Harbor Freight Tools 92840 User Manual

AIR FLOOR JACK

®

25 TON / 50 TON

Model 92840

ASSEMBLY and OPERATING

INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at http://www.harborfreight.com

TO PREVENT SERIOUS INJURY OR DEATH,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

Copyright© 2005 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

Specifications

Lift Capacity 25 Tons (Stage 2) to 50 Tons (Stage 1)
Lifting Range 8-5/8” to 13-1/4” (Stage 1)

13-1/4” to 19-1/8” (Stage 2)
Air Inlet 1/4”-18 NPT
Maximum Air Pressure 200 PSI
Minimum Air Pressure 150 PSI
Air Requirements 9.5 CFM
Overall Dimensions 40” L x 10-1/2” W x 60-1/4”
Ram (2) Diameter 2-3/4”
Weight 174 Lbs.

Save This Manual

You will need the manual for the safety warnings and precautions, assembly instructions,
operating and maintenance procedures, parts list and diagram. Keep your invoice with this
manual. Write the invoice number on the inside of the front cover. Keep the manual and
invoice in a safe and dry place for future reference.

Safety Warnings and Precautions

WARNING: When using tool, basic safety precautions should always be followed to
reduce the risk of personal injury and damage to equipment.

Read all instructions before using this tool!

1. Keep work area clean. Cluttered areas invite injuries.

2. Observe work area conditions. Do not use machines or equipment in damp or wet
locations. Don’t expose to rain. Keep work area well lit. Do not use electrically
powered compressors in the presence of flammable gases or liquids.

3. Keep children aw ay. Children must never be allo w ed in the work area. Do not let
them handle machines, tools, extension cords, or air hoses.

4. Store idle equipment. When not in use, tools must be stored in a dry location to
inhibit rust. Always lock up tools and keep out of reach of children.

5. Use the right tool for the job. Do not attempt to force a small tool or attachment to
do the work of a larger industrial tool. There are certain applications for which this tool
was designed. It will do the job better and more safely at the rate for which it was
intended. Do not modify this tool and do not use this tool for a purpose for which it
was not intended.

6. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear
are recommended when working. Wear restrictiv e hair covering to contain long hair.

7. Use eye protection. Always wear ANSI approved impact safety goggles. Wear
heavy work gloves.

Page 2SKU 92840 For technical questions, please call 1-800-444-3353

8. Do not overreach. Keep proper footing and balance at all times . Do not reach over or
across Jack or Jack Stands under a load.

9. Maintain tools with care. K eep tools clean f or better and saf er perf ormance. Follo w
instructions for lubricating and changing accessories. Inspect tool cords and air hoses
periodically and, if damaged, have them repaired by an authorized technician. The
handle must be kept clean, dry, and free from oil and grease at all times.

10. Disconnect air supply. Disconnect air hose when not in use.

11. Avoid unintentional starting. Be sure the controls are in the neutral position when
not in use and before plugging in. Do not move any tool while touching the controls,
whether it is connected to the air or not.

12. Stay alert. Watch what you are doing, use common sense . Do not operate any tool
when you are tired.

13. Check for damaged parts. Bef ore using an y tool, an y part that appears damaged
should be carefully checked to determine that it will operate properly and perform its
intended function. Check for alignment and binding of moving parts; any broken parts
or mounting fixtures; and any other condition that may affect proper operation. Any
part that is damaged should be properly repaired or replaced by a qualified technician.
Do not use the tool if the controls do not operate properly.

14. Guard against electric shock. Prevent body contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerator enclosures.

15. Replacement parts and accessories. When servicing, use only identical
replacement parts. Use of any other parts will void the warranty. Only use accessories
intended for use with this tool. Approved accessories are available from Harbor Freight
Tools.

16. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels if taking prescription medicine to determine if your judgement or reflexes are
impaired while taking drugs. If there is any doubt, do not operate the tool.

17. Use proper size and type extension cord. If an extension cord is required for the air
compressor, it must be of the proper size and type to supply the correct current to the
compressor without heating up. Otherwise, the extension cord could melt and catch
fire, or cause electrical damage to the compressor. Check your air compressor’s
manual for the appropriate size cord.

18. Maintenance. For your safety, maintenance should be performed regularly by a
qualified technician.

19. Compressed air only. Nev er use comb ustible gas as a power source.

Note: Performance of the compressor (if powered by line voltage) may vary depending on
variations in local line voltage. Extension cord usage may also affect tool performance.

Warning: The warnings, cautions, 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.

Page 3SKU 92840 For technical questions, please call 1-800-444-3353

Specific Jack Safety Instructions

Warning!! Stand clear of the Jack when raising or low ering a v ehicle.

