Harbor Freight Tools 40611 Assembly And Operating Instructions Manual

R

®

10 Ton

Air Hydraulic Pump

Model 40611

ASSEMBLY and OPERATING INSTRUCTIONS

www.HarborFreight.com

Copyright 1999 by Harbor Freight T ools. 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 T ools.

For technical questions and replacement parts, please call 1-800-444-3353

SPECIFICA TIONS

Hydraulic Capacity: 10,000 PSI
Air Operating Pressure: 70-140 PSI
Hydraulic Outlet: 1/4” x 18 NPT (female)
Air Inlet: 1/4” x 18 NPT (female)
Dimensions: 14-5/8” L x 5” W x 7-1/2” H
W eight: 26.7 LBS.

SAVE THIS MANUAL

Y ou will need the manual for the safety warnings and cautions, assembly instructions, operating procedures,
maintenance procedures, trouble shooting, parts list, and diagram. Keep your invoice with this manual.
Write the invoice number on the inside of the front cover . Keep both this manual and your invoice in a safe,
dry place for future reference.

SAFETY WARNING & CAUTIONS

W ARNING: When using pneumatic equipment, basic safety precautions should always be followed to
reduce the risk of personal injury and hazards due to over pressurization. READ ALL INSTRUCTIONS

BEFORE USING THIS TOOL!

1. KEEP WORK AREA CLEAN. Cluttered areas invite injuries.

2. OBSER VE WORK AREA CONDITIONS. Do not use tools in damp, wet, or poorly lit locations.
Don’t expose to rain. Keep work area well lit. Do not use electrically powered air compressors in the
presence of flammable gases or liquids.

3. KEEP CHILDREN A WA Y. Children must never be allowed in the work area. Do not let them handle
machines, tools, or hoses.

4. STORE IDLE EQUIPMENT . When not in use, tools must be locked up in a dry location to inhibit rust.
Always lock up tools and keep out of reach of children.

5. DO NOT FORCE THE TOOL. It will do the job better and more safely at the rate for which it was
intended. Do not use inappropriate attachments in an attempt to exceed the tool’s capacities.

6. USE THE RIGHT TOOL FOR THE JOB. Do not attempt to force a small tool or attachment to do the
work of a larger industrial tool. Do not use a tool for a purpose for which it was not intended.

7. DRESS PROPERL Y. Do not wear loose clothing or jewelry as they can be caught in moving parts.
Non-skid footwear is recommended. W ear restrictive hair covering to contain long hair .

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REV 07/03

1. USE EYE AND EAR PROTECTION. Always wear ANSI approved chemical splash goggles when
working with chemicals. Always wear ANSI approved impact safety goggles at other times. W ear a full
face shield if you are producing metal filings or wood chips. W ear ANSI approved dust mask or
respirator when working around metal, wood, and chemical dusts and mists.

2. DO NOT OVERREACH. Keep proper footing and balance at all times. Do not reach over or across
running machines.

3. MAINT AIN T OOLS WITH CARE. Keep tools sharp and clean for better and safer performance.
Follow instructions for lubricating and changing accessories. Inspect hydraulic lines and seals periodi­cally and, if damaged, have them repaired by an authorized technician. Inspect all hoses for leaks prior
to use. The handles must be kept clean, dry , and free from oil and grease at all times.

4. REMOVE ADJUSTING KEYS AND WRENCHES. Make it a habit to check that keys and adjusting
wrenches are removed from the tool or machine work surface before plugging it in.

5. ST A Y ALERT . W atch what you are doing, use common sense. Do not operate any tool when you are
tired.

6. CHECK DAMAGED P AR TS. Before using any tool, any part that appears damaged should be
carefully checked to determine that it will operate properly and perform its intended function. Check for
alignment and binding of moving parts; any broken parts or mounting fixtures; and any other condition
that may affect proper operation. Any part that is damaged should be properly repaired or replaced by
a qualified technician. Do not use the tool if any switch does not turn on and off properly .

