Harbor Freight Tools 10,000 PSI Pneumatic Hydraulic Pressure Pump Product manual

10,000 PSI AIR/Hydraulic
Foot Pump
Model 98318
Set up and Operating Instructions
Diagrams within this manual may not be drawn proportionally.
Due to continuing improvements, actual product may differ slightly from the product described herein.
Distributed exclusively by Harbor Freight Tools®.
3491 Mission Oaks Blvd., Camarillo, CA 93011
Visit our website at: http://www.harborfreight.com
Read this material before using this product.
Failure to do so can result in serious injury.
Save this manual.
Copyright© 2008 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 or replacement parts, please call 1-800-444-3353.
REV 11h
Save This Manual
NOTICE is used to
address practices
not related to personal injury.
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.
Safety Alert Symbol and Signal
Words
In this manual, on the labeling,
and all other information
provided with this product:
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.
DANGER indicates
a hazardous
situation which, if not
avoided, will result in death or
serious injury.
WARNING
indicates a
hazardous situation which, if
not avoided, could result in
death or serious injury.
CAUTION, without
the safety alert
symbol, is used to address
practices not related to
personal injury.
IMPORTANT SAFETY
INSTRUCTIONS
Instructions Pertaining
to a Risk of Fire,
Electric Shock, or
Injury to Persons
WARNING – When using tools, basic precautions should always be followed,
including the following:
General
a.
Work area
a.
Keep the work area clean and well
lighted. Cluttered benches and dark
areas increase the risks of electric
shock, fire, and injury to persons.
b.
Keep bystanders, children, and
visitors away while operating the
tool. Distractions are able to result in
the loss of control of the tool.
CAUTION, used
with the safety
alert symbol, indicates a
hazardous situation which, if
not avoided, could result in
minor or moderate injury.
SKU 98318
To reduce risks of electric shock,
fire, and injury to persons, read
instructions before using tool.
Personal safety
a.
Stay alert. Watch what you are doing and use common sense when
operating the tool. Do not use the
For technical questions, please call 1-800-444-3353.
Page 2
tool while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while
operating tool increases risk of injury.
b.
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 risk of injury to as result of
being caught in moving parts.
c.
Avoid unintentional starting. Be
sure the switch is off before connecting to the air supply. Do not
carry the tool with your finger on the
switch or connect the tool to the air
supply with the switch on.
d.
Do not overreach. Keep proper
footing and balance at all times.
Proper balance enables better control
of the tool in unexpected situations.
e.
Use safety equipment. A
dust mask, non-skid safety
shoes and a hard hat must
be used for the applicable
conditions. Wear heavy-duty work
gloves during use.
f.
Always wear eye protection. Wear ANSI-approved safety goggles.
g.
Always wear hearing
protection when using
the tool. Prolonged exposure to high intensity noise
is able to cause hearing loss.
Holding the work by hand or against
the body is unstable and is able to
lead to loss of control.
b.
Do not force the tool. Use correct
tool for application. The correct tool
will do the job better and safer at the
rate for which the tool is designed.
c.
Do not use the tool if the Foot Pedal (37) does not turn the tool on or
off. Any tool that cannot be controlled
is dangerous and must be repaired.
d.
Disconnect the tool from the air
source before making any adjustments, changing accessories, or
storing the tool. Such preventive
safety measures reduce the risk of
starting the tool unintentionally. Turn
off and detach the air supply, safely
discharge any residual air pressure,
and release the throttle and/or turn
the switch to its off position before
leaving the work area.
e.
Store the idle tool out of reach
of children and other untrained
persons. A tool is dangerous in the
hands of untrained users.
f.
Maintain the tool with care. Keep a
cutting tool sharp and clean. A properly maintained tool, with sharp cutting edges reduces the risk of binding
and is easier to control.
g.
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. There is a
risk of bursting if the tool is damaged.
h.
Use only accessories that are
identified by the manufacturer for
Tool use and care
a.
Use clamps or another practical
way to secure and support the
workpiece to a stable platform.
SKU 98318
For technical questions, please call 1-800-444-3353.
Page 3
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
a.
Tool service must be performed
only by qualified repair personnel.
b.
