12 TON

AIR HYDRAULIC JACK

94487

ASSEMBLY & OPERATING INSTRUCTIONS

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Due to continuing improvement, actual product may differ slightly from the product described herein.

®

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Website at www.harborfreight.com

Copyright

©

2006 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 and replacement parts please call 1-800-444-3353.

THANK YOU for choosing a HARBOR FREIGHT TOOLS product. For future reference, please complete the owner’s record below:

Model______________ Serial No._____________ Purchase Date_______________

SAVE THE RECEIPT, WARRANTY AND THESE INSTRUCTIONS. It is important that you read the entire manual to become familiar with the unit BEFORE you begin assembly.

Technical Specifications

Minimum Height

Maximum Height

10-1/4”

20-1/8”

Air Flow Required 7 CFM

Working PSI

Weight

Weight Capacity

110-120

26.5 lb.

12 T / 24,000 lb.

Inlet Valve

Ram Diameter

Ram Travel

Universal 1/4”-18 NPT

1-11/16”

6-3/4”

Air Hose 49” L X 1/2” diameter

Overall Dimensions 8-1/2” L X 5-1/2” W X 10-1/4” H

Base Dimensions 7-3/4” L X 5-1/4” W X 1-1/2” H

GENERAL SAFETY PRECAUTIONS

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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

Keep your work area clean and well lit. Cluttered work areas invite accidents.

Keep bystanders, children, and visitors away while operating jack. Distractions can cause you to lose control. Protect others in the work area.

Stay alert. Watch what you are doing, and use common sense when operating a jack.

Do not use a jack while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating jacks may result in serious personal injury.

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.

Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the jack in unexpected situations.

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10.

Use safety equipment. Always wear ANSI-approved safety impact goggles, steel-toed safety shoes/boots, and heavy duty work gloves when using this product.

Do not force the jack. Use the correct jack for your application. The correct jack will do the job better and safer at the rate for which it is designed.

Store idle jacks out of reach of children and other untrained persons. Jacks are dangerous in the hands of untrained users.

Maintain jacks with care. Do not use a damaged jack. Tag damaged jacks “Do not use” until repaired.

If damaged, have the jack serviced before using. Check for loose screws, misalignment or binding of moving parts, loose mounting, cracked or broken parts, low hydraulic oil level, and

SKU 94487 For technical questions please call 1-800-444-3353. Page 2

11.

12.

any other condition that may affect its safe operation. Many accidents are caused by poorly maintained jacks.

Jack service must be performed only by qualified repair personnel. Service or maintenance performed by unqualified personnel could result in a risk of injury.

When servicing a jack, use only identical replacement parts - refer to the Parts List on page 8 and Assembly Diagram on page 9 of this manual. Follow instructions in the “In-

spection, Maintenance, And Cleaning” section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of injury.

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WARNING! Do not exceed the maximum lift capacity for the Bottle Jack as stated on the product label and the specifications table. Overloading the Jack could cause serious personal injury and/or property damage.

The Bottle 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. Always use jack stands to support a vehicle over an extended period of time.

Maintain labels and nameplates on the Bottle Jack. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement.

Prior to using the Bottle Jack, make sure to read and understand all warnings, safety precautions, and instructions as outlined in the manufacturer’s instruction manual for the vehicle (or object) you will lift.

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 being lifted. Align the saddle of the jack stand directly under the vehicle’s seam or 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 or recommended lifting points. Also make sure the jack stands are adjusted at the same height.

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Make sure the Bottle Jack is used only on a dry, oil/grease free, flat, level, solid surface capable of supporting the weight of the vehicle being lifted and any additional tools and equipment.

WARNING! Do not work under the vehicle without properly supporting the vehicle with

jack stands. Make sure the load and jack stands are stable before getting under a vehicle.

Use the Bottle Jack only on vehicles whose frames have lifting points (on its seam or frame) capable of aligning with the Saddle of the Jack.

This bottle jack is not intended for roadside use. This jack requires a flat, stable surface to safely lift a load.

Do not use the Bottle 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.

Industrial applications must follow OSHA requirements.

24.

25.

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 Jack.

SKU 94487 For technical questions please call 1-800-444-3353. Page 3

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

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

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

Never support both ends of the 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.

Do not stand on the Bottle Jack as it may tip, causing personal injury.

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.