1. Jack Capacity. Never exceed the Jack’s capacity of 25 Tons (Stage 2) or 50 Tons
(Stage 1). Check the vehicle’s owner’s manual to determine the actual gross weight of
your vehicle before attempting to lift it. Never attempt to lift a load greater than 25 Tons
above the Stage 1 level.

2. Never ride on the Jack. Never ride on the Jack, and never have people or pets in the
vehicle you are raising.

3. Only use Jack to raise/lower vehic le. After raising the vehicle, use jack stands to k eep
the vehicle suspended for any period of time. Do not work on, around, or under the
vehicle while it is supported by the Jack.

4. Place Jack on correct surface. Only use this Jack on a stable, smooth, level,

clean, and dry surface that is capable of sustaining the load (ie. thick cured concrete
or thick steel). This Jack has exposed hoses in its undercarriage.

5. Stabilize the load. Ensure that the load remains stable at all times.

6. Vehicle lifting. When lifting a vehicle, apply the emergency brake and block all of the
wheels that will remain on the ground.

7. Center load. Center the load on the Jack Ram (2). Off-center loads can damage seals ,
causing Jack failure.

8. Lift only using correct vehicle lift points. Read the v ehicle manual to find the proper
lifting points for the vehicle.

9. Never use the Jack unless it is filled with hydraulic fluid. Filling with hydr aulic fluid
is covered in the maintenance section of this manual.

10. NEVER USE THIS JACK FOR AIRCRAFT PURPOSES.

11. Industrial applications must follow OSHA requirements.

12. Never move jack when under load. The wheels are intended for NO LO AD movement

only.

Unpacking

When unpacking, check to make sure that the product is intact and undamaged. If any parts
are missing or broken, please call Harbor Freight Tools at the number on the cover of this
manual as soon as possible.

Assembly

Before use, the Shipping Plug (99) must be remo ved and replaced with the Oil Plug (26).

The Oil Plug (26) is hanging from the Shipping Plug. Changing these plugs must be done
prior to running the unit. See FIGURE 4 under Maintenance, on page 7. Sav e the Shipping
Plug (99) for any further transport.

Page 4SKU 92840 For technical questions, please call 1-800-444-3353

Air Connection

Two Stage
Jack

For best service you should incorporate an oiler, regulator, and inline filter, as shown in the
diagram above. Hoses, couplers, oilers, regulators, and filters are all available at Harbor
Freight Tools.

1. You will need to prepare a 1/4” air connector (not included) to connect to the Air Inlet

(29) on the Handle (40) of the Jack. First, wrap the 1/4” air connector with pipe thread
seal tape before threading it into the Air Inlet (29). Connect the 3/8” ID air source hose
to a quick connect coupler, and then to the Impact Wrench. See FIGURE 1 .

Note: If y ou are not using an automatic oiler system, before operation, add a fe w drops
of Pneumatic Tool Oil to the airline connection. Add a few drops more after each hour
of continual use.

2. Set the air pressure on the regulator to 150-200 PSI. Do not exceed the recom-

mended air pressure of 200 PSI.

3. Check the air connection for leaks. Disconnect from the air source.

FIGURE 1

Lever (27)

Air Inlet (29)

Controls
Explanation

Handle Position Lever

Handle (40)

Page 5SKU 92840 For technical questions, please call 1-800-444-3353

Operation

Raising the V ehicle
Note: This Two Stage Ja ck comes with tw o Adapters (1). The two Adapters (1) are stored by

the wheels of the Jack (see FIGURES 2 and 3).

FIGURE 2

Both Adapter (1) extensions on.

Note: The Handle is adjustable. You can position it into any of the slots sho wn in FIGURE 3

below by pulling the Handle P osition Le ver , and moving the Handle until the le ver drops
into place (see FIGURE 1 on page 5).

FIGURE 3

Adapter (1)

Adapter (1)

Warning! The Jack and vehicle being lifted must be stable when lifted so they do not

fall and cause personal injury. Keep spectators a way from the work area. Read
the vehicle manual to find the proper lifting points for the vehicle.

1. Position the Jack under the vehicle to be lifted is at one of the recommended lifting

points. Connect to the air source and turn on the compressor. Turn the Lever (27) to
the right toward the UP arrow on the Controls (see FIGURE 1 on page 5). Lift the load
slightly and check that the load is stable on the jack. If not, lower the load and check
that the vehicle has no load on it and that the jack is in the proper position. Allow the
Jack to rise to the desired level, and then move the Lever (27) into the neutral position
between the UP and DOWN positions (shown in FIGURE 1).

2. Place jack stands (not included) under the vehicle before attempting to do any

work on, in, under, or around the vehicle.

