®
1.5 TON ALUMINUM FLOOR JACK
WITH ILLUMINATED SADDLE
Model 96562
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© 2007 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
symbol to avoid possible injury or death.
Danger
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in death
or serious injury.
Caution
CAUTION, used with the safety alert
symbol, indicates a hazardous situation
which, if not avoided, could result in minor
or moderate injury.
Notice
NOTICE is used to address practices not
related to personal injury.
Caution
SKU 96562
CAUTION, without the safety alert symbol,
is used to address practices not related to
personal injury.
For technical questions, please call 1-800-444-3353.
Page General Safety Rules
WARNING! Read all instructions
Failure to follow all instructions listed below may result in serious injury.
SAVE THESE INSTRUCTIONS
1.
Work area safety
a. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b. Do not operate tools in explosive atmospheres, such as in the presence of
flammable liquids, gases or dust. Tools create sparks which may ignite the
dust or fumes.
c. Keep children and bystanders away while operating a tool. Distractions
can cause you to lose control.
2.
Personal safety
a. Stay alert, watch what you are doing and use common sense when operating
tools. Do not use tool while you are tired or under the influence of drugs,
alcohol or medication. A moment of inattention while operating tools may
result in serious personal injury.
b.
Use safety equipment. Always wear eye protection. Safety
equipment such as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions will reduce per-
sonal injuries.
c. Do not overreach. Keep proper footing and balance at all times. This
enables better control of the tool in unexpected situations.
d. Dress properly. Do not wear loose clothing or jewellery. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewelery or long
hair can be caught in moving parts.
3.
Power tool use and care
a. 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.
b. Store idle tools out of the reach of children and do not allow people
unfamiliar with the tool or these instructions to operate the tool. Tools
are dangerous in the hands of untrained users.
c. Maintain tools. 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.
d. Use the tool, accessories, etc., in accordance with these instructions and
in the manner intended for the particular type of tool, taking into account
the working conditions and the work to be performed. Use of the tool for
operations different from those intended could result in a hazardous situation.
SKU 96562
For technical questions, please call 1-800-444-3353.
Page 4.
Service
a. Have your tool serviced by a qualified repair person using only identical
replacement parts. This will ensure that the safety of the tool is maintained.
Specific Safety Rules
WARNING
1.
Do not exceed the maximum lift capacity (1-1/2 tons/3,000
pounds). Overloading the Jack could cause serious personal injury and/or
property damage.
2.
This Floor Jack is designed for intermittent use only. Do not use the Jack to
support a vehicle over extended periods of time. The duration of the lifting job
should be kept as short as possible.
3.
Prior to using the Floor Jack, make sure to read and understand all warnings,
safety precautions, and instructions as outlined in the vehicle manufacturer’s
instruction manual.
4.
Do not work under a vehicle without properly supporting the vehicle with jack
stands (not included). Make sure the load and jack stands are stable before
getting under a vehicle.
5.
Make sure the Floor 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.
6.
Use the Floor Jack only on vehicles whose frames have lifting points (on its seam
or frame) capable of aligning with the Saddle (2) of the Jack.
7.
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).
8.
When lifting the entire 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 (recommended lifting points). Also, make sure
the jack stands are adjusted at the same height.
9.
Do not use the Floor 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 chock the tires opposite the tire being lifted.
10.
Avoid dangerous oncoming traffic. Always use the Floor Jack as far away from
the roadside as possible.
11.
Industrial applications must follow OSHA requirements.
SKU 96562
For technical questions, please call 1-800-444-3353.
Page 12.
Always keep hands, fingers, and feet away from all moving parts of the Floor
Jack when applying or releasing a load. Remain clear of the vehicle being raised
or lowered.
13.
Use extreme caution when applying or releasing a load. Never allow the load to
suddenly release. Slowly and carefully release the load.
14.
Do not allow anyone in the vehicle while using the Floor Jack. Keep all
bystanders a safe distance away from the vehicle.
15.
Never leave the Floor Jack unattended when the Jack is under a load.
16.
Never support both ends of a vehicle at the same time.
17.
Before lowering the Floor Jack, make sure tool trays, jack stands, and all other
tools and equipment are removed from under the vehicle.