This Bottle Jack is not to be used for aircraft purposes. Never modify the Bottle Jack in an attempt to use it for a purpose it was not designed for.

Never adjust the factory set safety valve.

Compressed air only. Never use compressed gas as a power source for this item.

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.

Unpacking

When unpacking your 12 Ton Bottle Jack, check to make sure that the parts listed on page 8 are included.

If any parts are damaged or broken , please call HARBOR FREIGHT TOOLS at: 1-800-444-3353.

Assembly

It is important that you read the entire manual to become familiar with the product BEFORE you operate the Bottle Jack.

Connect both parts of the Handle (45). Insert it into the Handle Bracket (34) - see Figure 1 on page 5 and the Assembly Diagram on page 9.

Operation

WARNING: Prior to its first use, make sure to check for proper hydraulic oil level in the Bottle

Jack. Then thoroughly test the Bottle Jack for proper operation prior to its actual use. If the

Bottle Jack appears not to be working properly, it may be necessary to bleed its hydraulic system of excess air.

1.

Bleeding the System

Remove the Filler Plug (16). Insert the slot on the lower portion of the Handle (45) over the Release Valve (4). Turn the Handle Assembly counterclockwise to open the Release Valve (4).

2.

Insert the Handle Assembly into the Handle Bracket (34). Pump the Handle (45) 10-15 times.

3.

Connect the air supply to the air inlet hose. Squeeze the air valve and allow it to operate for one minute. Disconnect the air supply.

SKU 94487 For technical questions please call 1-800-444-3353. Page 4

4.

5.

Bleeding the System (Cont’d)

Once air is bled, check the Oil Fill Hole and, if necessary, top off the Oil Fill Hole with hydraulic oil. Then, replace the Oil Filler Plug.

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.

Figure 1 Figure 2

Spring

Plate (20)

Filler

Plug (16)

Release

Valve (4)

Handle

Bracket (34) Handle (45)

1.

Raising the Jack

WARNING! Make sure the vehicle is parked on a flat, level, solid surface. Turn off the vehicle’s engine. Place the vehicle’s transmission in “PARK” (if automatic) or in its highest gear (if manual). Set the vehicle’s emergency brake. Then, block the wheels that are not being lifted.

Verify that the vehicle’s weight is not more than the weight capacity for this jack.

2.

Check to make sure the Jack is fully lowered. If not, insert the lower portion of the Handle into the Valve Release, and turn the Handle counterclockwise to lower the Jack. Once the Jack is fully lowered, turn the Handle firmly clockwise to close the Valve Release.

3.

4.

Adjust the Extension Screw (13-1) as needed to position the it directly underneath the lifting point. Turn it counterclockwise to raise, or clockwise to lower.

Lifting using pressurized air power: a.

Connect the air supply hose lock fitting into the Air Inlet Fitting. The Lock Lever (A-27) should be in the OFF (not locked) position.

b.

Connect the Air Compressor (compressor not included, must supply at least 7 CFM at 110-

120 PSI) to the Air Supply Hose.

c.

Turn the compressor on and allow it to pressurize, if not already pressurized.

d.

Press the Lever (A-28) to the ON position and lock it into place using the Lock Lever (A27).

This will provide a continuous air supply to the Air Motor (42), raising the jack.

Lifting manually:

Raise the Jack by alternately lifting and lowering the Handle.

SKU 94487 For technical questions please call 1-800-444-3353. Page 5

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Lowering the Jack

Caution: Avoid rapid descent of the load by turning the Release Valve slowly.

Make sure the Lock Lever (A27) is released to stop the air flow to the Air Motor (42).

If attached, remove the Air Supply Hose (43) from the Air Inlet Fitting.

Place the slotted end of the Handle (45) onto the Release Valve.

Slowly and carefully lower the load by turning the Release Valve counterclockwise in very small increments. Only use the Handle (45), never use your hand to turn the Release Valve.

Lower the Extension Screw (13-1) as needed by turning clockwise.

Remove the Jack.

Oil Replacement

Place the Jack in an upright position.

Completely lower the Ram (13). Remove the Filler Plug (16).

Fill with high quality hydraulic jack oil to the lower rim of the fill hole.

Purge the air from the hydraulic system as previously described.

Top off with hydraulic oil.

Replace the Filler Plug (16).

INSPECTION, MAINTENANCE, AND CLEANING

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2.

