ALUMINUM JACK 3,000 lb. Jack Capacity & JACK STAND COMBO 6,000 lb. Jack Stand Capacity (when used in pairs) Model 91850 ASSEMBLY AND OPERATING INSTRUCTIONS 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our Web site at: http://www.harborfreight.com TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE. Copyright 2004 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.
PRODUCT SPECIFICATIONS Item Description M axim um Lifting Capacity 1.5 Ton (3,000 Lbs.). (Jack) Height Range 3-1/2 to 17-1/2. Front W heel Dim ensions 5-3/8 W x 2 O.D. Handle Type/Length 3 Piece Alum inum /47 W hen Assem bled. Jack Stand Features Chained Steel Lock Pin (3-5/16 L x 1/2 O.D.). 6 Adjustable Heights (From 9-11/16 to 14-1/2 ). 3 Ton W eight Capacity W hen Used in Pairs. Construction M achined Alum inum. W e ig h t: Jack 38.5 Lbs. Alum inum Jack Stands 9.9 Lbs. (2 pairs) T o ta l W e ig h t 48.4 Lbs. UNPACKING When unpacking, check to make sure all the parts shown on the Parts Lists on page 10 are included. 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. SAVE THIS MANUAL You will need this manual for the safety warnings and precautions, assembly, operating, 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. GENERAL SAFETY PRECAUTIONS WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed in the following pages may result in electric shock, fire, and/or serious injury. SAVE THESE INSTRUCTIONS SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 2 REV 11/04
GENERAL SAFETY RULES 1. Keep your work area clean and well lit. Cluttered work areas invite accidents. 2. Do not operate tools and equipment in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools and equipment create sparks which may ignite flammables. 3. Keep bystanders, children, and visitors away while operating tools and equipment. Distractions can cause you to lose control. Protect others in the work area. Provide barriers or shields as needed. 4. Stay alert. Watch what you are doing, and use common sense when operating a power tool. Do not use tools and equipment while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury. 5. Dress properly. 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. 6. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations. 7. Use safety equipment. Always wear ANSI approved safety impact goggles, safety shoes/boots, and heavy duty work gloves when using this product. 8. 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 is designed. 9. Store idle tools and equipment out of reach of children and other untrained persons. Tools and equipment are dangerous in the hands of untrained users. 10. Maintain tools with care. Do not use a damaged tool. Tag damaged tools Do not use until repaired. 11. If damaged, have the tool serviced before using. Check for loose screws, misalignment or binding of moving parts, loose mounting, cracked or broken parts, low hydraulic oil level, and any other condition that may affect its safe operation. Many accidents are caused by poorly maintained tools. 12. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool may become hazardous when used on another tool. SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 3
13. Tool service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury. 14. When servicing a tool, use only identical replacement parts. 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 injury. SPECIFIC SAFETY RULES 1. WARNING! Do not exceed the maximum lift capacity (1.5 Tons/3,000 pounds) for the Hydraulic Jack. Overloading the Jack could cause serious personal injury and/or property damage. 2. WARNING! Jack Stands maximum weight capacity is 3 Tons/6,000 lbs. when used in pairs. Never exceed this maximum weight capacity. Overloading the Jack Stands could cause serious personal injury and/or property damage. 3. This Jack and its Stands are designed for intermittent use only. Do not use the Jack or its Stands to support a vehicle over extended periods of time. The duration of the lifting job should be kept as short as possible. 4. Maintain labels and nameplates on the Jack and its Stands. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 5. Prior to using the Jack and its Stands, make sure to read and understand all warnings, safety precautions, and instructions as outlined in the vehicle manufacturer s instruction manual. Always check instruction manual for proper lifting and support locations. 