Harbor Freight 2 Ton Aluminum Racing Floor Jack With Rapidpump Product Manual

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2015-05-27

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Owner’s Manual & Safety Instructions
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.

Item 61406 shown.
Item

62457

61406

61386

Weight Capacity

2 Tons (4,000 lb.)

3 Tons (6,000 lb.)

Maximum Height

16-3/8"

18-1/2"

19-1/4"

Minimum Height

3-3/8"

3-1/4"

3-3/4"

Meets 2005 ANSI/ASME PALD standards.

REV 14h

Visit our website at: http://www.harborfreight.com
Email our technical support at: productsupport@harborfreight.com

When unpacking, make sure that the product is intact
and undamaged. If any parts are missing or broken,
please call 1-888-866-5797 as soon as possible.
Copyright© 2013 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.

Read this material before using this product.
Failure to do so can result in serious injury.
SAVE THIS MANUAL.

WARNING SYMBOLS AND DEFINITIONS
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.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.

Addresses practices not related to personal injury.

IMPORTANT SAFETY INFORMATION
Floor Jack Safety Warnings
1. Study, understand, and follow all instructions
before operating this device.

16. Inspect before every use; do not use
if parts are loose or damaged.

2. Do not exceed rated capacity.

17. Do not use for aircraft purposes.

3. Use only on hard, level surfaces.

18. 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.

4. Lifting device only. Immediately after lifting,
support the vehicle with appropriate means.
5. Do not move or dolly the vehicle while on the jack.
6. Failure to heed these markings may result in
personal injury and/or property damage.
7. Lift only areas of the vehicle as specified
by the vehicle manufacturer.
8. No alterations shall be made to this product.
9. Never work on, under or around a load
supported only by this device.

19. WARNING: The brass components of this product
contain lead, a chemical known to the State
of California to cause cancer and birth defects
or other reproductive harm. (California Health
& Safety Code § 25249.5, et seq.)

11. Wear ANSI-approved safety goggles and
heavy-duty work gloves during use.

20. WARNING: This product contains di (2-ethylhexyl)
phthalate (DEHP), a chemical known to the State
of California to cause cancer and birth defects
or other reproductive harm. (California Health
& Safety Code § 25249.5, et seq.)

12. Keep clear of load while lifting and lowering.

IMPORTANT! Before first use:

13. Lower load slowly.

Check hydraulic oil level and fill to 1/4″ below
the fill port as needed as stated on page 3.
Thoroughly test the Jack for proper operation.
If it does not work properly, bleed air from its
hydraulic system as stated on page 3.

10. Do not adjust safety valve.

14. Apply parking brake and chock
tires before lifting vehicle.
15. Lift vehicle only at manufacturer
recommended locations.

SAVE THESE INSTRUCTIONS.

Page 2

For technical questions, please call 1-888-866-5797.

Item 61386 61406 62457

Setup - Before Use:
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 Parts Lists and Assembly Diagrams on page 6.

Attaching the Handle
CAUTION! The Handle may contain a spring under tension. Wear ANSI‑approved safety goggles
before loosening or removing Handle. Remove Handle carefully.
1. Fasten the Upper Handle to the Lower Handle.

3. Tighten the Set Screw.

2. Loosen the Set Screw and insert the
assembled Handle into the Handle Socket.

Bleeding
1. Loosen the Fill Screw.
2. Turn the Handle counterclockwise
to open the Release Valve.

3. Pump the Handle up and down quickly several
times to purge air from the system.
4. Tighten the Fill Screw.

Adding Oil
1. Remove Fill Screw, see Figure B: Hydraulic Unit.
2. For model 61406/62457 only: Remove Screw also.
3. Add high grade hydraulic fluid into the Fill Screw
slowly until the oil reaches the top of the oil fill hole.

Note: Do not touch the Handle when
adding the hydraulic oil.
4. Replace the Fill Screw.
5. For model 61406/62457 only: Replace Screw also.

Functions
Saddle

Cover Screw for
Safety Valve.
Do not open
or adjust.

Handle
Oil Fill Screw
(Not Shown)

Lifting Arm

Screw

Handle
Socket

61406/
62457

Fill Screw

Carry Handle

61386

Rear Caster
Figure A

Item 61386 61406 62457

Safety Valve
Cover Screw.
Do not open
or adjust.

Figure B: Hydraulic Unit

For technical questions, please call 1-888-866-5797.

Page 3

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.