When servicing a tool, use only
identical replacement parts. Use
only authorized parts.
c.
b.
Symbol Definitions
Symbol
no
.../min
Use only the lubricants supplied
with the tool or specified by the
manufacturer.
Air source
a.
Symbols and Specific Safety Instructions
Save these
instructions.
SKU 98318
No-load speed
Revolutions or reciprocation per
minute
PSI
Pounds per square inch of pressure
ft-lb
Foot-pounds of torque
BPM
Blows per minute
CFM
Cubic Feet per Minute flow
SCFM
Cubic Feet per Minute flow at
standard conditions
NPT
National pipe thread, tapered
NPS
National pipe thread, straight
Never connect to an air
source that is capable of
exceeding 120 psi. Over
pressurizing the tool may
cause bursting, abnormal operation,
breakage of the tool or serious injury
to persons. Use only clean, dry,
regulated compressed air at the rated
pressure or within the rated pressure
range as marked on the tool. Always
verify prior to using the tool that the
air source has been adjusted to the
rated air pressure or within the rated
air-pressure range.
Never use oxygen, carbon dioxide,
combustible gases or any bottled
gas as an air source for the tool.
Such gases are capable of explosion
and serious injury to persons.
Property or statement
WARNING marking concerning Risk
of Eye Injury. Wear ANSI-approved
eye protection.
WARNING marking concerning Risk
of Hearing Loss. Wear hearing
protection.
WARNING marking concerning Risk
of Respiratory Injury. Wear NIOSHapproved dust mask/respirator.
WARNING marking concerning Risk
of Explosion.
Specific Safety Instructions
1.
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.
For technical questions, please call 1-800-444-3353.
Page 4
2.
3.
Do not adjust the factory set Safety
Valve. This valve should only be set
or reset by a qualified technician.
This air hydraulic Foot Pump must be
secured tightly to a stable surface to
prevent dynamic pressure from moving it around during use. Make sure
there is no tripping hazard.
Vibration Precautions
This tool vibrates during use. Repeated or long-term exposure to vibration may cause temporary or permanent
physical injury, particularly to the hands,
arms and shoulders. To reduce the risk of
vibration-related injury:
1.
Anyone using vibrating tools regularly or for an extended period should
first be examined by a doctor and
then have regular medical checkups to ensure medical problems are
not being caused or worsened from
use. Pregnant women or people
who have impaired blood circulation
to the hand, past hand injuries, nervous system disorders, diabetes, or
Raynaud’s Disease should not use
this tool. If you feel any medical or
physical symptoms related to vibration (such as tingling, numbness, and
white or blue fingers), seek medical
advice as soon as possible.
2.
Do not smoke during use. Nicotine reduces the blood supply to the
hands and fingers, increasing the risk
of vibration-related injury.
3.
Wear suitable gloves to reduce the
vibration effects on the user.
4.
Use tools with the lowest vibration
when there is a choice between different processes.
5.
Include vibration-free periods each
day of work.
10. Obey the manual for the air compressor used to power this tool.
6.
11. Install in-line shutoff valve to allow
control over the air supply in an emergency, even if a hose is ruptured.
Grip tool as lightly as possible (while
still keeping safe control of it). Let
the tool do the work.
7.
To reduce vibration, maintain tool as
explained in this manual. If abnormal
vibration occurs, stop immediately.
4.
Follow manufacturer’s instructions for
compressor and attachments used.
5.
WARNING: The brass components
of this product contain lead, a chemical known to the State of California
to cause birth defects (or other reproductive harm). (California Health &
Safety code § 25249.5, et seq.)
6.
Hydraulics must be opened and serviced only by a qualified technician.
7.
Only use with hose (not included) and
other accessories rated to handle
the forces exerted by this tool during
operation. Other accessories not designed for the forces generated may
break and forcefully launch pieces.
8.
9.
Never press the end of the hose (not
included) against your skin or the skin
of another person or animal. It is possible to inject fluids into your skin if
using this tool inappropriately.
Attach all accessories properly to the
tool before connecting the air supply. A loose accessory may detach or
break during operation.
SKU 98318
For technical questions, please call 1-800-444-3353.