6. When lifting only one wheel, make sure to support the load immediately with one Jack Stand placed under the side of the vehicle being lifted. Align the Saddle of the Jack Stand directly under the vehicle s seam (recommended lifting point). Always block the tires opposite the tire being lifted. 7. When lifting the entire front end or rear end of a vehicle, make sure to support the load immediately with both Jack Stands. Align the Saddles of the Jack Stands directly under the vehicle s frame (recommended lifting points). Also make sure the Jack Stands are adjusted at the same height. 8. Make sure the Hydraulic Jack is used only on a dry, oil/grease free, flat, level, ground surface capable of supporting the weight of the vehicle being lifted and any additional tools and equipment. 9. Do not work under the vehicle without properly supporting the vehicle with the Jack Stands. Make sure the load and Jack Stands are stable before getting under a vehicle. SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 4
10. Use the Hydraulic Jack only on vehicles whose frames have lifting points (on its seam or frame) capable of aligning with the Saddles of the Jack and its Jack Stands. 11. Avoid dangerous oncoming traffic. Always use the Hydraulic Jack as far away from the roadside as possible. 12. Do not use the Hydraulic Jack with the vehicle s engine running. Make sure to place the vehicle s transmission in Park (if automatic) or 1st Gear (if manual). Then set the emergency brake, and block the tires opposite the tire being lifted. 13. Industrial applications must follow OSHA requirements. 14. Always keep hands, fingers, and feet away from all moving parts of the Hydraulic 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 Jack. 15. Use extreme caution when applying or releasing a load. Never allow the load to suddenly release. Slowly and carefully apply and release the load. 16. Do not allow anyone in the vehicle while using the Hydraulic Jack. Keep all bystanders a safe distance away from the vehicle. 17. Never leave the Hydraulic Jack unattended when the Jack is under a load. 18. Never support both ends of the vehicle at the same time. 19. Before lowering the Hydraulic Jack, make sure tool trays, Jack Stands, and all other tools and equipment are removed from under the vehicle. 20. Do not stand on the Hydraulic Jack or its Stands as they may tip, causing personal injury. 21. For added protection, make sure to insert the Lock Pins (3B) into the holes located in the Saddle (1B) and Outer Tube (2B) of the Jack Stands. 22. If changing a damaged tire, make it easier to remove the lug nuts by slightly loosening the lug nuts before raising the tire off the ground. 23. WARNING! The warnings, precautions, and instructions discussed in this manual cannot cover all possible conditions and situations that may occur. The operator must understand that common sense and caution are factors, which cannot be built into this product, but must be supplied by the operator. SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 5
OPERATING INSTRUCTIONS NOTE: For additional references to the parts listed in the following pages, refer to the Assembly Diagrams on pages 11 and 12. 1. IMPORTANT! Make sure to thoroughly test the Hydraulic Jack for proper operation prior to its actual use. If the Hydraulic Jack appears not to be working properly, it may be necessary to purge its hydraulic system of excess air. To do so, remove the Oil Fill Plug (3C). Assemble the Upper Handle (6A), Bumper (7A), and Lower Handle (8A) of the Jack. Insert the Lower Handle into the Handle Yoke (12A) and tighten the Handle Yoke Bolt (10A). Turn the Handle Assembly clockwise. Apply pressure to the Saddle (28A), and pump the Handle Assembly slowly several times. The trapped air is pressurized and will be audible when released in this manner. Once purged of air check the Oil Reservoir (22C) and, if necessary, top off the Oil Reservoir with hydraulic oil. Then, replace the Oil Fill Plug. Turn the Handle Assembly counterclockwise slowly to completely lower the Jack. Test the Jack several times for proper operation before attempting to lift a load. If, after purging, the Jack still does not appear to be working properly, do not use the Jack until it has been repaired by a qualified service technician. (See Figures A and C.) REAR VIEW UPPER HANDLE (6A) BUMPER (7A) HANDLE YOKE (12A) OIL FILL PLUG (3C). LOWER HANDLE (8A) HANDLE YOKE BOLT (10A) FIGURE A SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 6
