LONG FRAME
ALUMINUM JACK
3000 LBS.
40105
ASSEMBLY AND OPERATING INSTRUCTIONS
Read this material before using this product.
Failure to do so can result in serious injury.
SAVE ThIS MANUAL.
Copyright© 2002 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. Diagrams within this manual may not be drawn proportionally. Due to continuing improvements, actual
product may differ slightly from the product described herein. Tools required for assembly and service may not
be included.
For technical questions or replacement parts, please call 1-800-444-3353.
Revised Manual 09j
instructions for lubricating and changing accessories. Inspect tool periodically, and
if damaged, have it repaired by an authorized technician. The handle must be kept
clean, dry, and free from oil and grease at all times.
10. Stay alert. Watch what you are doing, use common sense. Do not operate any tool
when you are tired.
11. Check for damaged parts. Before using any tool, any 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 handle and pedal do not operate properly.
12. Guard against electric shock. Prevent body contact with grounded surfaces such as
pipes, radiators, ranges, and refrigerator enclosures.
13. 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.
14. Do not operate tool if under the influence of alcohol or drugs. Read warning
labels on prescriptions to determine if your judgment or reflexes are impaired while
taking drugs. If there is any doubt, do not operate the tool.
15. Maintenance. For your safety, maintenance should be performed regularly by a
qualified technician.
16. Jack Capacity. Never exceed the Jack’s capacity of 3000 Lbs. Check the vehicle’s
owner’s manual to determine the actual gross weight of your vehicle before attempting
to lift it.
17. Never ride on the Jack. Never ride on the Jack, and never have people or pets in the
vehicle you are raising.
18. Only use Jack to raise vehicle. After raising the vehicle, use jack stands to keep the
vehicle suspended for periods of time. Do not work on the vehicle while it is up on the
Jack. The Jack is designed for lifting the vehicle only.
19. Do not move the vehicle while it is on the Jack.
20. Do not make any alterations or modifications to this Jack.
Warning!! Stand clear of the Jack when raising or lowering a vehicle.
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.
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SKU 40105
Unpacking
When unpacking, check to make sure the parts listed on pages 7 and 8 are included. 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
1. Slide the Upper Handle (#23) into Lower Handle (#20). As you slide it on, depress the
Lock Button (#22) and allow the hole in the bottom of the Upper Handle (#23) to line up
with the Lock Button (#22). The Lock Button (#22) should snap out securely holding the
Upper Handle (#23).
2. Unscrew the holding screw on the Handle Base (#17) and slide the entire handle assembly
into the Handle Base (#17). Tighten the screw to hold the handle in place.
3. Bleed Air. See page 5 for bleeding instructions.
Operation
Warning!! Only operate this Jack on a level, flat, hard surface capable of supporting the
weight of the Jack, the vehicle, and the tools. Use of an uneven or weak surface can cause
damage to the floor, or cause the vehicle to become unstable and potentially fall, causing
serious damage or injury.
Warning!! Consult the vehicle’s manual for the advised lift points. Only use the advised lift
points when using this Jack. Lifting in other areas can cause damage to the vehicle and cause
an unplanned, sudden lowering of the vehicle.
Warning!! Whenever the vehicle is to remain elevated more than momentarily, install
appropriate Jack Stands (not included) under the vehicle. Never work under the vehicle un-
less jack stands have been positioned.
Warning!! Before lifting or lowering a vehicle with the Jack, put a block below each Jack
wheel to stop it from moving.
Warning!! Never exceed the Jack’s maximum capacity of 3000 Lbs.
Warning!! When raising or lowering vehicle make sure no people are immediate area.
Raising the vehicle.
1. Position the Jack so that the Saddle Pad (#43) is at one of the recommended lifting points.
Turn the Upper Handle (#23) clockwise to lock the release valve. Pump the Upper Handle
(#23) until the Saddle Pad (#43) fully engages the lifting point, then continue to pump the Jack
to the needed height. If the Jack does not reach its full height or more than eight pumps are
needed, the Jack will require bleeding or refilling.