7. REPLACEMENT P AR TS AND ACCESSORIES. When servicing, use only identical replacement
parts. Use of any other parts will void the warranty . Only use accessories intended for use with this tool.
Approved accessories are available from Harbor Freight T ools.

8. DO NOT OPERATE TOOL IF UNDER THE INFLUENCE OF ALCOHOL OR DRUGS. Read
warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking
drugs. If there is any doubt, do not operate the tool.

9. MAKE SURE ALL EQUIPMENT IS RA TED TO THE APPROPRIA TE CAP ACITY. Do not
attempt any operations or hook up any equipment that would exceed the rated capacities of this tool.

UNPACKING

When unpacking, check to make sure that all parts shown in the parts diagram are included. If any parts are
missing or broken, please call Harbor Freight T ools at the number on the cover of this manual. Please note
that the air hose and parts shown in Figure 2 are options which are sold separately .

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SET UP & OPERATION

Preparation prior to first time use:

Before using your compressor for the first time, loosen the Nut (1), allowing any trapped air to

escape. Then proceed to step 1 below to fill with oil.

Step 1: Open the OIL FILL PLUG (61) and

allow any air to escape. Fill the OIL
T ANK (5) with hydraulic oil. See Figure

1. Replace with the attached VENTED
PLUG.

Step 2: Setup Air Compressor. Suggested set up,

including the installation of an inline oiler
system is detailed in
Figure 2.

Step 3: Install air hose (sold separately) into the

CAP (54) as shown in Figure 3.

Step 4: Connect the other end of the air hose to

the compressor’s (or inline oiler’s) outlet.

(61)

(5)

Nut (1)

Figure 1. Filling the Oil Tank

NOTE:

Use PTFE Pipe Thread Seal on all threaded

connections.

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Figure 2 — Connecting the Air Compressor

(54)

Figure 3 — Installing the Air Hose

REV 08/04

Step 5: Remove the HYDRAULIC VAL VE CAP (62) and install hydraulic hose (sold separately) in

NUT (1) as shown in Figure 4.

(1)

(62)

Figure 4 — Installing the Hydraulic Hose

Step 6: Connect the other end of the hydraulic hose to the desired hydraulic accessory .

Step 7: Set the Air Compressor’ s regulator at 70-140 PSI (depending upon the required hydraulic

pressure).

Step 8: Make sure VAL VE PIN (13) is up, and turn on Air Compressor .

Step 9: Push down on the PEDAL (1 1) as shown by the direction arrow in Figure 5. This will push the

VAL VE PIN down, and activate the Pump.

(11)

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Figure 5 — Activating the Pump

Step 10: To stop the hydraulic pumping action, release pressure on the PEDAL. Do not press down

on the front of the PEDAL yet.

Step 11: T o release the pressure in the Hydraulic Accessory, push forward on the PEDAL as shown

in Figure 6.

(11)

Figure 6 — Releasing Pressure in the Hydraulic Accessory

MAINTENANCE

Step 1: Keep OIL T ANK (5) filled as detailed in SETUP & OPERA TIONS S tep 1.

Step 2: If Hydraulic Hose is removed, replace the HYDRAULIC VAL VE CAP (62).

Step 3: Do not allow dirt or other contaminants to get into either the Hydraulic or Air connections.

Step 4: To Bleed the System:

Important: During this entire procedure, keeping the pump full of hydraulic fluid is
essential.

A. Push forward on the PEDAL (shown in Figure 6) to release the pressure in the hydraulic hose.
B. Open the OIL FILL PLUG (61) and top the system off with fresh, clean hydraulic fluid.
C. Disconnect the hydraulic hose from the unit it is powering, point it into a container for storing the

hydraulic fluid, and carefully open the end of the hose by pressing in the pin valve. Activate the
pump (making certain to keep the reservoir full) until fluid comes out of the hose with no
bubbles.

D. Replace the OIL FILL PLUG (61), reattach the hose, and test for proper operation.

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REV 08/04

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS
MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR 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 STA TES THAT ALL REP AIRS 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.

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REV 08/04

PARTS DIAGRAM MODEL # 40611 10 TON AIR - HYDRAULIC PUMP

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REV 08/04