18.
If changing a damaged tire, it is easier to loosen the lug nuts slightly before
raising the tire off the ground.
19.
Maintain labels and nameplates on the tool. These carry important safety
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.
20.
This product is not a toy. Keep it out of reach of children.
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 and caution are factors which
cannot be built into this product, but must be supplied by the operator.
Save these instructions.
Specifications
Electrical Requirements
LED Power Input: Three AA Batteries (Not Included)
Maximum Lifting Capacity
1-1/2 Tons (3,000 Pounds)
Height Range
3-3/8” to 14-3/4”
Saddle Diameter
4”
LED Light
Press Button Once to Turn On. Light Will
Illuminate for 60 Seconds. Then Automatically
Turn Off.
Number of LED Lights
6
Overall Handle Length
37” (Assembled)
Net Weight
27.16 Pounds
SKU 96562
For technical questions, please call 1-800-444-3353.
Page PRODUCT FEATURES
LED LIGHTS
SADDLE (2)
OIL FILL PLUG (61)
THREE “AA” BATTERIES
(NOT INCLUDED)
HANDLE YOKE (60)
LED LIGHT BUTTON (on 20)
LED BATTERY CASE (56)
FIGURE A
LOWER SECTION HANDLE (22)
UPPER SECTION HANDLE (53)
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.
SKU 96562
For technical questions, please call 1-800-444-3353.
Page Set Up Instructions
Read the entire Important Safety Information section at the
beginning of this manual including all text under subheadings therein
before set up or use of this product.
Note: For additional information regarding the parts listed in the following pages, refer
to the Assembly Diagram near the end of this manual.
Assembly
1.
Align the snap lock hole at the open end of the Lower Handle (22) with the
spring loaded push button lock (not shown) on the Handle Connector (53). Push
the handle until it is locked in position. With a 4 mm hexagonal wrench (not
supplied), retighten the hexagonal head cap screw which secures the upper
handle to the Handle Connector (53). Back off the Handle Set Screw (46) at
the back of the Handle Yoke (60), insert the square drive end of the handle into
the Yoke and rotate the handle until it aligns with the square drive of the Valve
Release (not shown) and bottom out inside the Handle Yoke (60). Finger-tighten
the Handle Set Screw (46). (See Figure B.)
UPPER SECTION HANDLE (53)
FIGURE B
LOWER SECTION HANDLE (22)
HANDLE YOKE (60)
2.
HANDLE SET SCREW (46)
To install the three “AA” Alkaline or rechargable Batteries (not included) for the
LED lights, unscrew and remove the Battery Case Screw (57) located on the
underside of the Floor Jack. Remove the Case Cover (58). Then install the
three Batteries in the Battery Case (56), making sure to match the polarity of
each Battery with the polarity shown on the inside of the Battery Case. Once
installed, replace the Case Cover and Battery Case Screw. Do not over tighten
the screw. (See Figure A.)
SKU 96562
For technical questions, please call 1-800-444-3353.
Page Operating Instructions
Read the entire Important Safety Information section at the
beginning of this manual including all text under subheadings therein
before set up or use of this product.
TOOL SET UP
1.
HOW TO BLEED THE FLOOR JACK:
•
During shipment and handling, air may get trapped in the hydraulic system which
can interfere with the Jack’s lifting performance. Follow these Steps to release
the air:
•
Turn the Handle (22, 53) assembly counterclockwise no more than two full turns
to open the release valve. (See Figure B.)
•
Unscrew, and remove the Oil Fill Plug (61). (See Figure A.)
•
Rapidly pump the Handle (22, 53) assembly six to eight full strokes to release
any pressurized air that may be trapped in the hydraulic system. (See Figure B.)
•
Make sure the hydraulic oil level is just below the threads in the Oil Fill Plug hole.
If oil needs to be added, follow the instructions below for adding oil.
•
Replace and tighten the Oil Fill Plug (61). (See Figure A.)
2.
HOW TO ADD HYDRAULIC OIL:
•
Place Floor Jack on level ground. Turn the Handle (22,53) assembly
counterclockwise to lower the saddle fully. Wipe Power Unit (55) particularly
around the Oil Fill Plug (61). Unscrew and remove the Oil Fill Plug (61).