2. Use jack stands (not included) to secure the vehicle. Use your vehicle’s owner’s manual
to determine the specified points to safely position jack stands.
3. Once the vehicle is safely positioned over the jack stands, slowly turn the Upper
Handle (#23) counterclockwise to open the release valve to lower the vehicle onto the jack
stands.
4. To determine if the vehicle is safely up on jack stands, stand away and attempt to gently
rock the vehicle. If it sways and seems unstable, repeat the procedure and reposition the jack
stands. Test again.
5. Completely lower the Jack and remove it from under the vehicle.
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SKU 40105
Operation (continued)
Lowering Vehicles.
1. First, clear any tools or equipment from under the vehicle. Make sure there are no
obstructions.
2. Position the Jack so that the Saddle Pad (#43) is at one of the recommended lifting points.
Turn the Upper Handle (#23) clockwise to lock the release valve. Pump the Upper Handle
(#23) until the Saddle Pad (#43) fully engages the lifting point, then continue to pump the
Jack above the jack stands.
3. Remove the jack stands.
4. Slowly turn the Upper Handle (#23) counterclockwise to open the release valve, and gently
to lower the vehicle.
5. Pull the Jack clear of the vehicle and store in a safe place.
Bleeding And Refilling
To Bleed/Purge excessive air from system:
1. Place Jack on flat, level and solid surface.
2. Turn the Breathing Screw (14A) fully counterclockwise. (See Figure 1, below)
3. Turn the Handle (20) to a position where the Discharge Valve is closed enough for the
Saddle (41) to rise when you pump with no pressure on the Saddle, but open enough so
that the Saddle does not rise when you pump with one hand while applying pressure to the
Saddle with your other hand. (If the Saddle is up, turn the Handle slowly counterclockwise
until the Saddle begins to go down slowly. If the Saddle is down, while pumping quickly, turn
the Handle slowly clockwise until the Saddle begins to rise.)
4. While holding down the Saddle with one hand, rapidly pump the Handle with the other
hand, so that air comes out from between the Breathing Screw and the Oil Plug (13A). Con-
tinue pumping until air stops coming out and you see oil appearing between the Breathing
Screw and the Oil Plug.
5. Tighten the Breathing Screw by turning it clockwise as far as it will go. Then turn it 360°
counterclockwise.
To Refill Hydraulic fluid (if unable to bleed/purge or Saddle stops part way):
1. Use wrench (not included) to unscrew Oil Plug.
2. Pour high-quality hydraulic oil into hole and replace Oil Plug. Tighten with wrench.
3. Follow the Bleed/Purge Instructions above.
Oil Plug
(13A)
Breathing
Screw
(14A)
Seal
Bolt
(6A)
FIGURE 1
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SKU 40105
General Maintenance
If Saddle does not lower and the valve is open, there is too much Hydraulic fluid:
1. Unscrew Oil Plug.
2. Push Saddle and Handle down at the same time.
3. Wipe off any oil that spills.
4. Replace Oil Plug and tighten with Wrench.
If more than eight strokes of Handle is needed to raise Saddle, there may be air in the
system. In that case, follow the Bleed/Purge Instructions, making sure to use full strokes.
If the Saddle does not go up at all during full strokes and valve is closed, there may be
excessive air or insufficient hydraulic fluid in the system:
1. Place Jack on a flat, level surface and turn Handle clockwise as far as it goes.
2. Turn Breathing Screw clockwise fully.
3. Turn Handle clockwise fully.
4. Repeatedly pump Handle. Continue as long as air comes out or until Saddle begins to rise.
Once Saddle begins to rise, stop pumping and follow Bleed/Purge Instructions. If Saddle
does not begin to rise and air does not seem to be purging or bleeding, follow Refilling In-
structions.