2. CAUTION! Make sure the vehicle is parked on a flat, level, solid, ground surface safely away from oncoming traffic. Turn off the vehicle s engine. Place the vehicle s transmission in PARK (if automatic) or in its lowest gear (if manual). Set the vehicle s emergency brake. Then, block the wheels that are not being lifted. 3. Check to make sure the Jack is fully lowered. If not, assemble the Upper Handle (6A), Bumper (7A), and Lower Handle (8A). Insert the Lower Handle into the Handle Yoke (12A). Then, turn the Lower Handle counterclockwise to lower the Jack. Once the Jack is fully lowered, turn the Handle Assembly firmly clockwise. (See Figure A.) 4. Carefully position the Saddle (1B) of the Hydraulic Jack under the vehicle manufacturer s recommended lifting point. (See vehicle manufacturer s owner 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.) 5. Pump the Handle Assembly until the top of the Jack s Saddle (28A) has nearly reached the vehicle lifting point. NOTE: The Jack should be positioned at 90 degrees to the vehicle s lifting point to ensure the Jack s Saddle and lifting point are in alignment. If not, remove and reposition the Jack before lifting the vehicle. (See Figure A.) 6. To lift the vehicle, pump the Handle Assembly (6A, 7A, 8A) of the Jack. Use smooth, full strokes for best results. (See Figure A.) 7. Raise the vehicle to just above the minimum height of the Jack Stand. Then, slide the Jack Stand to the proper lifting points referred to in the vehicle owner s manual. Also, if using two Jack Stands, make sure they are on the same point on each side of the vehicle. (See Figure B, next page.) 8. Center the vehicle s lifting point on the Saddle (1B) of the Jack Stand. Pull up on the Saddle of the Jack Stand until it is just below the contact points on the vehicle. Next, insert the Lock Pin (3B) through the Outer Tube (2B) and Saddle to lock the Saddle in place. If using two Jack Stands make sure they are at the same height. (See Figure B.) 9. If using two Jack Stands, turn the Handle Assembly counterclockwise slowly to lower the vehicle onto the Saddles (1B) of the Jack Stands. Do this release slowly until you are familiar with the rate at which the Jack lowers a load. Then, turn the Handle Assembly firmly clockwise. (See Figure B.) 10. If using two Jack Stands, gently rock the vehicle to determine if it is stable on the Jack Stands. If it is not, raise the vehicle, and reposition the Jack Stands. CAUTION! When performing this procedure be prepared and stand clear of the vehicle, as the vehicle can fall off the Jack Stands causing personal injury and/or property damage. SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 7
SADDLE (1B) SADDLE (28A) LOCK PIN (3B) FIGURE B HANDLE ASSY. (6A, 7A, 8A) 11. When the repair work to the vehicle is completed, make sure to remove all tools, old vehicle parts, etc. from under the vehicle. 12. Turn the Handle Assembly (6A, 7A, 8A) firmly clockwise, and pump the Handle Assembly to raise the vehicle slightly above the Saddles (1B) of the Jack Stands. Then, collapse the Jack Stands and remove them from under the vehicle. 13. Slowly turn the Handle Assembly (6A, 7A, 8A) counterclockwise (never more than two full turns) to lower the vehicle onto the ground. (See Figure B.) 14. Lower the Hydraulic Jack completely. Then, store the Jack and Jack Stands in a safe, dry location. INSPECTION, MAINTENANCE, AND CLEANING 1. Before each use, inspect the general condition of the Hydraulic Jack and Jack Stands. Check for broken, cracked, or bent parts, loose or missing Lock Pins, and any condition that may affect the proper operation of the product. If a problem occurs, have the problem corrected before further use. Do not use damaged equipment. 2. Change the hydraulic oil at least once every three years. To do so, with the Hydraulic Jack fully lowered, remove the Oil Fill Plug (3C) on the end of the Base Plate (5C). Tip the Hydraulic Jack to allow the old hydraulic oil to drain out of the oil Reservoir (22C) completely, and dispose of the old hydraulic oil in SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 8
