Carlyle Tools Napa 791-6440 User manual

791-6440 1 04/02/20
Capacity ................................................ 3-1/2 Ton
Low Height .................................................3-1/2"
High Height .................................................. 21"
Chassis Height ..............................................6-1/4”
Handle Length ................................................ 50"
Overall Length .............................................30-1/8"
Overall Width ..............................................14-5/8"
Saddle Diameter................................................ 5"
Weight ...................................................102 lbs.
SPECIFICATIONS
791-6440791-6440791-6440
3.5 TON PROFESSIONAL LOW PROFILE JACK
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ASME PASE-2019

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OPERATING MANUAL FOR 791-6440
WARNING INFORMATION
This is the safety alert symbol. It is used to alert you
to potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
IMPORTANT: READ THESE INSTRUCTIONS BEFORE OPERATING
BEFORE USING THIS DEVICE, READ THIS MANUAL COMPLETELY AND THOROUGHLY, UNDERSTAND ITS OPERATING
PROCEDURES, SAFETY WARNINGS AND MAINTENANCE REQUIREMENTS.
It is the responsibility of the owner to make sure all personnel read this manual prior to using the device. It is also the responsibility of
the device owner to keep this manual intact and in a convenient location for all to see and read. If the manual or product labels are lost
or not legible, contact NAPA for replacements. If the operator is not fluent in English, the product and safety instructions shall be read to
and discussed with the operator in the operator's native language by the purchaser/owner or his designee, making sure that the operator
comprehends its contents.
THE NATURE OF HAZARDOUS SITUATIONS
The use of portable automotive lifting devices are subject to certain hazards that cannot be prevented by mechanical means, but only by the
exercise of intelligence, care and common sense. It is therefore essential to have owners and personnel involved in the use and operation of
the equipment who are careful, competent, trained and qualified in the safe operation of the equipment and its proper use. Examples of haz-
ards are dropping, tipping or slipping of loads caused primarily by improperly securing loads, overloading, off-centered loads, use on other
than hard level surfaces, and using equipment for a purpose for which it was not designed.
METHODS TO AVOID HAZARDOUS SITUATIONS
• Read, study, understand and follow all instructions before operating this device.
 • Inspectthejackbeforeeachuse.Donotuseifdamaged,altered,modied,inpoorcondition,leakinghydraulicuidorunstabledue
to loose or missing components. Make corrections before using.
• Use only on a hard level surface capable of supporting load and free from obstructions so the jack is free to reposition itself during lifting
and lowering operations.
 • Liftonlyonareasofthevehicleasspeciedbythevehiclemanufacturer.
• User and bystanders must wear eye protection that meets ANSI Z87.1 and OSHA standards.
• Do not use jack beyond its rated capacity. Do not shock load.
• This is a lifting device only. Immediately after lifting, support the vehicle with jack stands capable of sustaining the load
before working on the vehicle.
• Center load on saddle. Be sure setup is stable before working on vehicle.
• Do not move or dolly the vehicle while on the jack.
• Do not use any materials that may serve as risers, spacers or extenders between the stock lifting saddle and the load.
• Do not use any adaptors that replace the stock lifting saddle unless approved or supplied by the jack manufacturer.
• Do not use (or modify) this product for any other purpose than that for which it was designed without consulting the manufacturer's
authorized representative.
• Always lower the jack slowly and carefully.
• Failure to heed these warnings may result in serious or fatal personal injury and/or property damage.
WARNING: This product can expose you to chemicals including nickel, which is known to the State of California to cause cancer and
birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.
CONSEQUENCES OF NOT AVOIDING HAZARDOUS SITUATIONS
Failure to read this manual completely and thoroughly, failure to understand its OPERATING INSTRUCTIONS, SAFETY WARNINGS,
MAINTENANCE INSTRUCTIONS and comply with them, and failure to comply with the METHODS TO AVOID HAZARDOUS SITUATIONS
could cause accidents resulting in serious or fatal personal injury and/or property damage.
WARNING: Indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
WARNING
WARNING
WARNING
WARNING

