Harbor Freight Tools 4 ton Heavy Duty Portable Hydraulic Equipment Kit Product 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

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, set the parking brake, and block the tires before working on a vehicle.

2.

Keep the work area clean and

well lighted. Cluttered benches and dark areas increase the risk of injury to persons.

3.

Keep bystanders and children away

while operating the tool. Distractions can result in loss of control of the tool.

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

Items 44899, 44900

Personal safety

1.

Stay alert. 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.

2.

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.

3.

Use safety equipment.

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

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.

5.

Avoid off-center loads. If the Pump seems unusually hard to operate, immediately stop. Adjust the Ram to eliminate or diminish an offoff center load.

The Flange Base and Flange Head must only prevent an off-center load.

6.

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.

7.

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.

Service

1.

Tool service must be performed only by qualified repair personnel.

2.

When servicing a tool, use only identical replacement parts.

Use only authorized parts.

SAVE THESE INSTRUCTIONS.

Items 44899, 44900 For technical questions, please call 1-800-444-3353.

Page 3

Specifications

Model

Ram Capacity

Ram Travel

Extension Pole Length

Spreader Capacity

Hose Length

44899

4 Tons

2 Tons w/ extensions

5″

4′ 5

⁄ ⁄ ⁄ ⁄ Ton

3-

2

3 ⁄ ⁄ ″ Maximum Opening

6′

⁄ ⁄ ⁄ ⁄ ″ Maximum

44900

10 Tons

5 Tons w/ extensions

6″

5′ Maximum

⁄ ⁄ ⁄ ⁄ Ton

3-

2

3 ⁄ ⁄ ″ Maximum Opening

6′

Setup

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

Extensions connect in different combinations to reach desired lengths.

Male Connector is used to connect the female end of the Ram to a Base.

3. The Flat Base is used on the stationary side to spread out the force of the Ram.

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 to spread out force on curved surfaces.

Cap Head is used on the pushing end to prevent slipping.

Rubber Head is used for popping dents out of sheet metal such as doors or body panels and to minimize damage to the work surface.

Wedge Head is used to repair small dents and areas located in angles and tight spaces.

Flange Base and Flange are used together to allow spreading in areas that the Ram cannot fit into.

The Flange Base and

Flange Head must only together to prevent an off-center load.

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 inlet on the Ram. Unscrew and save the End Plugs located on the end of the Hose and Ram.

Flange

Head

Flange

Base

2. Attach the Hose to the Ram.

3. Assemble attachments as shown below:

Ram 90° V Base or

Flat Base

(install

Extensions here as needed)

Ram

If using the Flange Base and

Flange Head, thread the Flange Base onto the Ram completely and align the Flange Head to it.

Cap Head,

Rubber Head, or Wedge Head

(install

Extensions here as needed)

Male

Connector

Spreader Setup

Spreader is used when the Ram is too long to fit between the stationary side and the damaged area.

1. Clean the end of the Hose and the inlet on the Spreader.

2. Unscrew and save the

End Plugs located on the end of the Hose and Spreader.

3. Attach the Hose to the

Spreader, as shown below:

Hose

Pump

Spreader

Items 44899, 44900 For technical questions, please call 1-800-444-3353.

Page 5

Operation

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.

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 the stationary side of the Ram, and connect the appropriate head to the pushing end of the Ram.

When repairing larger body panel dents such as a dented door, fender or quarter-panel use the

Rubber Head on the pushing end.

b.

If using the Flange Base or

Flange Head:

Thread the Flange Base onto the

Ram completely and align the

Flange Head to it. The Flange Base and Flange Head must only together to prevent off-center load.

c. Position the Ram so that the Base is resting against a frame member opposite the damaged area. It must also be in line with the direction in which the damaged area needs to be pushed. The vehicle body part must be stronger than the area to be bent or it may be damaged.

