1.5 TON ALUMINUM FLOOR JACK WITH ILLUMINATED …images.harborfreight.com/manuals/96000-96999/96562.pdf · SKU 96562 For technical questions, please call 1-800-444-3353. Page 2 SAVE

1.5 TON ALUMINUM FLOOR JACK WITH ILLUMINATED SADDLE

Model 96562SET 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.

®

Page 2SKU 96562 For technical questions, please call 1-800-444-3353.

SAVE THIS MANUALKeep 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 INFORMATIONIn 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 indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNINg indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

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.

DANgERDANgER

WARNINgWARNINg

CAUTIONCAUTION

NOTiCeNOTiCe

CAUTIONCAUTION


gENERAL SAFETY RULES WARNINg! Read all instructions Failure to follow all instructions listed below may result in serious injury.

SAVe THeSe iNSTRUCTiONS

Work area safetyKeep 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. Tools create sparks which may ignite the dust or fumes.Keep children and bystanders away while operating a tool. Distractions can cause you to lose control.

personal safetyStay 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. 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 personal injuries.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 jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelery or long hair can be caught in moving parts.

power tool use and careDo 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.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.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.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.

1.a.b.

c.

2.a.

b.

c.

d.

3.a.

b.

c.

d.


ServiceHave 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 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.

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.

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.

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.

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.

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.

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).

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.

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.

Avoid dangerous oncoming traffic. Always use the Floor Jack as far away from the roadside as possible.

Industrial applications must follow OSHA requirements.

4.a.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

WARNINg


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.

Use extreme caution when applying or releasing a load. Never allow the load to suddenly release. Slowly and carefully release the load.

Do not allow anyone in the vehicle while using the Floor Jack. Keep all bystanders a safe distance away from the vehicle.

Never leave the Floor Jack unattended when the Jack is under a load.

Never support both ends of a vehicle at the same time.

Before lowering the Floor Jack, make sure tool trays, jack stands, and all other tools and equipment are removed from under the vehicle.

if changing a damaged tire, it is easier to loosen the lug nuts slightly before raising the tire off the ground.

Maintain labels and nameplates on the tool. These carry important safety information. if unreadable or missing, contact Harbor Freight Tools for a replacement.

This product is not a toy. Keep it out of reach of children.

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.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

SpECIFICATIONSElectrical 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 LightPress Button Once to Turn On. Light Willilluminate for 60 Seconds. Then AutomaticallyTurn Off.

Number of LeD Lights 6Overall Handle Length 37” (Assembled)Net Weight 27.16 Pounds


pRODUCT FEATURES

LOWER SECTION HANDLE (22)

UppER SECTION HANDLE (53)

HANDLE YOKE (60)

SADDLE (2)LED LIgHTS

LED BATTERY CASE (56)

THREE “AA” BATTERIES(NOT INCLUDED)

OIL FILL pLUg (61)

FIgURE A

LED LIgHT BUTTON (on 20)

UNpACKINgWhen 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.


SET Up INSTRUCTIONSRead 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.

AssemblyAlign 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.)

1.

LOWER SECTION HANDLE (22)

UppER SECTION HANDLE (53)

HANDLE YOKE (60)HANDLE SET SCREW (46)

FIgURE B

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.)

2.


OpERATINg INSTRUCTIONSRead 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 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.)

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.)

IMpORTANT: Do NOT allow dirt or debris to enter the hydraulic system.

1.

•

•

•

•

•

•

2.

•

•

•

3.


gENERAL OpERATION INSTRUCTIONS 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.)

1.

UppER & LOWER SECTIONHANDLE ASSEMBLY

(53, 22)

SADDLE(2)

FIgURE C

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.)

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.)

2.

3.

LED LIgHT BUTTON

FIgURE D


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.)

To lift the vehicle, pump the Handle (22, 53) assembly. Use smooth, full strokes for best results. (See Figure C.)

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.

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.

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.)

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.

When the repair work to the vehicle is completed, make sure to remove all tools, old vehicle parts, etc. from under the vehicle.