Note: Oil Fill Plug is the one on the right hand side when viewed from front of
the Jack. (See Figure A.)
•
Using a good grade of S.A.E. 5W hydraulic jack oil, fill the Oil Reservoir to the
bottom of the threads in the Oil Fill Plug hole. (See Figure A.)
•
Replace and tighten the Oil Fill Plug (61). (See Figure A.)
3.
IMPORTANT: Do NOT allow dirt or debris to enter the hydraulic system.
SKU 96562
For technical questions, please call 1-800-444-3353.
Page GENERAL OPERATION INSTRUCTIONS
1.
Check to make sure the Floor Jack is fully lowered. If not, turn the Handle (22,
53) assembly counterclockwise to completely lower the Saddle (2). Once the
Saddle is lowered, turn the Handle assembly clockwise. (See Figure C.)
FIGURE C
UPPER & LOWER SECTION
HANDLE ASSEMBLY
(53, 22)
SADDLE
(2)
2.
Carefully position the Saddle (2) of the Floor 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 Figure C.)
3.
Press the Button on the Lift Arm Assembly (20) to illuminate the six LED Lights
located on the Saddle (2). The illuminated LED Lights will act as a visual aid to
help properly position the Saddle. Once the Button is pressed, the LED Lights
will remain illuminated for approximately sixty seconds and then automatically
turn off. If necessary, press the Button repeatedly until the Saddle is properly
positioned under the seam or frame lifting points. (See Figure D.)
LED LIGHT BUTTON
FIGURE D
SKU 96562
For technical questions, please call 1-800-444-3353.
Page 4.
Pump the Handle (22, 53) assembly until the top of the Saddle (2) has nearly
reached the vehicle lifting point. NOTE: The Floor Jack should be positioned
at 90 degrees to the vehicle’s lifting point to ensure the Saddle and lifting point
are in alignment. If not, remove and reposition the Floor Jack before lifting the
vehicle. (See Figure C.)
5.
To lift the vehicle, pump the Handle (22, 53) assembly. Use smooth, full strokes
for best results. (See Figure C.)
6.
Raise the vehicle to just above the minimum height of the Jack Stand(s)
being used. Then slide the Jack Stand(s) under the proper lifting points as
recommended by the vehicle manufacturer.
7.
Center the Saddle of the Jack Stand(s) just below the lifting points on the vehicle.
NOTE: If using two Jack Stands, make sure they are of the same height.
8.
Slowly turn the Handle (22, 53) assembly of the Floor Jack counterclockwise to
ease the vehicle onto the Jack Stand(s). Then turn the Handle assembly firmly
clockwise. (See Figure C.)
Caution
When performing this procedure, be prepared and stand
clear of the vehicle as the vehicle can fall off the Jack Stand(s) causing personal
injury and/or property damage.
9.
When the repair work to the vehicle is completed, make sure to remove all tools,
old vehicle parts, etc. from under the vehicle.
10.
Turn the Handle (22, 53) assembly firmly clockwise, and pump the Handle
assembly to raise the vehicle slightly above the Saddle of the Jack Stand(s).
Then, collapse the Jack Stand(s) and remove them from under the vehicle.
(See Figure C.)
11.
Slowly turn the Handle (22, 53) assembly counterclockwise (never more than two
full turns) to lower the vehicle onto the ground. (See Figure C.)
12.
Lower the Saddle (2) of the Floor Jack completely. Then store the Floor Jack in
a clean, dry, safe location out of reach of children and other unauthorized people.
(See Figure C.)
Maintenance And Servicing
WARNING
Risk of serious personal injury. Always remove all load
from the Floor Jack before performing any inspection,
maintenance, or cleaning procedures.
Damaged equipment can fail, causing serious personal
injury. Do not use damaged equipment. If abnormal noise or
vibration occurs, have the problem corrected before further
use.
SKU 96562
For technical questions, please call 1-800-444-3353.
Page 10
Inspection, maintenance, and cleaning
1.