Page 5
Save these
instructions.
Air Supply
To prevent
explosion:
Use only clean, dry, regulated,
compressed air to power this
tool. Do not use oxygen,
carbon dioxide, combustible
gases, or any other bottled
gas as a power source for this
tool.
Specifications
Air Pressure Range
110-120 PSI
Maximum Air Pressure
120 PSI
Maximum Hydraulic
Pressure
10,000 PSI
Air Inlet
1/4” -18 NPT
Oil Capacity
23 oz.
Air Consumption
7 CFM @ 110-120 PSI
Adapter
Pump
Initial Tool Set Up/
Assembly
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 the Assembly Diagram near
the end of this manual.
1.
Unpacking
When unpacking, check to make sure
that the item is intact and undamaged. If
any parts are missing or broken, please
call Harbor Freight Tools at the number
shown throughout the manual as soon as
possible.
• This air tool may be shipped with a
protective plug covering the air inlet.
Remove this plug before set up.
Note: If an automatic oiler system is not
used, add a few drops of Pneumatic
Tool Oil to the airline connection before operation. Add a few more drops
after each hour of continual use.
2.
SKU 98318
Incorporate an in-line oiler, shut-off
valve, hose, regulator with pressure
gauge, and filter for best service, as
shown in the diagram above. An inline shutoff valve is an important
safety device because it controls
the air supply even if the air hose
is ruptured.
Attach an air hose (not included) to
the compressor’s air outlet. Attach
For technical questions, please call 1-800-444-3353.
Page 6
the Air Nipple (1) to the air inlet and
tighten it.
WARNING! To prevent serious
injury from accidental
operation:
Do not install a female quick
coupler on the tool. Such a coupler
contains an air valve that allows air
tool to retain pressure and operate
accidentally after the air supply is
disconnected. The Foot Pedal is
designed to fit a 1/4” NPT air nipple
(included). Also verify air source can
dedicate 7 CFM @ 110-120 PSI.
Note: Air flow, and therefore tool performance, can be hindered by undersized air supply components.
3.
The air hose must be long enough
to reach the work area with enough
extra length to allow free movement
while working.
4.
Make sure throttle or switch is in the
off position; refer to Operation section
for description of controls.
5.
Close the in-line safety valve between the compressor and the tool.
6.
Turn on compressor according to the
manufacturer’s directions and allow it
to build up pressure until it cycles off.
7.
Adjust the air compressor’s output
regulator so that the air output is
enough to properly power the tool,
but the output will not exceed the
tool’s maximum air pressure at any
time. Adjust the pressure gradually,
while checking the air output gauge
to set the right pressure range.
8.
Inspect the air connections for leaks.
Repair any leaks found.
SKU 98318
9.
If the tool will not be used at this
time, turn off and detach the air supply, safely discharge any residual air
pressure, and release the throttle
and/or turn the switch to its off position to prevent accidental operation.
Note: Residual air pressure should not be
present after the tool is disconnected
from the air supply. However, it is a
good safety measure to attempt to
discharge the tool in a safe fashion
after disconnecting to ensure that the
tool is disconnected and unpowered.
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.
Inspect tool before use, looking
for damaged, loose, and
missing parts. If any problems
are found, do not use tool until
repaired.
Tool Set Up
To prevent
serious injury
from accidental
operation:
Turn off the tool, detach the
air supply, safely discharge
any residual air pressure in
the tool, and press down on
the Release Bar (43) before
performing any inspection,
maintenance, or cleaning
procedures.
For technical questions, please call 1-800-444-3353.
Page 7
To prevent serious
injury:
Do not adjust or tamper with
any control or component in a
way not specifically explained
within this manual. Improper
adjustment can result in
tool failure or other serious
hazards.
Note: This Air Hydraulic Foot Pump is
designed to operate pneumatically. It
is an ideal power source for various
body, frame and alignment applications. It can be used with different
ram kits, shop presses and hydraulic
pullers (not included) that operate up
to 10,000 PSI. It is equipped with a
factory set Safety Valve to prevent
sudden hydraulic failure.