accordance with local regulations. With the Hydraulic Jack upright, completely fill the Reservoir with a high quality hydraulic oil (not included). Then, reinstall the Oil Fill Plug. (See Figures A and C.) 3. Purge the hydraulic system of air occasionally. Occasionally, the Hydraulic Jack will exhibit signs of excessive air in its hydraulic system such as slow response to pumping, a spongy feeling to the pumping action, and a general lack of performance. To purge the hydraulic system of air, remove the Oil Fill Plug (3C). Assemble the Upper Handle (6A), Bumper (7A), and Lower Handle (8A) of the Jack. Insert the Lower Handle into the Handle Yoke (12A) and tighten the Handle Yoke Bolt (10A). Turn the Handle Assembly clockwise. Apply pressure to the Saddle (28A), and pump the Handle Assembly slowly several times. The trapped air is pressurized and will be audible when released in this manner. Once purged of air check the Oil Reservoir (22C) and, if necessary, top off the Oil Reservoir with hydraulic oil. Then, replace the Oil Fill Plug. Turn the Handle Assembly counterclockwise slowly to completely lower the Jack. Test the Jack several times for proper operation before attempting to lift a load. If, after purging, the Jack still does not appear to be working properly, do not use the Jack until it has been repaired by a qualified service technician. (See Figures A and C.) 4. When cleaning, use a clean cloth with a detergent or mild solvent. Then, store the Hydraulic Jack and Jack Stands together in a safe, dry location. DO NOT REMOVE FACTORY PRE-SET SCREW (25C) DO NOT REMOVE FACTORY PRE-SET SCREW (32C) FIGURE C OIL FILL PLUG (3C) 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 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 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. SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 9
PARTS LIST A Part # Description Qty. Part # Description Qty. 1A Power Unit Assembly 1 24A Shaft Sleeve 2 2A Connecting Block 1 25A Connecting Rod Shaft 1 3A Return Rod Pin 2 26A Front Wheel 1 4A Return Rod 2 27A Saddle Shaft 1 5A Spring Washer (18) 4 28A Saddle 1 6A Upper Handle 1 29A Saddle Base 1 7A Bumper 1 30A Front Wheel Shaft 1 8A Lower Handle 1 31A Lifting Arm 1 9A Right Spring 1 32A Saddle Base Shaft 1 10A Handle Yoke Bolt 1 33A Lifting Arm Shaft 1 11A Cotter Pin (10) 1 34A Screw (M10 x 25) 1 12A Handle Yoke 1 35A Left Spring 1 13A Pump Roller 1 36A Connecting Rod Pin 2 14A Handle Yoke Back Shaft 1 37A Nut (M10) 2 15A Supporting Shaft 1 38A Nut (M12) 4 16A Screw (M10 x 20) 6 39A Caster Assembly 2 17A Supporting Shaft Sleeve 2 40A Washer (16) 2 18A Rear Wheel Assembly 2 41A Nut (M16) 2 19A Connecting Rod 2 42A Screw (M12 x 25) 8 20A Side Handle Nut 4 43A Handle Yoke Shaft 2 21A Front Side Handle 2 44A Screw (M8 x 20) 2 22A Side Plate 2 45A Location Block 2 23A Cotter Pin (16) 6 PARTS LIST B Part # Description Qty. Part # Description Qty. 1B Saddle 2 4B Chain 2 2B Outer Tube 2 5B Base 2 3B Lock Pin 2 6B Bolt 2 PARTS LIST C Part # Description Qty. Part # Description Qty. 1C Screw 2 21C Washer 1 2C Ball (5mm) 2 22C Reservoir 1 3C Oil Fill Plug 1 23C O-Ring 1 4C O-Ring 2 24C Ring 1 5C Base Plate 1 25C Screw 1 6C Top Cover 2 26C O-Ring 1 7C O-Ring 2 27C High Pressure Oil Plug 1 8C Base Plate Washer 1 28C Ball (3mm) 1 9C Y-Ring 1 29C Spring Base 1 10C Washer 1 30C Spring 1 11C Piston Head 1 31C O-Ring 1 12C Piston Rod 1 32C Screw 1 13C Cylinder 1 33C Spring Washer 1 14C Ball (6mm) 2 34C Washer 1 15C Cone Shape Spring 1 35C Washer 1 16C Ball (9mm) 1 36C O-Ring 1 17C Spring 1 37C Pump Body 1 18C Top Cup 1 38C Pump Shaft 1 19C O-Ring 1 39C Spring 1 20C O-Ring 1 40C Copper Washer 1 NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 10
ASSEMBLY DIAGRAM A - ASSEMBLY DIAGRAM B 7A 6A 5A 16A 15A 14A 13A 12A 9A 11A 10A 8A 4A 17A 18A 3A 19A 2A 1A 20A 21A 22A 1B 23A 5A 24A 23A 45A 2B 3B 25A 38A 44A 26A 43A 27A 28A 23A 5B 42A 6B 41A 29A 30A 31A 32A 23A 33A 19A 23A 34A 35A 36A37A 22A 17A 38A 39A 40A 24A NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. 4B SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 11
ASSEMBLY DIAGRAM C 18C 19C 20C 21C 22C 23C 24C 4C 25C 14C 26C 27C 13C 12C 11C 10C 9C 8C 7C 16C 15C 14C 17C 28C 31C 30C 29C 32C 7C 8C 33C 34C 35C 36C 37C 38C 6C 39C 40C 5C 4C 3C 2C 1C 2C 1C NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 91850 For technical questions, please call 1-800-444-3353 PAGE 12