Page 6SKU 92840 For technical questions, please call 1-800-444-3353

Operation (continued)

Lowering the Vehicle

1. First, clear any tools or equipment from under the vehicle. Make sure there are no

obstructions and that people are at a safe distance from the vehicle.

Note: Position yourself safely so that your body is not under any part of the
vehicle before lowering the Jack or removing the jack stands.

2. Position the Jack so that the Ram (2) is at one of the recommended lifting points.

Turn the Lever (27) to the right toward the UP arrow on the Controls (see FIGURE 1 on
page 5). Raise the Jack just enough so that you can remove the jack stands. Then,
turn back the Lever (27) to the neutral position and remove the jack stands.

3. Lower the load slowly in a controlled fashion: Turn the Lever (27) slightly to the left

toward the DO WN arrow on the Controls (see FIGURE 1 on page 5), and allow the load
to lower

4. Remove the Jack from under the vehicle. Disconnect the air supply.

slowly.

Maintenance

1. Keep the Jack clean and dry. When not in use, store in a dry location to inhibit rust.

Always lock up equipment and keep out of reach of children.

2. Have a qualified service technician periodically dismantle and lubricate the handle

assembly and all lift arm linkages.

3 . Before each use, check the oil le vel through the oil plug hole shown in FIGURE 4 below .

Make sure it is full bef ore each use . Fill oil if necessary by removing the Oil Plug (26).
Watch for hydraulic oil leaks. If leaks are present, contact a qualified service techni­cian. Have a qualified service technician change the oil and lubricate the Jack annu­ally.

FIGURE 4

Replace Shipping Plug (99)

with Oil Plug (26)

Page 7SKU 92840 For technical questions, please call 1-800-444-3353

Parts List

Part No. Description Qty. Part No. Description Qty. Part No. Description Qty.
1 Adapter 2 35 Rod 1 69 Washer 5
2 Ram 1 36 Pin 1 70 Screw 5
3 Dust Ring 1 37 0-ring 3 71 Spring 1
4 0-ring 1 38 Bolt 2 72 Spring 1
5 Piston Rod 1 39 Spring Washer 4 73 Spring 1
6 0-ring 1 40 Handle 1 74 0-ring 1
7 y-ring 1 41 Bolt 2 75 Union 1
8 Bushing 1 42 Union 1 76 Box 1
9 Sp. Washer 1 43 Ring 4 77 Spg. Washer 4
10 Plate 1 44 Tube 2 78 Bolt 4
1 1 0-ring 1 45 Union 1 79 Bolt 1
12 Ring 1 46 Screw 1 80 Spg. Washer 1
13 0-ring 1 47 Bolt 4 81 Valve Base 1
14 y-ring 1 48 Switch Case 1 82 0-ring 2
15 Ring 1 49 0-ring 2 83 Bushing 1
16 0-ring 1 50 Union 1 84 Ring 1
17 Bushing 1 51 Tube 1 85 y-ring 1
18 Union 1 52 Air Pipe Assy. 1 86 Bolt 1
19 Hand Ring 1 53 Union 1 87 Piston Rod 1
20 Ring 2 54 Tube 1 88 Plate 1
21 Screw 2 55 Union 2 89 Big Piston 1
22 Wheel 2 56 Oil Box 1 90 Pro. Ring 1
23 Sp. Washer 2 57 Bolt 4 91 0-ring 1
24 Rod 1 58 Sp. Washer 2 92 Pump Body 1
25 Sp. Washer 2 59 Union 1 93 Bushing 1
26 Oil Plug 1 60 0-ring 5 94 Seal Washer 1
27 Lever 1 61 Cover 1 95 Small Piston 1
28 Ring 1 62 Spring 1 96 Cover 1
29 Air Inlet 1 63 Rel. Rod 1 97 Ball 1
30 Sp. Base 1 64 Spring 4 98 Cyl. Base 1
31 Valve Block 1 65 Bearing 5 99 Ship. Plug 1
32 0-ring 1 66 Sp. Seat 1 100 0-ring 1
33 Valve Body 1 67 Spring 1
34 Union 2 68 Screw 1

PLEASE READ THE FOLLO WING CAREFULLY

THE MANUF ACTURER AND/OR DISTRIBUT OR HAS PRO VIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBU­TOR MAKES ANY REPRESENTA TION OR WARRANTY OF ANY KIND T O 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 ST ATES THAT ALL REP AIRS AND P AR TS REPLACEMENTS
SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NO T BY THE
BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER
REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PAR TS THERET O , OR ARISING
OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERET O.

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

Page 8SKU 92840 For technical questions, please call 1-800-444-3353

Assembly Drawing

Page 9SKU 92840 For technical questions, please call 1-800-444-3353