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SETUP
PLEASE REFER TO THE EXPLODED VIEW DRAWING IN THIS MANUAL IN ORDER TO IDENTIFY PARTS.
1. Remove the 2-piece handle from box. Insert narrow portion of top section (15) into bottom section (17) and secure with the spring button
(16) provided.
2. Grease the inside of the handle yoke (19) and remove the handle set screw (18) from the handle yoke (19). Insert the handle (17) all the way
in the handle yoke (19) until it engages the release valve assembly (24). Secure the handle (17) to the handle yoke (19) with the handle set
screw (18).
3. 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) Rotate the handle (15) in a clockwise direction until tight. Rotate the handle in a counterclockwise direction two complete revolutions.
b) Pump the handle approximately 10-15 complete pump strokes.
c) Rotate the handle in a clockwise direction until tight. Proceed to pump the jack to maximum lift height.
d) Repeat steps a) through c) until all air has been purged from the system.
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: Close release valve tightly (by turning handle clockwise). DO NOT OVERTIGHTEN. Position jack under load so that saddle will
contact load firmly and load is centered so it cannot slip. Operate jack handle until saddle approaches the load. Once again, check to
see that saddle is correctly positioned. Raise load to desired height. Place jack stands of appropriate capacity under the vehicle. DO NOT
CRAWL UNDER VEHICLE WHILE LIFTING VEHICLE OR PLACING OR REMOVING JACK STANDS! Place jack stands at vehicle manufacturer’s recommended
support areas that provide stable support for the raised vehicle. Once jack stands are positioned, open the release valve VERY SLOWLY
(by turning the handle counterclockwise). Lower the load to rest on the jack stands. Then, make sure that the release valve on the jack is
closed tightly (by turning the handle clockwise).
2. To lower load: Re-check to make sure release valve is tightly closed. Then, operate the jack handle until the load is raised enough to remove
the jack stands. DO NOT CRAWL UNDER VEHICLE WHILE LIFTING VEHICLE OR REMOVING THE JACK STANDS! Once jack stands are removed, open
release valve very slowly to lower the vehicle. Lower jack completely so that the vehicle is securely resting on the ground and the jack no
longer makes contact with vehicle. 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
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 4 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.
OPERATING MANUAL FOR 791-6440

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HYDRAULIC JACK MAINTENANCE GUIDE
IMPORTANT: Service jacks are designed for lifting purposes only; always support raised load with jack stands.
REGULAR MAINTENANCE
• MONTHLY or as necessary (depending on usage)
#1 Using a grease gun, add grease to grease fitting in the lift arm pivot shaft.
(Use a multi-purpose NLGI type grease only.)
#2. Lubricate all linkages and pivot points.
(Use white lithium spray grease only.)
#3. Remove handle (not shown); lubricate handle
receptacle and handle end.
(Use white lithium spray grease only.)
#4. Lubricate both rear casters, bearing and both
front wheels. (Use white lithium spray grease only.)
5. Tighten all accessible hardware.
OPERATING MANUAL
#3
#2
#2
#2 #2
#1
#2
#2
#4
#4
OPERATING MANUAL FOR 791-6440

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PROBLEM ACTION
1. Unit will not lift rated load. Purge air from hydraulic system by following procedure under SETUP.
2. Unit will not sustain rated load or feels “spongy” under rated load. Purge air from hydraulic system as above.
3. Unit will not lift to full height. Purge air from hydraulic system as above.
4. Handle tends to raise up while the unit is under rated load. Pump the handle rapidly several times to push oil past ball valves in
power unit.
5. Unit still does not operate. For a complete list of authorized hydraulic repair centers please visit
www.toolwarrantyrepair.com.
INSPECTION
Visual inspection should be made before each use of the jack, checking for leaking hydraulic fluid and damaged, loose or missing parts.
Each jack must be inspected by a manufacturer’s repair facility immediately if subjected to an abnormal load or shock. Any jack which
appears to be damaged in any way, is found to be badly worn, or operates abnormally MUST BE REMOVED FROM SERVICE until necessary
repairs are made by a manufacturer’s authorized repair facility. It is recommended that an annual inspection of the jack be made by a
manufacturer’s authorized repair facility and that any defective parts, decals or warning labels be replaced with manufacturer’s specified
parts. A list of authorized repair facilities is available from the manufacturer.
PROPER STORAGE
It is recommended that the jack be stored in a dry location with all wheels touching the ground on a relatively level surface.
TROUBLESHOOTING
Important: Service jacks are self-contained devices used for lifting, but not sustaining, a partial vehicular load. In accordance with
ASME PASE-2019 Load Sustaining Test: “A load not less than the rated capacity…shall not lower more than 1/8"(3.18mm) in the first minute,
nor a total of .1875"(4.76mm) in 10 minutes.” Lowering within this range is considered normal operation and is NOT a warrantable defect.
OWNER/USER RESPONSIBILITY
The owner and/or user must have an understanding of the manufacturer’s operating instructions and warnings before using this jack.
Personnel involved in the use and operation of equipment shall be careful, competent, trained, and qualified in the safe operation of the
equipment and its proper use when servicing motor vehicles and their components. Warning information should be emphasized and
understood. If the operator is not fluent in English, the manufacturer’s instructions and warning shall be read to and discussed with the
operator in the operator’s native language by the purchaser/owner, making sure that the operator comprehends its contents. Owner and/or
user must study and maintain for future reference the manufacturers’ instructions. Owner and/or user is responsible for keeping all warning
labels and instruction manuals legible and intact. Replacement labels and literature are available from the manufacturer.
OPERATING MANUAL FOR 791-6440
WARRANTY
Please contact your local NAPA Auto Parts Store for details on warranty.