Lifting
Park vehicle on a flat, level, solid, surface safely away from oncoming traffic. Turn off the vehicle’s engine.
Place the vehicle’s transmission in “PARK” (if automatic) or in its lowest gear (if manual).
Set the vehicle’s emergency brake. Then, chock the wheels that are not being lifted.
1. Turn the Handle counterclockwise to lower the Jack.
Once the Jack is fully lowered, turn the
Handle firmly clockwise to close it.
2. Carefully position the Saddle of the Jack under the
vehicle manufacturer’s recommended lifting point.
(See vehicle manufacturer’s owner’s manual
for location of frame lifting point.)
3. Pump the Handle until the top of the Jack’s Saddle
has nearly reached the vehicle lifting point. Position
the Saddle directly under the vehicle’s lifting point.
4. To lift the vehicle, pump the Handle of the Jack.
Use smooth, full strokes.
5. Once the vehicle is raised, slide a jack stand of
appropriate capacity (not included) under a proper
lifting point referred to in the vehicle owner’s
manual. Always use two jack stands, position them
at the same point on each side of the vehicle.

WARNING! The rated capacity of jack stands is per
pair, not the individual capacities combined unless
specifically noted on the product by the jack stand
manufacturer. Do not exceed rated jack stand capacity.
Ensure that the vehicle support points are fully seated
in the saddle of both jack stands. Use a matched pair
of jack stands per vehicle to support one end only.
Failure to do so may result in the load suddenly falling,
which may cause personal injury and/or property damage.
6. Center the vehicle’s lifting point(s) on the saddle of
the jack stand(s). Set the jack stand(s) to the same
height according to the manufacturer’s instructions,
making sure that they lock securely into position.
7. Slowly turn the Handle counterclockwise to lower
the vehicle onto the saddle(s) of the jack stand(s).
Then, turn the Handle firmly clockwise to close it.

Lowering
1. Carefully remove all tools, parts, etc.
from under the vehicle.

4. Lower the Jack completely. Then, store in a
safe, dry location out of reach of children.

2. Position the Saddle under the lifting point.
Turn the Handle firmly clockwise and raise
load high enough to clear the jack stands,
then carefully remove jack stands.

5. To prevent accidents, turn off the tool and
disconnect its power supply after use. Clean, then
store the tool indoors out of children’s reach.

3. Slowly turn the Handle counterclockwise
(never more than 1/2 full turn) to lower
the vehicle onto the ground.

Page 4

For technical questions, please call 1-888-866-5797.

Item 61386 61406 62457

Maintenance and Servicing
Procedures not specifically explained in this manual must
be performed only by a qualified technician.

TO PREVENT SERIOUS INJURY FROM TOOL FAILURE:
Do not use damaged equipment. If abnormal noise or vibration occurs,
have the problem corrected before further use.

Cleaning, Maintenance, and Lubrication
1. Before each use, inspect the general condition of
the 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.
2. Before each use, thoroughly test the Jack
for proper operation prior to its actual use.
If the Jack appears not to be working properly,
follow Bleeding instructions on page 3.
3. Change the hydraulic oil at least
once every three years:

B. Tip the 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.
C. With the Jack upright, completely fill the
Housing with a high quality hydraulic oil (not
included) until the oil is 1/4″ below the fill hole.
D. Open the valve by turning the Handle
counterclockwise and pump the Handle
to bleed air from the system.
E. Recheck oil level and re-fill as needed.
F. Reinstall the Oil Filler Plug.

A. With the Jack fully lowered, remove the
Oil Filler Plug on the side of the Housing.

7. Wipe dry with a clean cloth. Then, store the
Jack in a safe, dry location out of reach of
children and other non-authorized people.

Troubleshooting
TO PREVENT SERIOUS INJURY:
Use caution when troubleshooting a malfunctioning jack. Stay well clear of the supported load.
Completely resolve all problems before use. If the solutions presented in the Troubleshooting guide
do not solve the problem, have a qualified technician inspect and repair the jack before use.
After the jack is repaired: Test it carefully without a load by raising and lowering it fully,
checking for proper operation, BEFORE RETURNING THE JACK TO OPERATION.

DO NOT USE A DAMAGED OR MALFUNCTIONING JACK!
POSSIBLE SYMPTOMS
Jack will
not lift at
its weight
capacity

Saddle
lowers
under
load

Check that Release Valve is fully closed.
Bleed air from the system.

Valves may be blocked and may not close fully. To flush the valves:
1. Lower the Saddle and securely close the Release Valve.
2. Manually lift the saddle several inches.
3. Open the release valve and force the saddle down as quickly as possible.