BEFORE EACH USE, inspect the general condition of the Floor Jack. Check
for loose components, misalignment or binding of moving parts, bent, cracked or
broken parts, and any other condition that may affect its safe operation.
2.
BEFORE EACH USE, BLEED THE FLOOR JACK OF EXCESS AIR IN ITS
SYSTEM: See pages 6 and 8 of this manual.
3.
TO FILL THE FLOOR JACK WITH HYDRAULIC OIL: See pages 6 and 8 of this
manual.
4.
After Use, clean the external surfaces of the tool with a clean, moist cloth and
mild detergent. Do not use solvents.
5.
STORAGE: Always store the Floor Jack in a clean, dry, safe location out of
reach of children and other unauthorized people. The valve should be in the
open position.
6.
LUBRICATION: Lubricate the ram, linkages, saddle and pump mechanism with
light oil and grease wheel bearings and axles.
7.
Caution All maintenance, service, and repairs not mentioned in this
manual must only be performed by a qualified service technician.
Troubleshooting
Problem
Possible Causes
Floor Jack does
not raise or lower
properly.
1. Handle not seated properly.
1. Loosen Retaining Screw (45), seat
handle, and retighten.
2. Improper use of Handle.
2. Turn Handle clockwise to raise,
counterclockwise to lower.
3. Excess air in unit’s system.
3. Bleed system of excess air. See
pages 6 and 8 of this manual.
4. Unit low on hydraulic oil.
4. Fill unit with hydraulic oil. See
pages 6 and 8 of this manual.
1. “AA” Batteries low.
1. Replace Batteries. See pages 6
and 7 of this manual.
LED Lights do not
illuminate.
SKU 96562
Possible Solutions
For technical questions, please call 1-800-444-3353.
Page 11
PARTS LIST
Part
Description
Q’ty
Part
Description
Q’ty
1
Hex Screw
1
32
Washer (#8)
2
2
Saddle
1
33
Screw (M6x35)
2
3
LED Plate
1
34
Nut (M10)
2
4
Insulating Plate
1
35
Rear Caster Assy.
2
5
Saddle Base
1
36
Rear Caster Base
2
6
Brush
1
37
Handle Yoke Bolt
2
7
Screw (M4x8)
2
38
Bolt (M6x25)
2
8
Long Link Connecting Tube
1
39
Retaining Ring (#19)
2
9
Retaining Ring (#13)
2
40
Return Spring
2
10
Saddle Base Bolt
1
41
Linkage Block
1
11
Front Rolling Wheel Axle
1
42
Pin (4x26)
1
12
Side Plate
2
43
Handle Yoke Roller Bolt
1
13
Screw (M10x16)
2
44
Handle Yoke Roller
1
14
Washer (#10)
2
45
Retaining Ring
1
15
Washer (#10)
2
46
Handle Set Screw
1
16
Screw (M6x20)
2
47
Screw (M8x20)
6
17
Front Rolling Wheel
1
48
Washer (#10)
6
18
Long Linkage
2
49
Rubber Protective Layer
2
19
Screw (M8x16)
4
50
Rod
1
20
Lift Arm Assy.
1
51
Rear Carrying Handle
1
21
Long Link Bolt
2
52
Handle Protective Layer
1
22
Handle (Lower Section)
1
53
Handle (Upper Section)
1
23
Washer (#8)
2
54
Carrying Handle
1
24
Washer (#8)
2
55
Power Unit
1
25
Nut (M16)
2
56
Battery Case
1
26
Screw (M10x25)
6
57
Battery Case Screw
2
27
Spring Washer (#10)
6
58
Case Cover
1
28
Screw (M6x20)
2
59
Case Cover Screw (M2x6)
1
29
Washer (#6)
2
60
Handle Yoke
1
30
Handle Yoke Screw
2
61
Oil Fill Plug
1
31
Washer (#8)
2
62
Valve Actuator (not shown)
1
SKU 96562
For technical questions, please call 1-800-444-3353.
Page 12
Note: Valve Actucator (62) (no shown)
61
60
ASSEMBLY DIAGRAM
SKU 96562
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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 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
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
available individually as replacement parts.
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 96562
For technical questions, please call 1-800-444-3353.
Page 14