Harbor Freight Tools 4 ton Heavy Duty Portable Hydraulic Equipment Kit Product manual
Contents
1. 44899 Parts List and Assembly Diagram A Spreader 10 Part Description Part Description Items 44899 44900 For technical questions please call 1 800 444 3353 Page 13 44899 Parts List and Assembly Diagram B Ram 2 18B 6B Cylinder 9B ProtectorCap t CCC URC 19B Page 14 For technical questions please call 1 800 444 3353 Items 44899 44900 44899 Parts List and Assembly Diagram C Pump Part Description Part Description _ 17C_ Spring 32C Part Description _ i gies E D 13C i se 2 34C e O 36C C Items 44899 44900 For technical questions please call 1 800 444 3353 Page 15 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 li2. Hydraulic Fluid Keep the surface of this tool and its accessories free of hydraulic fluid and grease Use only a mild detergent and damp cloth when cleaning Do not use a flammable or combustible solvent to clean this tool or its accessories 2 Before each use examine the general condition of the tool and its accessories Check for loose components misalignment binding of moving parts broken parts and any other condition that may affect its safe operation Do not use a damaged tool or its damaged accessories Keep hydraulic connections clean Clean all hydraulic ports and replace Dust Covers immediately after use Store the Pump with the Release Valve open If the Pump operation feels spongy or the Ram lowers while the Release Valve is closed there may be air in the Pump Bleed the Pump as follows I 2 Set Pump flat on a level surface Remove the Fill Screw The Seal Ring should come off with it The fluid level should be near the bottom of the opening If required add high grade hydraulic fluid Make sure the Seal Ring is still in place around the Fill Screw and thread the Fill Screw into the Pump securely Do not use thread seal tape Firmly close the Release Valve by turning it clockwise Changing Hydraulic Fluid 1 2 Items 44899 44900 Change the hydraulic fluid yearly Remove the Fill Screw and tilt the Pump to drain out the old fluid 6 For technical questions please ca
3. Ram completely and align the Flange Head to it Cap Head install Male Rubber Head Extensions Connector or Wedge Head here as needed Spreader Setup The Spreader is used when the Ram 3 Attach the Hose to the is too long to fit between the stationary Spreader as shown below side and the damaged area Hose 1 Clean the end of the Hose and the inlet on the Spreader 2 Unscrew and save the End Plugs located on the end Spreader of the Hose and Spreader Pump Items 44899 44900 For technical questions please call 1 800 444 3353 Page 5 Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before use of this product 1 Check the Hydraulic Fluid level following the instructions in the Cleaning and Maintenance section 2 Determine which direction the frame needs to be bent 3 Remove any obstructions that could be damaged or are in the way Note When using the Pump in a vertical position keep the Hose end of the Pump downward 4A USING RAM a Connect the appropriate Base to c Position the Ram so that the Base the stationary side of the Ram is resting against a frame member and connect the appropriate head opposite the damaged area It must to the pushing end of the Ram also be in line with the direction in Note When repairing larger body which the damaged area needs to panel dents such as a dented door be pushed The vehicle body part fender
4. or quarter panel use the must be stronger than the area Rubber Head on the pushing end to be bent or it may be damaged b If using the Flange Base or A block of wood or a towel may be used to protect the body part Flange Head Thread the Flange Base onto the d Aim the pushing end towards the Ram completely and align the area that needs to be repaired and Flange Head to it The Flange Base slowly apply pressure with the Pump and Flange Head must only be used Note To prevent damage together to prevent off center load do not overextend the Ram 4B USING SPREADER a Place the Spreader so that the b Carefully hold the Spreader in hinged pushing arm is resting position and apply pressure against the part to be moved with the Pump and the stationary arm is resting against a non movable base 5 Once both ends have made contact move as far away as possible and continue to slowly apply pressure to the damaged area until the desired bend has been made CAUTION Keep hands away from contact areas and tight spaces The tool may slip and cause injury 6 When the damaged area has been bent to the desired position slowly turn the Release Valve counterclockwise to release the hydraulic pressure and remove the Ram or Spreader 7 Clean all hydraulic ports and cover them with clean End Plugs Page 6 For technical questions please call 1 800 444 3353 Items 44899 44900 Cleaning and Maintenance ie Filling and Bleeding
5. questions please call 1 800 444 3353 Items 44899 44900 44900 Parts List and Assembly Diagram A Ram 5 Part Description _ 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 Items 44899 44900 For technical questions please call 1 800 444 3353 Page 9 44900 Parts List and Assembly Diagram B Spreader 14 Part Part Description 8B _ Piston C clip 10B__ Pivoting Pin 11B__ Pushing Arm 12B__ Spring 6B Washer 13B__ Stationary Arm Page 10 For technical questions please call 1 800 444 3353 Items 44899 44900 44900 Parts List and Assembly Diagram C Pump 2C 16C 3C 4C 5C Spri 19C C 22C 2C 13 27C 14 28C 13C T 38C 2 10C 34C O 36C H Items 44899 44900 For technical questions please call 1 800 444 3353 Page 11 44899 Parts Lists and Diagrams 44899 Main Parts List and Assembly Diagram Part Description Qty Part Description _ _ Qty C2 ae eae 2 3 4 Rubber Head 3 Hoss _ 1 4 19 1 2 Extension 1 16 1 2 Extension 6 8 1 2 Extension 8 3 1 4 Extension 1 9 CapHead t A NSA aae PENY Wy Ow wy cv NY Nii ra yi AN i Page 12 For technical questions please call 1 800 444 3353 Items 44899 44900
6. Owner s Manual amp 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 PI TTSB UR GH Rna ITEMS 44899 44900 Hydraulic Equipment Kit Item 44900 10 Ton kit shown Visit our website at http www harborfreight com REV 13c Email our technical support at tech harborfreight com When unpacking make sure that the product is intact and undamaged If any parts are missing or broken AWARNING please call 1 800 444 3353 as soon as possible Copyright 2001 by Harbor Freight Tools All rights reserved 3 No portion of this manual or any artwork contained herein may be reproduced in Read this material before using this product any shape or form without the express written consent of Harbor Freight Tools Failure to do so can result in serious injury Diagrams within this manual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included PITTSBURGH WARNING SYMBOLS AND DEFINITIONS This is the safety alert symbol It is used to alert you to potentia