Note: Check the oil level and purge air
from system before use. The Reservoir (72) should be full but after
shipping it may need to be topped off.
Check the oil in the pump reservoir
prior to use. Place Pump on flat and
horizontal surface. Wipe top of cylinder with clean, dry rag. Remove the
Fill Plug (77) and add the fluid being
careful not to spill. Replace the Fill
Plug and wipe up any spilled hydraulic fluid. Periodically check the fluid
level.
For best operation: Before
use, unscrew the Breather Valve.
After use, shut the Breather Valve.
Work Piece and Work Area Set Up
1.
Designate a work area that is clean
and well-lit. The work area must not
allow access by children or pets to
prevent injury and distraction.
SKU 98318
2.
Route the air hose along a safe route
to reach the work area without creating a tripping hazard or exposing the
air hose to possible damage. The air
hose must be long enough to reach
the work area with enough extra
length to allow free movement while
working.
Release Bar (43)
Breather
Valve (79)
Foot Pedal (37)
Base Plate (80)
Air Cylinder (15)
Bleeding Plate (41)
Pneumatic Tool Operation
1.
Push down momentarily on Foot
Pedal (37) and release it. The Air
Valve (12) should be raised in order
to operate. (Feel underneath the Foot
Pedal to make sure Valve is raised.)
2.
Attach the air hose from your compressor to the Air Nipple (1).
3.
As pressure may be present, verify
that the system is not pressurized before hydraulic hoses are connected or
disconnected. Verify this by pressing
Release Bar (43) with hand to release any internal hydraulic pressure.
Remove the Protective Plug (84) from
the Adapter (85), attach your hydraulic hose with a 1/4” NPT end to the
hose Connector (68) directly. If you
use our SKU 95944 Hydraulic Hose
For technical questions, please call 1-800-444-3353.
Page 8
(not included) with thread-on 13/16”20 UNF fitting, please first attach the
Adapter (85) to the Hose Connector (68), which is supplied in the bag
containing instruction manual. Use
this hose to attach to any tool that is
to be activated/deactivated with this
Pump.
4.
Then press down Pedal (37) to apply
pressure. Please note: There is no
high/low settings for Pump. Once the
Pedal is pressed, pressure is applied
at a constant setting. Press on Release Bar (43) to release pressure.
5.
To prevent accidents, turn off the tool,
shut the Air Valve (12), and detach
the air supply, and safely discharge
any residual air pressure in the tool
after use. Clean external surfaces
of the tool with clean, dry cloth, and
apply a thin coat of tool oil. Then
store the tool indoors out of children’s
reach.
User-Maintenance
Instructions
Procedures not specifically
explained in this manual
must be performed only by a
qualified technician.
To prevent
serious injury
from accidental
operation:
Turn off the tool, detach the
air supply, safely discharge
any residual air pressure in
the tool, and release the
throttle and/or turn the switch
to its off position before
performing any inspection,
maintenance, or cleaning
procedures.
To prevent serious
injury from tool
failure:
Do not use damaged
equipment. If abnormal
noise, vibration, or leaking
air occurs, have the problem
corrected before further use.
To prevent explosion:
Lubricate the tool only
with specified lubricants.
Lubricate the air inlet using
only pneumatic tool oil. Other
lubricants may damage the
mechanism and may be
highly flammable, causing an
explosion.
SKU 98318
For technical questions, please call 1-800-444-3353.
Page 9
Cleaning, Maintenance, and
Lubrication
Bleeding Instructions
1.
WARNING! Air may accumulate in
the Foot Pedal’s system during shipping and/or use. Before each use,
bleed air from system for better performance. To do this:
2.
Open the Fill Plug (77) by turning it
counterclockwise.
3.
Depress the Release Bar (43) to
open the Release Valve Seat (46).
4.
Depress the Air Valve (12) located
on the top of the Air Cylinder (15) to
remove air from system.
5.
Top off with hydraulic oil and close
the Fill Plug (77).
Note: These procedures are in addition to
the regular checks and maintenance
explained as part of the regular operation of the air-operated tool.
WARNING! Make sure the Foot
Pump is disconnected from air supply
and all hydraulic pressure is released
before performing any inspection,
maintenance, or cleaning procedures.