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4.

Before each use, inspect the general condition of the Bottle Jack. Check for broken, cracked, or bent parts, loose or missing parts, 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.

Before each use, make sure to thoroughly test the Bottle Jack for proper operation prior to its actual use. If the Bottle Jack appears not to be working properly, it may be neces-

sary to bleed its hydraulic system of excess air. Refer to pages four and five for complete instructions on bleeding the system.

Change the hydraulic oil at least once every three years. To do so, with the Bottle Jack fully lowered, remove the Oil Filler Plug on the side of the Housing. Tip the Bottle Jack to allow the old hydraulic oil to drain out of the Housing completely, and dispose of the old hydraulic oil in accordance with local regulations. With the Bottle Jack upright, completely fill the Housing with a high quality hydraulic oil (not included) until the oil just begins to run out of the Oil Fill

Hole. Then, reinstall the Oil Filler Plug.

When cleaning, use a clean cloth with a detergent or mild solvent. Then, store the Bottle Jack in a safe, dry location out of reach of children and other non-authorized people.

5.

WARNING! All maintenance, service, or repairs not listed in this manual are only to be attempted by a qualified service technician.

SKU 94487 For technical questions please call 1-800-444-3353. Page 6

SKU 94487 For technical questions please call 1-800-444-3353. Page 7

Part Description

1 Base

2 Ball

3 Seal

4 Release Valve

5 Ball Cup

6 Spring

7 Spring

8 Screw

9 Nylon Ring

10 Cylinder

11 O-Ring

12 Cup Seal

13 Ram

13-1 Extension Screw

14 Packing

15 Reservoir

Q’ty

1

1

1

1

1

1

1

1

1

2

1

1

2

1

6

1

Parts List-Main Body

Part Description

16 Filler Plug

17 Nylon Ring

18 Top Nut

19 O-Ring

20 Spring Plate

21 Spring

22 Eye Bolt

23 Nut

24 Lock Washer

25 Washer

26 Pump Cylinder

27 O-Ring

28 Nylon Ring

29 Backup Ring

30 Piston

31 Pin

1

1

1

Q’ty

1

1

1

1

1

1

1

1

1

1

3

2

1

Part Description

32 R-Pin

33 Connector

34 Handle Bracket

35 Ball

36 Ball Cup

37 Spring

38 Screw

39 O-Ring

40 Screw

41 Plastic Cap

42 Air Motor

43 Air Hose

44 Air Valve

45 Handle

1

1

1

1

1

2

1

1

1

1

1

1

Q’ty

3

1

Part Description Q’ty

A1 Air Pump Cylinder 1

A2 Nut 1

A3 Sealing Ring

A4 Nylon Ring

A5 Copper Ring

1

1

1

A6 Air Cylinder Seat

A7 Nut

A8 Spring

A9 Air Pump Piston

A10 O-Ring

A11 Sealing Ring

A12 Big Piston

A13 O-Ring

A14 Small PIston

2

1

1

1

1

1

1

1

1

Parts List-Air Motor

Part Description

A15 O-Ring

A16 Big Piston Cap

A17 Sealing Ring

A18 Nylon Ring

A19 Air Cylinder

A20 Air Cylinder Cap

A21 Bolt

A22 Coupler Seat

A23 Retaining Ring

A24 O-Ring

A25 Coupler

A26 Air Hose

A27 Lock Lever

A28 Lever

1

1

1

2

1

1

1

1

1

1

1

1

Q’ty

1

1

Part Description

A29 Nut

A30 O-Ring

A31 O-Ring

A32 Packing

A33 Throttle

A34 Spring

A35 Lock Nut

A36 Bolt

A37 Valve Body

A38 Screw

A39 Screen

A40 O-Ring

A41 Quick Coupler-

Male

1

1

1

1

1

1

1

1

1

1

1

Q’ty

1

1

SKU 94487 For technical questions please call 1-800-444-3353. Page 8

Assembly and Parts Diagram-Main Body

Note: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts.

SKU 94487 For technical questions please call 1-800-444-3353. Page 9

Assembly and Parts Diagram-Air Motor

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL

ONLY. NEITHER THE MANUFACTURER NOR 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 94487 For technical questions please call 1-800-444-3353. Page 10

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 ninety 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, 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.

SKU 94487 For technical questions please call 1-800-444-3353. Page 11