7. ect a a e ps rO DAMNE the female end of the Ram to a Base AAE EENE Sees 3 The Flat Base is used on the stationary The Te m gt ae Pig side to spread out the force of the Ram Se E eee in angles and tight spaces 4 The 90 V Base is used to offset the force of the Ram when there is not a straight line between the stationary side and the damaged side or The Flange Base and Flange Head are used together to allow spreading in areas that the Ram cannot fit into to spread out force on curved surfaces Note The Flange Base and Flange Head must only be used Th p Head i th 5 e Cap Head is used on the together to prevent an off center load pushing end to prevent slipping Page 4 For technical questions please call 1 800 444 3353 Items 44899 44900 Ram Setup Note When positioning the Ram use a smaller attachment on the side that is to be bent instead of the stationary side If the stationary side is in danger of being bent or damaged place a block of wood or other material behind the Flat Base to distribute pressure over a greater area 1 Clean the end of the Hose and the Flange Flange inlet on the Ram Unscrew and Head Base save the End Plugs located on the end of the Hose and Ram 2 Attach the Hose to the Ram Assemble attachments as shown below Ram 90 V Base or install Flat Base Extensions here Ram as needed hee Note If using the Flange Base and AME Flange Head thread the Flange Base onto the
8. l 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 A DANGER will result in death or serious injury Indicates a hazardous situation which if not avoided AWARNING could result in death or serious injury Indicates a hazardous situation which if not avoided ACAUTION could result in minor or moderate injury NOTICE CAUTION Addresses practices not related to personal injury IMPORTANT SAFETY INFORMATION AWARNING Read all safety warnings and instructions Failure to follow the warnings and instructions may result in serious injury Save all warnings and instructions for future reference The warnings and precautions discussed in this 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 Work area 1 Turn off the engine 3 Keep bystanders and children away set the parking brake and block the while operating the tool Distractions tires before working on a vehicle can result in loss of control of the tool 2 Keep the work area clean and well lighted Cluttered benches and dark areas increase the risk of injury to persons Page 2 For technical questions please call 1 800 444 3353 Items 44899 44900 Personal safety 1 Stay ale
9. ll 1 800 444 3353 Press the tip of the Coupler against a hard surface and pump the pump handle Continue pumping until the hydraulic fluid coming out the end of the Coupler tip is free of air bubbles Recheck the fluid level and add fluid if necessary Turn the Release Valve counterclockwise to release the pressure in the Pump and Hose Refill the hydraulic fluid and bleed the system several times to ensure all air is out of the system Page 7 PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS DOCUMENT 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 44900 Parts Lists and Diagrams 44900 Main Parts List and Assembly Diagram Part Description Qty Part Description _ Qty Flange Base 1 10 Wedge Head 1 10 7 14 13 Page 8 For technical
10. mitation 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 PITTSBURGH 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353
11. oves during use Avoid off center loads If the Pump seems unusually hard to operate immediately stop Adjust the Ram to eliminate or diminish an off center load The Flange Base and Flange Head must only be used together to prevent an off center load Protect the Hose Do not drop heavy objects on the Hose Avoid kinks in the Hose Maintain proper clearance to avoid damage to the Hose and Couplers Inspect repair before using vehicle Repairs to structural or frame members must be inspected by a qualified technician to ensure that the structure is still strong enough to safely fulfill its function When servicing a tool use only identical replacement parts Use only authorized parts A SAVE THESE INSTRUCTIONS Items 44899 44900 For technical questions please call 1 800 444 3353 Page 3 Specifications Ram Capaci 4 Tons 10 Tons pacity 2 Tons w extensions 5 Tons w extensions C E 4 51 2 Maximum Y Ton 3 34 Maximum Opening 5 Maximum 2 Ton 3 34 Maximum Opening Extension Pole Length Spreader Capacity Hose Hose Length Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this document including all text under subheadings therein before set up or use of this product Ram Attachments 1 The Extensions connect in different The Rubber Head is used for popping combinations to reach desired lengths dents out of sheet metal such as 2 The Male Connector is used to conn
12. rt Watch what you are doing and use common sense when operating the tool Do not use the tool while tired or under the influence of drugs alcohol or medication A moment of inattention while operating the tool increases the risk of injury to persons Tool use and care 1 Do not force the tool Use the correct tool for the application The correct tool will do the job better and safer at the rate for which the tool is designed 2 Store the tool when it is idle out of reach of children and other untrained persons A tool is dangerous in the hands of untrained users 3 Check for misalignment or binding of moving parts breakage of parts and any other condition that affects the tool s operation If damaged have the tool serviced before using Many accidents are caused by poorly maintained tools 4 Use only accessories that are identified by the manufacturer for the specific tool model Use of an accessory not intended for use with the specific tool model increases the risk of injury to persons Service 1 Tool service must be performed only by qualified repair personnel Dress properly Do not wear loose clothing or jewelry Contain long hair Keep hair clothing and gloves away from moving parts Loose clothes jewelry or long hair increases the risk of injury to persons as a result of being caught in moving parts Use safety equipment Wear ANSI approved safety goggles and heavy duty work gl
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