A block of wood or a towel may be used to protect the body part.

d. Aim the pushing end towards the area that needs to be repaired, and slowly apply pressure with the Pump.

To prevent damage, do not overextend the Ram.

4B.

USING SPREADER: a. Place the Spreader so that the hinged (pushing) arm is resting against the part to be moved and the stationary arm is resting against a non-movable base.

b. Carefully hold the Spreader in position and apply pressure with the Pump.

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

1. 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.

3. Keep hydraulic connections clean.

Clean all hydraulic ports and replace

Dust Covers immediately after use.

4. Store the Pump with the

Release Valve open.

Filling and Bleeding Hydraulic Fluid

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:

1. Set Pump flat on a level surface.

2. Remove the Fill Screw.

The Seal Ring should come off with it.

6. Press the tip of the Coupler against a hard surface and pump the pump handle.

3. The fluid level should be near the bottom of the opening.

If required, add high grade hydraulic fluid.

7. Continue pumping, until the hydraulic fluid coming out the end of the Coupler tip is free of air bubbles.

8. Recheck the fluid level and add fluid if necessary.

4. 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.

9. Turn the Release Valve counterclockwise to release the pressure in the Pump and Hose.

5. Firmly close the Release Valve by turning it clockwise.

Changing Hydraulic Fluid

1. Change the hydraulic fluid yearly.

2. Remove the Fill Screw and tilt the

Pump to drain out the old fluid.

3. Refill the hydraulic fluid and bleed the system several times to ensure all air is out of the system.

Items 44899, 44900 For technical questions, please call 1-800-444-3353.

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

3 Pump Handle

4 Hose

5 Ram

6 Pump

7 Male Connector

8 Flange Head

9 Flange Base

10

Flange Base

Wedge Head

11 90° V Base

Qty

1

1

1

1

1

1

1

1

1

Part

12 Flat Base

13 Rubber Head

14 Spreader

15 Cap Head

16 5″ Extension

17 10″ Extension

18 18″ Extension

19 27″ Extension

3

1

1

1

1

1

1

1

1

4

6

18

16

12

11

5

15

17

Page 8

8 9 10 7 14 13

For technical questions, please call 1-800-444-3353.

Items 44899, 44900

44900 Parts List and Assembly Diagram A - Ram (5)

Part Description

1A Dust Cap

2A

3A

4A

Coupling

Coupling Ring

C Snap Ring

5A Bushing

6A

7A

Bushing

Protecting Cap

Ring

8A Screw

9A Spring

10A C Clip

11A Washer

12A Spreader

13A Cap

14A Cap

15A Cap

Bushing

Bearing

18A Washer

19A Ram

Cylinder

11A

10A

9A

19A

5A

8A

20A

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.

8A

3A

Items 44899, 44900 For technical questions, please call 1-800-444-3353.

2A

17A

16A

15A

13A

14A

13A

12A

1A

Page 9

6A

7A

4A

18A

44900 Parts List and Assembly Diagram B - Spreader (14)

Part

1B

2B

3B

4B

5B

6B

7B

Dust Cap

O-ring

Coupler

Coupler Ring

End Plug

Washer

Cup Seal

Part

8B

9B

10B

11B

12B

13B

Description

Piston

C-clip

Pushing Arm

Spring

11B

10B

12B

9B

13B

8B 7B 6B 5B

4B 3B 2B 1B

Page 10 For technical questions, please call 1-800-444-3353.