X
X

Pump
stroke
feels
spongy

Saddle
will not
lift all
the way

Handle
moves up
when jack is
under load

PROBABLE SOLUTION
Oil leaking
(Make certain that the jack is not supporting a load while attempting a solution.)
from filler
plug

X
X

Jack may be low on oil. Check the oil level and refill if needed.

Jack may require bleeding - see instructions on page Bleeding on page 3.

X
Item 61386 61406 62457

Unit may have too much hydraulic oil inside, check fluid level and adjust if needed.

For technical questions, please call 1-888-866-5797.

Page 5

Parts Lists and Assembly Diagrams

61406 Parts List and Assembly Diagram
Part
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Description

Qty

Axle
Linkage Rod
Retaining Ring
Screw
Spacer Sleeve
Front Wheel
Washer
Nut
Handle Bar
Screw
Spring Washer
Washer
Spring Washer
Screw
Rear Cast
Screw
Screw
Rear Cast Saddle
Screw
Spring Washer
Nut
Spacer Sleeve

Part

1
2
2
4
2
2
2
4
2
2
2
4
10
2
2
6
2
2
2
6
2
2

23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43

Description

Screw
Handle Socket Axle
Power Unit
Handle Socket Assembly
Handle Sleeve
Handle Upper
Handle Lower
Spring
Elastic Pin
Pull Rod
Retaining Ring
Block Linkage
Eye Bolt
Connecting Rod Pin
Rubber Sleeve
Handle Socket Rod
Shaft
Lift Arm
Limit Axle
Saddle Base Axle
Side Plate

Qty
4
2
1
1
1
1
1
2
1
2
2
1
2
2
2
1
1
1
1
1
2

27
28

33
38

34
35

39
43
41

23
36

18
17

12 13 14

4
2

16
16

9
5

Page 6

For technical questions, please call 1-888-866-5797.

Item 61386 61406 62457

61386 Parts List and Assembly Diagram
Part
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Description

Front Axle Cover
Axle
Linkage Rod
Retaining Ring
Screw
Screw
Spacer Sleeve
Front Wheel
Washer
Nut
Spring Washer
Screw
Handle Bar
Washer
Spring Washer
Screw
Spring Washer
Screw
Screw
Rear Cast
Rear Cast Saddle
Screw
Spring Washer
Nut
Handle Socket Axle
Spacer Sleeve
Retaining Ring
Power Unit
Handle Socket Assembly
Handle Sleeve

Qty
1
1
2
2
4
6
2
2
2
4
2
2
2
4
8
8
8
8
4
2
2
2
2
2
2
2
2
1
1
1

Part
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45

Description

Qty

Handle Upper
Handle Lower
Pull Rod
Elastic Pin
Block Linkage
Spring
Eye Bolt
Connecting Rod Pin
Rubber Sleeve
Handle Socket Rod
Shaft
Lift Arm
Limit Axle
Saddle Base Axle
Side Plate

1
1
2
1
1
2
2
2
2
1
1
1
1
1
2

30
32

41
42

35
27
16

14
15

22 14

15 16

10
21

17 18 19

12
10

62457 Parts List and Assembly Diagram
Part
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Description

Axle
Linkage Rod
Retaining Ring
Screw
Spacer Sleeve
Front Wheel
Washer
Nut
Handle Bar
Screw
Spring Washer
Washer
Spring Washer
Screw
Rear Cast
Spring Washer
Screw
Screw
Rear Cast Saddle
Screw
Washer
Nut
Spacer Sleeve
Screw
Handle Socket Axle
Power Unit
Handle Socket Assembly
Handle Sleeve
Handle Upper
Handle Lower

Item 61386 61406 62457

Qty
1
2
2
2
2
2
2
4
1
2
2
2
8
4
2
8
4
2
2
2
2
2
2
4
2
1
1
1
1
1

Part
31
32
33
34
35
36
37
38
39
40
41
42
43

Description

Spring
Elastic Pin
Retaining Ring
Block Linkage
Eye Bolt
Connecting Rod Pin
Rubber Sleeve
Handle Socket Rod
Shaft
Lift Arm
Limit Axle
Saddle Base Axle
Side Plate

Qty
2
1
2
1
2
2
2
1
1
1
1
1
1

26
31
32
33
38

39
43
41

13
14 21 20
16

18
12 13 14

2
1

For technical questions, please call 1-888-866-5797.

17
17

9
5

Page 7

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.

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 • 1-888-866-5797

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Harbor Freight 2 Ton Aluminum Racing Floor Jack With Rapidpump Product Manual

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