1.
Before use, inspect the general
condition of the Foot Pump. Check
for loose screws, misalignment or
binding of moving parts, cracked or
broken parts, cracked welds, cracked
or broken hoses, leaking oil, and
any other condition that may affect
its safe operation as well as abnormal noise or vibration. If any of this
should occur, have the problem corrected before further use.
Do not use damaged equipment.
2.
After use, wipe off with a clean
cloth. Be sure to wipe away any
spilled hydraulic fluid.
3.
Monthly, check and refill hydraulic fluid. (See Bleeding Instructions,
below.)
SKU 98318
For technical questions, please call 1-800-444-3353.
Page 10
Troubleshooting
Problem
Possible Causes
Likely Solutions
Foot Pedal (37) will
not depress when
trying to pump.
Low hydraulic
pressure
Reservoir (72) is overfilled with
hydraulic oil.
Make sure the Breather Valve (79) is open,
letting the trapped oil escape if necessary.
1. Loose air fittings.
2. Cracked hose.
Housing heats
during use.
1. Incorrect lubrication or not
enough lubrication.
2. Worn parts.
1. Tighten all fittings.
2. Change any cracked or broken hoses. DO
NOT FEEL FOR LEAKS WITH HANDS.
HIGH PRESSURE CAN INJECT FLUID
UNDER SKIN. DO NOT REPAIR WITH TAPE
OR METAL CLAMPS. ALWAYS REPLACE
THE HOSE.
1. Lubricate using air tool oil and grease
according to directions.
2. Have qualified technician inspect internal
mechanism and replace parts as needed.
1. Check for incorrect alignment and uneven
gaps. If cross-threaded, disassemble and
replace damaged parts before use.
2. Tighten housing assembly. If housing cannot
tighten properly, internal parts may be
misaligned.
3. Replace damaged components.
4. Clean or replace valve assembly.
Severe air
1. Cross-threaded housing
leakage.
components.
(Slight air leakage
is normal,
2. Loose housing.
especially on older
tools.)
3. Damaged valve or housing.
4. Dirty, worn or damaged valve.
Follow all safety precautions whenever diagnosing or servicing the tool.
Disconnect air supply before service.
SKU 98318
For technical questions, please call 1-800-444-3353.
Page 11
PARTS LIST
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
31
32
33
34
35
36
37
38
39
40
41
42
43
Description
Air Nipple
Oil Port
Screw
Lock Washer
Cover
O-Ring
O-Ring
Small piston
Air Valve Seat
O-Ring
O-Ring
Air Valve
O-Ring
Spring
Air Cylinder
Screw
Lock Washer
Sealing Ring
Snap Retainer
Sealing Ring
O-Ring
Air Piston
Sealing Ring
Piston
Washer
Spring
Nut
Sealing Ring
Cylinder
Screw
Copper Washer
Spring
Ball
Spring
Ball
Valve Base
Foot Pedal
Screw
Lock Washer
Washer
Bleeding Plate
Washer
Release Bar
PARTS LIST
Q’ty
1
1
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Part
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
Description
Spring
O-Ring
Release Valve Seat
Pin
O-Ring
Ball
Screw
Strainer
Needle Valve
Safe Valve Spring
Screw
O-Ring
Screw
Ball
Ball Cup
Spring
Screw
Oil Filter
O-Ring
Retainer
Torsion Spring
Oil Outlet Seat
Retainer
O-Ring
Hose Connector
Lock Nut
O-Ring
Lever
Reservoir
Reservoir Cover
O-Ring
Nut
Nylon Ring
Fill Plug
Sealing Ring
Breather Valve
Base Plate
Rubber Foot
Lock Washer
Screw
Protective Plug
Adapter
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
1
1
1
1
1
1
1
1
1
1
4
3
3
1
1
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.
SKU 98318
For technical questions, please call 1-800-444-3353.
Page 12
ASSEMBLY DIAGRAM
SKU 98318
For technical questions, please call 1-800-444-3353.
Page 13
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 • (800) 444-3353
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.
REV 11h
SKU 98318
For technical questions, please call 1-800-444-3353.
Page 14