possible Note For additional information regarding the parts listed in the following pages refer to the Assembly Diagram near the end of this manual SKU 66242 For technical questions please call 1 800 444 3353 ASSEMBLY Assemble the Handle and its 6 x series parts that come in Box B See Assembly Drawing Adjustable Rod 6 3 Adapters 12 1 12 3 12 4 Spring Washers 12 7 U Bolts 12 6 ot Nuts 12 8 Adapter Holder 12 5 Outside Tube Fe 61 y PES 12 9 Fig 1 Attach the Adapter Holder 12 5 to the Handle Assembly with two U bolts 12 6 Lock Washers 12 7 and Nuts 12 8 See Fig 1 a Tighten the Nuts to secure the Adapter Holder to the Handle 3 Put height adjustment Adapters into the Adapter Bracket and lock each with
9. ease call 1 800 444 3353 Page 7 SKU 66242 Turn on air compressor and set its regulator to 90 145 PSI Do not ex ceed 145 PSI Allow the compressor to build up pressure and cycle off Depress the Lever of the Air Valve Assembly 5 until the Saddle of the Bottle Jack has nearly reached the vehicle lifting point The Jack should be positioned at 90 to the vehicle s lifting point to ensure the Bottle Jack s Saddle and vehicle lifting point are in alignment If not remove and repo sition the Bottle Jack before lifting See Assembly Diagram To lift the vehicle continue to depress the Lever on the Air Valve Assembly 5 Once the vehicle is lifted place the Lock Lever of the Air Valve As sembly 5 in its locked position See Assembly Diagrams Once the vehicle is raised slide a jack stand not included to the prop er lifting point referred to in the ve hicle manufacturer s manual If using two jack stands make sure they are at the same point on each side of the vehicle Always raise the vehicle the least amount possible Slightly lower the Jack to ease the vehicle onto the jack stands Do this by slowly turning the Knob 6 11 counterclockwise until the Saddle 1 2 lowers slightly While standing safely aside gently rock the vehicle to determine if it is stable on the jack stand s If it is not raise the vehicle and reposi tion the jack stand s WARNING When performing this procedure be prep
10. isconnect the air hose from the tool and release any remaining air pressure before making any adjustments changing accessories or storing the tool Such preventive safety measures reduce the risk of starting the tool accidentally d Store idle tools out of the reach of children and do not allow people unfamiliar with the tool or these instructions to operate this tool Tools are dangerous in the hands of untrained users Maintain this tool Check for misalignment or binding of moving parts breakage of parts and any other condition that may affect the tool s operation If damaged have the tool repaired before use Many accidents are caused by poorly maintained tools Use the tool and its accessories in accordance with these instructions and in the manner intended for this particular type of tool taking into account the working conditions and the work to be performed Use of this tool for operations different from those intended could result in a hazardous situation Service 1 For technical questions please call 1 800 444 3353 a Have the tool serviced by a qualified repair person using only identical replacement parts This will ensure the safety of the tool is maintained Specific Safety Rules Maintain labels and nameplates on the Bottle Jack These carry important safety information If unreadable or missing contact Harbor Freight Tools for a replacement Page 3 SKU 66242 Use clea
11. l to avoid possible injury or death DANGER indicates ADANGER a hazardous situation which if not avoided will result in death or serious injury AWARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION used ACAUTION Kith the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury SKU 66242 NOTICE 1 CAUTION a a For technical questions please call 1 800 444 3353 NOTICE is used to address practices not related to personal injury CAUTION without the safety alert symbol is used to address practices not related to personal injury General Safety Rules WARNING Read all instructions Failure to follow all instructions listed below may result in serious injury The term tool in all of the warnings listed below refers to your Bottle Jack SAVE THESE INSTRUCTIONS Work area safety Keep work area clean and well lit Cluttered or dark areas invite accidents Do not operate tools in explosive atmospheres such as in the presence of flammable liquids gases or dust Air and hydraulic tools create sparks which may ignite the dust or fumes Keep children and bystanders away while operating this tool Distractions can cause you to lose control Personal safety Stay alert watch what you are doing and use common sense when operating this t
12. n dry regulated compressed air at 90 145 PSI Do not exceed the recommended maximum air pressure Do not use oxygen carbon dioxide combustible gases or any other bottled gas as a power source for this tool Do not exceed the 22 ton 44 000 lbs capacity of the Bottle Jack Bleed the hydraulic system of the Bottle Jack before its initial use Always place the Bottle Jack on 15 a dry oil grease free solid level floor surface capable of supporting the weight of the Jack and all other additional tools and accessories 16 Apply the vehicle s parking brake and chock the tires before lifting the vehicle Lift the vehicle only by the manufacturer recommended lifting points Stay out from under the load while it 17 is being lifted or supported Avoid rapid load descent Turn the Release Screw slowly Do not use for aircraft purposes Do not leave the tool unattended when it is connected to a compressed air supply Release the tool s load and disconnect it from its compressed air supply before leaving This product is not a toy Keep it out of reach of children When lifting only one wheel make sure to support the load immediately with one jack stand not included placed under the side of the vehicle 14 For technical questions please call 1 800 444 3353 being lifted Align the saddle of the jack stand directly under the vehicle s seam or recommended lifting point When lifting the e