If Handle will not go down:
1. Make sure load is not exceeding 3,000 lb. capacity.
2. Make sure Saddle is not already at maximum height. If it is, lower and reposition under
different part of vehicle.
3. If Jack functions properly and you are unable to push down and apply the required 150 lbs.
of force needed to operate Jack, seek the help of another person for assistance.
Other Maintenance Tips
1. Keep the Jack clean and dry.
2. Periodically lubricate the caster wheels with high quality grease.
3. Periodically dismantle and lubricate the Handle assembly and all lift arm linkages.
4. Watch for hydraulic oil leaks. Fill oil if necessary. If leaks persist, contact an
authorized service technician.
5. If the Jack does not lift to satisfaction, take it to an authorized service technician.
PLEASE READ THE FOLLOWING CAREFULLY
THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDEDTHE PARTS DIAGRAM INTHIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBU-
TOR 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 STATESTHAT 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.
NOTE: Some parts are listed and shown for illustration purposes only and are not available
individually as replacement parts.
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SKU 40105
Parts List and Assembly Diagram
Part
Description
Q’ty
Part
Description
Q’ty
1
1
1
2
1A Aluminum Base
2A Safety Valve
3A Relief Valve Spring
4A Regulator Bolt
5A Seal Washer
6A Seal Bolt
1
1
1
1
1
1
30A O-Ring
31A Hydraulic Cylinder
32A Snap Ring
33A O-Ring
34A Rear Seal
35A Bushing
1
1
7A Steel Ball
1
36A O-Ring
2
8A Separator
1
37A Ram
1
9A Steel Ball
1
1
1
1
1
1
1
1
38A Aluminum Bar
39A Block Linkage
40A Spring Pin
41A Snap Ring 12
42A Piston Cover
43A Press Spring
44A Pump Case
45A Pump Core
46A Back-Seal
47A O-Ring
1
1
1
1
1
1
1
1
10A High Pressure Spring
11A High Pressure Bolt
12A O-Ring
13A Oil Plug
14A Breathing Screw
15A Steel Ball
16A O-Ring
17A Discharge Valve Rod
26A Bolt
1
1
2
2
27A Oil Strainer
28A O-Ring
2
2
48A Washer
49A Steel Ball
1
1
29A Oil Cover
2
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SKU 40105
Parts List
ITEM
NO.
DESCRIPTION
Screw M10x25
QTY ITEM
NO.
DESCRIPTION
Handle Upper
QTY
1
2
3
4
5
6
7
8
9
2
2
2
2
4
2
2
8
2
2
2
2
2
2
6
2
1
2
1
1
1
1
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
1
1
1
2
2
4
1
2
2
2
2
2
1
4
1
1
1
1
1
1
1
1
Eye Bolt M8x14
Link Rod Axis
Power Unit Assy
Raise Arms Axis
Pull Rod Axis
Pull Rod
Screw M8x25
Inner Tighten Washer 8
Washer 8
Inner Angular Set Screw
Front Caster Wheel
Frame
Screw Bushing
Inner Tighten Washer 10
Rear Wheel Set
Handle Bar
10 Rear Wheel Saddle
11 Screw M10x25
“C”-Ring S16
Link Rod
12 Linkage Washer
13 Nut M12
Link Rod Washer
Saddle Base Axis (Long)
“C”-Ring S20
Saddle Base Axis (Short)
Lift Arm
14 Washer 10
15 Case
16 Axis
17 Handle Base
18 Handle Base Axis
19 Spring
Saddle Base
Nylon Washer
Saddle
20 Handle Lower
21 Eye Bolt M8x35
22 Hex Bolt M6x18 Lock Button
Holder Axis
Rubber Saddle Pad
Nut M8
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SKU 40105
Assembly Diagram
Page 9
SKU 40105
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 OTH-
ER WARRANTIES, ExPRESS OR IMPLIED, INCLUDINg THE WARRANTIES OF MER-
CHANTABILITY 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 prod-
ucts 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
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