2.5 Horsepower industrial breaker hammer kit
Model 96035 
Set up and Operating Instructions
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Read this material before using this product. Failure to do so can result in serious injury. Save this manual.
Copyright© 2007 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 10e
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.
Important SAFETY
Information
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, used with the safety alert
symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE is used to address practices not
related to personal injury.
CAUTION, without the safety alert symbol, is
used to address practices not related to personal injury.
General Power Tool Safety Warnings
WARNING Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The term ″power tool″ in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
1.Work area safety
a.Keep work area clean and well lit.
Cluttered or dark areas invite accidents.
b.Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
c.Keep children and bystanders away while operating a power tool.
Distractions can cause you to lose control.
2.Electrical safety
a.Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with grounded power tools.
Unmodified plugs and matching outlets will reduce risk of electric shock.
b.Do not expose power tools to rain or wet conditions. Water entering
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SKU 96035 |
a power tool will increase the risk of electric shock.
c.Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock.
d.When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock.
e.If operating a power tool in a damp location is unavoidable, use a Ground Fault Circuit Interrupter (GFCI) protected supply. Use of a
GFCI reduces the risk of electric shock.
3.Personal safety
a.Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol
or medication. A moment of inattention while operating power tools may result in serious personal injury.
b.Use personal protective equipment. Always wear eye protection. Safety equipment such as dust mask, nonskid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
c.Prevent unintentional starting. Ensure the Trigger is in the offposition before connecting to power source, picking up or carrying the tool. Carrying power tools with your finger on the trigger or energizing power tools that have the trigger depressed invites accidents.
d.Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations.
e.Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewelry or long hair can be caught in moving parts.
f.Only use safety equipment that has been approved by an appropriate standards agency. Unapproved safety equipment may not provide adequate protection. Eye protection must be ANSI-approved and breathing protection must be NIOSH-approved for the specific hazards in the work area.
4.Power tool use and care
a.Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed.
b.Do not use the power tool if the Trigger does not turn it on and off.
Any power tool that cannot be controlled with the Trigger is dangerous and must be repaired.
c.Disconnect the plug from the power source before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
d.Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
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e.Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
f.Keep cutting tools sharp and clean.
Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control.
g.Use the power tool, accessories and tool Chisels etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
5.Service
a.Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.
Breaker Hammer Safety Warnings
1.Wear ear protectors. Exposure to noise can cause hearing loss.
2.Use auxiliary handles supplied with the tool. Loss of control can cause personal injury.
3.Hold power tools by insulated gripping surfaces when performing an operation where the cutting tool may contact hidden wiring or its own cord. Contact with a ″live″ wire will make exposed metal parts of the tool ″live″ and shock the operator.
4.Do not operate this tool if you have back, neck, or wrist injuries, or other conditions
that will be aggravated by the severe jerking forces that this tool exerts upon the operator.
5.Maintain labels and nameplates on the tool. These carry important safety information. If unreadable or missing, contact Harbor Freight Tools for a replacement.
6.Avoid unintentional starting. Prepare to begin work before turning on the tool.
7.Do not lay the tool down until it has come to a complete stop. Moving parts can grab the surface and pull the tool out of your control.
8.When using a handheld power tool, maintain a firm grip on the tool with both hands to resist starting torque.
9.Do not leave the tool unattended when it is plugged into an electrical outlet. Turn off the tool, and unplug it from its electrical outlet before leaving.
10.This product is not a toy. Keep it out of reach of children.
11.People with pacemakers should consult their physician(s) before use.
Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure. In addition, people with pacemakers should:
•Avoid operating alone.
•Properly maintain and inspect to avoid electrical shock.
•Any power cord must be properly grounded. Ground Fault Circuit
Interrupter (GFCI) should also be implemented – it prevents sustained electrical shock.
12.WARNING: Some dust created by power sanding, sawing, grinding, drilling, and other construction activities, contains
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chemicals known [to the State of California] to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:
•Lead from lead-based paints
•Crystalline silica from bricks and cement or other masonry products
•Arsenic and chromium from chemically treated lumber
Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles. (California Health & Safety Code § 25249.5, et seq.)
13.WARNING: Handling the cord on this product will expose you to lead, a chemical known to the State of California to cause cancer, and birth defects or other reproductive harm. Wash hands after handling. (California Health & Safety Code § 25249.5, et seq.)
14.The warnings, precautions, 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.
Vibration Safety
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 check-ups 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 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.
5.Include vibration-free periods each day of work.
6.Let the tool do the work.
7.To reduce vibration, maintain the tool as explained in this manual. If any abnormal vibration occurs, stop use immediately.
Save these instructions.
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Grounding
To prevent electric shock
and death from incorrect grounding wire connection:
Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.
Do not modify the power cord plug provided with the tool. Never remove the grounding prong from the plug. Do not use the tool if the power cord or plug is damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the outlet, have a proper outlet installed by a qualified electrician.
Grounded Tools: Tools with Three Prong Plugs
3-Prong Plug and Outlet
1.Tools marked with “Grounding Required” have a three wire cord and three prong grounding plug. The plug must be connected to a properly grounded outlet.
If the tool should electrically malfunction or break down, grounding provides a low resistance path to carry electricity away from the user, reducing the risk of electric shock. (See 3-Prong Plug and
Outlet.)
2.The grounding prong in the plug is connected through the green wire inside the cord to the grounding system in the tool. The green wire in the cord must be the only wire connected to the tool’s grounding system and must never be attached to an electrically “live” terminal.
(See 3-Prong Plug and Outlet.)
3.The tool must be plugged into an appropriate outlet, properly installed and grounded in accordance with all codes and ordinances. The plug and outlet should look like those in the preceding illustration. (See 3-Prong Plug and
Outlet.)
Extension Cords
1.Grounded tools require a three wire extension cord. Double Insulated tools can use either a two or three wire extension cord.
2.As the distance from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with inadequately sized wire causes a serious drop in voltage, resulting in loss of power and possible tool damage.
(See Table A.)
3.The smaller the gauge number of the wire, the greater the capacity of the cord.
For example, a 14 gauge cord can carry a higher current than a 16 gauge cord.
(See Table A.)
4.When using more than one extension cord to make up the total length, make sure each cord contains at least the minimum wire size required.
(See Table A.)
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