13. ns counter clockwise releasing pressure See Assembly Diagram Remove the Filler Plug 1 19 and fill the Cylinder Base 1 14 reservoir with hydraulic oil not included See Assembly Diagram Rapidly pump the Handle several times to purge air from the system See Assembly Diagram Turn the Knob 6 11 clockwise until snug to hold pressure See Assembly Diagram Top off the reservoir with hydraulic oil Then replace the Filler Plug 1 19 See Assembly Diagram IMPORTANT After bleeding the Bottle Jack test the Jack for proper op eration prior to its actual use NOTE To prevent damage to the Bottle 9 For technical questions please call 1 800 444 3353 Jack check for excessive air and or low hydraulic oil regularly WHEN STORING turn Lock Lever 6 5 to its open position counterclockwise Always store the Bottle Jack and its accessories in a clean dry safe location out of reach Page 9 of children and other unauthorized people SKU 66242 For technical questions please call 1 800 444 3353 Page 10 PLEASE READ THE FOLLOWING CAREFULLY 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 MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUC
14. ntire front end or rear end of a vehicle make sure to support the load immediately with two jack stands Align the saddles of the jack stands directly under the vehicle s frame or recommended lifting points Also make sure the jack stands are adjusted at the same height Use the Bottle Jack only on vehicles whose frames have lifting points on its seam or frame capable of aligning with the Bottle Jack Do not use the Bottle Jack with the vehicle s engine running When running the vehicle s engine produces carbon monoxide a colorless odorless toxic fume that when inhaled can cause serious personal injury or death Always keep hands fingers and feet away from all moving parts of the Bottle Jack when applying or releasing a load Remain clear of the vehicle being raised or lowered People and animals should be kept at a safe distance when using the Bottle Jack Do not allow anyone in the vehicle when using the Bottle Jack Keep all bystanders a safe distance away from the vehicle Never use Bottle Jacks to lift both ends of a vehicle at the same time Before lowering the Bottle Jack make sure tool trays jack stands and all other tools and equipment are removed from under the vehicle Page 4 21 The warnings precautions and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be understood by the operator that common sense an
15. nual use Attach an air hose to the compres sor s air outlet Connect the air hose to the Air Valve Assembly 5 of the Bottle Jack Other components such as aconnector and quick coupler will make operation more efficient but are not mandatory Page 6 SKU 66242 IMPORTANT Prior to use check for proper hydraulic oil level in the Bottle Jack See page 9 Thoroughly test the Jack for proper operation prior to its actual use If the Jack appears not to be working properly it may be necessary to purge its hydraulic system of air To do so Turn Knob 6 11 counterclockwise until snug See Assembly Dia gram Wipe Filler Plug area with a clean and lint free rag Remove the Filler Plug 1 19 and fill the Cylinder Base 1 14 reservoir with hydraulic oil not included See Assembly Diagram Rapidly pump the Handle several times to purge air from the system See Assembly Diagram Then turn the Knob 6 11 clockwise until snug See Assembly Dia gram Top off the Cylinder Base 1 14 reservoir with hydraulic oil if needed Note Oil level should reach the edge of oil fill hole Then replace the Filler Plug 1 19 and wipe the jack s exterior See Assembly Diagram IMPORTANT After bleeding the Bottle Jack test the unit to ensure it op erates properly Make sure the vehicle is parked ona flat level solid ground surface Turn off the vehicle s engine Place the vehicle s
16. ool Do not use this tool while you are tired or under the influence of drugs alcohol or medication A moment of inattention while operating this tool may result in serious personal injury Page 2 SKU 66242 Use safety equipment Always wear ANSI approved safety impact goggles and heavy duty work gloves Safety equipment such as non skid safety shoes hard hat or hearing protection used for appropriate conditions will reduce personal injuries Avoid accidental starting Ensure that the Lock Lever of the Air Valve Assembly 5 is in the unlocked position before connecting to an air supply Connecting this tool with the Lock Lever engaged invites accidents Stay out from under loads being lifted even loads held by jack stands if possible Do not overreach Keep proper footing and balance at all times This enables better control of the tool in unexpected situations Dress properly Do not wear loose clothing or jewelry Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts Tool use and care Do not force the tool Use the correct tool for your application The correct tool will do the job better and safer at the rate for which it was designed Do not use the tool if the Air Valve s on off switch valve does not operate properly Any tool that cannot be controlled with its Air Valve is dangerous and must be repaired D
17. 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 Box 6009 Camarillo CA 93011 800 444 3353 Record Product s Serial Number Here Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not avail able individually as replacement parts SKU 66242 For technical questions please call 1 800 444 3353 Page 14
18. the Bottle Jack completely Be aware that it will take a good amount of effort to lower the ram down to be level with the reservoir Do not hammer on the ram Store the Jack in a clean dry safe location out of reach of children and other unauthorized people MAINTENANCE AND SERVICING Procedures not specifically explained in this manual must be performed only by a qualified technician TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Disconnect the Bottle Jack from its compressed air supply source and turn the Knob 6 11 assembly counterclockwise to loosen the Release Valve Screw before performing any inspection maintenance or cleaning procedures BEFORE EACH USE inspect the general condition of the Bottle Jack Check for loose screws misalignment or binding of moving parts cracked or broken parts damaged Air Hose and any other condition that may affect its safe operation A AFTER USE clean external surfaces of the Bottle Jack with a clean moist cloth and a mild detergent Do not use solvents BLEEDING INSTRUCTIONS 3 N Before each use or when the Bottle Jack lacks in performance make sure to check for excessive air and proper hydraulic oil level in the Bottle Jack If the Jack appears not to be working properly it may be neces sary to purge its hydraulic system of excessive air To do so Grasp the handle and pump it up and down quickly 5 6 times Then turn the Knob 6 11 1 1 2 tur
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