Items 44899, 44900

44900 Parts List and Assembly Diagram C - Pump

Part Description

Screw (Safety Valve)

2C Plastic Cap

3C Screw

4C O-ring Seal

5C Spring

6C Stem

7C Ball Valve

8C Washer

9C Valve

10C Release Valve

Spring

12C Ball Valve

13C Fill Screw

14C Ball Valve

Part Description

End Plug

16C Coupling

17C Spring

18C Hose

Fluid Fitting

20C Grip

21C Handle

22C Circle Clip

23C Pivot Pin Arm

24C Pivot Pin Arm

25C Pivot Pin Arm

26C Plunger

27C Washer

28C Seal

Part Description

Filter Ring

30C Cylinder

31C Washer

32C Seal

33C Spacer

O-ring

35C O-ring O-ring

36C Bolt

37C Pump Foot

38C Screw

39C Reservoir

40C Seal

41C Filter

Housing

20C

38C

39C

21C

25C

22C

2C

3C

4C

5C

6C

7C

1C

42C

27C

29C

31C

9C

8C

40C

41C

23C

26C

24C

28C

30C

32C

17C 18C

12C

14C

33C

11C

10C

15C

19C

16C

13C

36C

34C

37C

Items 44899, 44900 For technical questions, please call 1-800-444-3353.

Page 11

3

44899 Parts Lists and Diagrams

44899 Main Parts List and Assembly Diagram

Part Description

1 Pump

2 Ram

3 Hose

4 19-1/2” Extension

5 16-1/2” Extension

6 8-1/2” Extension

7 5” Extension

8 3-1/4” Extension

9 Cap Head

1

1

1

1

1

1

1

1

1

Part

10 Spreader

11 2-3/4” Rubber Head

12 Wedge Head

13 90° V Base

14

15

Flange Head

Flange Base

16 Male Connector

17 Flat Base

12

13

9

15

17

4

5

6

7

8

16

10

2

14

1

1

1

1

1

1

1

1

1

Page 12 For technical questions, please call 1-800-444-3353.

Items 44899, 44900

44899 Parts List and Assembly Diagram A - Spreader (10)

Part

1A

2A

3A

4A

5A

6A

7A

Dust Cap

O-ring

Coupler

Coupler Ring

End Plug

Washer

Cup Seal

Part

8A

9A

10A

11A

12A

13A

Piston

Stationary Arm

C-clip

Spring

Pivoting Pin

10A

13A

12A

11A

9A

8A 7A 6A 5A

4A 3A 2A 1A

Items 44899, 44900 For technical questions, please call 1-800-444-3353.

Page 13

44899 Parts List and Assembly Diagram B - Ram (2)

Part Description

1B End Plug

2B O-ring

3B Coupler

4B Coupler Ring

5B Screw

6B Cylinder

7B Spring

8B Ring

9B Protector Cap

10B Circle Clip

11B Washer

12B “U” Seal

13B Backup Ring

14B Bushing

15B Bearing

16B Ram

17B Washer

18B C-clip

19B Bushing

9B

8B

7B

19B

5B

6B

Page 14

5B

4B

3B

2B

1B

For technical questions, please call 1-800-444-3353.

Items 44899, 44900

44899 Parts List and Assembly Diagram C - Pump

Part Description

1C Screw (Safety Valve)

2C Plastic Cap

3C Screw

4C O-ring Seal

5C Spring

6C Stem

7C Ball Valve

8C Washer

9C Valve

10C Release Valve

11C Spring

12C Ball Valve

13C Fill Screw

14C Ball Valve

20C

38C

Part Description

End Plug

16C Coupling

17C Spring

18C Hose

Fluid Fitting

20C Grip

21C Handle

22C Circle Clip

23C Pivot Pin Arm

24C Pivot Pin Arm

25C Pivot Pin Arm

26C Plunger

27C Washer

28C Seal

39C

21C

25C

22C

2C

3C

4C

5C

6C

7C

1C

42C

27C

29C

31C

9C

8C

40C

41C

23C

26C

24C

28C

30C

32C

17C

Part Description

Filter Ring

30C Cylinder

31C Washer

32C Seal

33C Spacer

O-ring

35C O-ring O-ring

36C Bolt

37C Pump Foot

38C Screw

39C Reservoir

40C Seal

41C Filter

Housing

12C

14C

33C

18C

11C

10C

15C

19C

16C

13C

36C

34C

37C

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 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.