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.)

Slowly turn the Handle (22, 53) assembly counterclockwise (never more than two full turns) to lower the vehicle onto the ground. (See Figure C.)

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 SERVICINgRisk 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.

4.

5.

6.

7.

8.

9.

10.

11.

12.

WARNINgWARNINg

CAUTION


Inspection, maintenance, and cleaningBEFORE 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.

BEFORE EACH USE, BLEED THE FLOOR JACK OF EXCESS AIR IN ITS SYSTEM: See pages 6 and 8 of this manual.

TO FILL THE FLOOR JACK WITH HYDRAULIC OIL: See pages 6 and 8 of this manual.

AFTER USE, clean the external surfaces of the tool with a clean, moist cloth and mild detergent. Do not use solvents.

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.

LUBRiCATiON: Lubricate the ram, linkages, saddle and pump mechanism with light oil and grease wheel bearings and axles.

All maintenance, service, and repairs not mentioned in this manual must only be performed by a qualified service technician.

Troubleshooting

problem possible Causes possible SolutionsFloor Jack does not raise or lower properly.

1. Handle not seated properly.

2. improper use of Handle.

3. excess air in unit’s system.

4. Unit low on hydraulic oil.

1. Loosen Retaining Screw (45), seat handle, and retighten.

2. Turn Handle clockwise to raise, counterclockwise to lower.

3. Bleed system of excess air. See pages 6 and 8 of this manual.

4. Fill unit with hydraulic oil. See pages 6 and 8 of this manual.

LeD Lights do not illuminate.

“AA” Batteries low.1. 1. Replace Batteries. See pages 6 and 7 of this manual.

1.

2.

3.

4.

5.

6.

7. CAUTION


part Description Q’ty1 Hex Screw 12 Saddle 13 LeD Plate 14 insulating Plate 15 Saddle Base 16 Brush 17 Screw (M4x8) 28 Long Link Connecting Tube 19 Retaining Ring (#13) 2

10 Saddle Base Bolt 111 Front Rolling Wheel Axle 112 Side Plate 213 Screw (M10x16) 214 Washer (#10) 215 Washer (#10) 216 Screw (M6x20) 217 Front Rolling Wheel 118 Long Linkage 219 Screw (M8x16) 420 Lift Arm Assy. 121 Long Link Bolt 222 Handle (Lower Section) 123 Washer (#8) 224 Washer (#8) 225 Nut (M16) 226 Screw (M10x25) 627 Spring Washer (#10) 628 Screw (M6x20) 229 Washer (#6) 230 Handle Yoke Screw 231 Washer (#8) 2

part Description Q’ty32 Washer (#8) 233 Screw (M6x35) 234 Nut (M10) 235 Rear Caster Assy. 236 Rear Caster Base 237 Handle Yoke Bolt 238 Bolt (M6x25) 239 Retaining Ring (#19) 240 Return Spring 241 Linkage Block 142 Pin (4x26) 143 Handle Yoke Roller Bolt 144 Handle Yoke Roller 145 Retaining Ring 146 Handle Set Screw 147 Screw (M8x20) 648 Washer (#10) 649 Rubber Protective Layer 250 Rod 151 Rear Carrying Handle 152 Handle Protective Layer 153 Handle (Upper Section) 154 Carrying Handle 155 Power Unit 156 Battery Case 157 Battery Case Screw 258 Case Cover 159 Case Cover Screw (M2x6) 160 Handle Yoke 161 Oil Fill Plug 162 Valve Actuator (not shown) 1

pARTS LIST


ASSEMBLY DIAgRAM

60

61

Not

e: V

alve

Act

ucat

or (6

2) (n

o sh

own)


LIMITED 90 DAY WARRANTYHarbor 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 CAREFULLYTHe 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.

Documents

1.5 TON ALUMINUM FLOOR JACK WITH ILLUMINATED …images.harborfreight.com/manuals/96000-96999/96562.pdf · SKU 96562 For technical questions, please call 1-800-444-3353. Page 2 SAVE