Harbor Freight Tools 92038 User Manual

®

R

220 VOLT, HYDRAULIC, ELECTRIC PUMP

Model 92038

ASSEMBLY AND OPERATING INSTRUCTIONS

TO PREVENT SERIOUS INJURY,

READ AND UNDERSTAND ALL WARNINGS

AND INSTRUCTIONS BEFORE USE.

3491 Mission Oaks Blvd., Camarillo, CA 93011

Visit our Web site at: http://www.harborfreight.com

Copyright 2004 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 and replacement parts, please call 1-800-444-3353.

REV 12/04

PRODUCT SPECIFICATIONS

Electrical Requirements 2 HP, 220 V, 50 Hz, Single Phase, 10.6 Amps (work load)
Pressure 2200 PSI
Speed 2820 RPM
Duty 5 Minute
Oil Tank Capacity 4.5 Gallons
Overall Dimensions 35-1/2” H x 11” L x 8-1/2” W

SAVE THIS MANUAL

You will need this manual f or the safety warnings and precautions, assembly,
operating, inspection, maintenance and cleaning procedures, parts list and
assembly diagram. K eep your inv oice with this manual. Write the invoice number
on the inside of the front cover. Keep this manual and invoice in a safe and dry
place for future reference.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below may result in

electric shock, fire, and/or serious injury .

SAVE THESE INSTRUCTIONS

WORK AREA

1. Keep your work area clean and well lit.

2. Do not operate electric pumps in explosive atmospheres, such as in the
presence of flammable liquids, gases, or dust. Pumps may create sparks
and arcing, which may ignite the dust or fumes.

3. Keep bystanders, children, and visitors away while operating a Pump.

SKU 92038 For technical questions, please call 1-800-444-3353. Page 2

ELECTRICAL SAFETY

4. Avoid body contact with gr ounded surfaces suc h as pipes, radiators,
ranges, and refrigerators. There is an increased risk of electric shock if y our

body is grounded.

5. Do not expose Electric Pumps to rain or wet conditions. W ater entering a
Pump will increase the risk of electric shock.

6. Do not abuse the Power Cord. N ever use the Power Cord to carry the tools

or pull the Plug from an outlet. Keep the P o wer Cord a way fr om heat, oil,
sharp edges, or mo ving parts. Replace dama ged P ower Cor ds immediately.

Damaged Po w er Cords increase the risk of electric shock.

7. When operating a power tool outside, use an outdoor extension cord
marked “W-A” or “W”. These extension cords are rated for outdoor use, and
reduce the risk of electric shock.

PERSONAL SAFETY

8. Stay alert. W atc h what y ou are doing, and use common sense when
operating a the Pump. Do not use the Pump while tired or under the
influence of drugs, alcohol, or medication. A moment of inattention while

operating this Pump may result in serious personal injury.

9. Dress properly . Do not wear loose c lothing or je welry. Contain long hair .
Keep your hair, c lothing, and gloves a way fr om mo ving parts. Loose
clothes, jewelry, or long hair can be caught in moving parts.

10. Do not overreach. Keep proper footing and balance at all times. Proper
footing and balance enables better control of the power tool in unexpected
situations.

TOOL USE AND CARE

11. Do not force the Pump. Use the correct Pump for your application. The
correct Pump will do the job better and safer at the rate for which it is designed.

12. Disconnect the Po wer Cord Plug from the power source before making any
adjustments, changing accessories, or storing the tool. Such preventive
safety measures reduce the risk of starting the Pump accidentally .

13. Store idle Pumps out of reach of children and other untrained persons.
Electric Pumps are dangerous in the hands of untrained users.

SKU 92038 For technical questions, please call 1-800-444-3353. Page 3

14. Maintain Pumps with care. Keep them c lean. Do not use a damaged Pump.
Tag damaged Pumps “Do not use” until repaired.

15. Check for, breakage of parts and any other condition that may aff ect the

Pump’s operation. If damaged, have the Pump serviced before using.

Many accidents are caused by poorly maintained Pumps.

16. Use only accessories that are recommended by the manufacturer for your
model. Accessories that may be suitable for one Pump may become hazardous
when used on another Pump.

SERVICE

17. Pump service must be performed only by qualified repair personnel.
Service or maintenance performed by unqualified personnel could result in a risk
of injury .

18. When servicing a Pump, use only identical replacement parts. Follow

instructions in the
manual. Use of unauthorized parts or failure to f ollo w maintenance instructions

may create a risk of electric shock or injury .

“Inspection, Maintenance, And Cleaning”

section of this

SPECIFIC SAFETY RULES

1. Maintain labels and nameplates on the Pump. These carry important
information. If unreadable or missing, contact Harbor Freight Tools for a
replacement.

2. Always wear ANSI approved safety impact eye goggles and heavy work
gloves when using the Pump. Using personal safety devices reduce the risk
for injury. Safety impact eye goggles and heavy work gloves are available from
Harbor Freight Tools.

3. Maintain a safe working environment. Keep the work area well lit. Make sure
there is adequate surrounding workspace. Always keep the work area free of
obstructions, grease, oil, trash, and other debris. Do not use an Electric Pump in
areas near flammable chemicals, dusts, and vapors. Do not use this product in a
damp or wet location.

4. Avoid unintentional starting. Make sure y ou are prepared to begin w ork
before turning on the Pump.

5. All hydraulic hoses and hydraulic systems to be used with this pump must

be rated at a working pressure of at least 2200 PSI.

6. Never leave the Pump unattended when it is plugged into an electrical
outlet. Turn off the Pump and unplug it from its electrical outlet before leaving.

SKU 92038 For technical questions, please call 1-800-444-3353. Page 4

7. Make sure the Oil T ank (13) is completely filled with a high quality h ydraulic
oil prior to use.

8. This Pump should be mounted in a properly vented area at least 18 inches

above the floor.
WARNING!! Allow 2 seconds between motor starts. Failure to comply may

burn out the motor.

9. Always unplug the Pump from its electrical outlet before performing any

inspection, maintenance, or cleaning procedures.

10. WARNING! People with pacemakers should consult their physician(s)
before using this product. Electromagnetic fields in close proximity to a heart
pacemaker could cause interference to or failure of the pacemaker.

GROUNDING

WARNING!

The Power Cord requires the attachment of a 220 volt, grounded, 3-Prong Plug
(not included). For safety purposes, only a qualified, certified, electrician should
attach a Plug to the Po wer Cord. Ne v er modify the Plug in any w a y. To comply with
the National Electric Code, and to provide additional protection from the risk of
electrical shock, this product should only be connected to a 220 volt electrical outlet
that is protected by a Ground F ault Circuit Interrupter (GFCI).

SKU 92038 For technical questions, please call 1-800-444-3353. Page 5

EXTENSION CORDS

1.

Grounded

tools require a 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 Figure C, next page.)

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 Figure C.)

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 Figure C.)

5. If you are using one extension cord for more than one tool, add the nameplate
amperes and use the sum to determine the required minimum cord size.

(See Figure C.)

6. If you are using an extension cord outdoors, make sure it is marked with the
suffix “W-A” (“W” in Canada) to indicate it is acceptable for outdoor use.

7. Make sure your extension cord is properly wired and in good electrical condition.
Always replace a damaged extension cord or have it repaired by a qualified
electrician before using it.

8. Protect your extension cords from sharp objects, excessive heat, and damp or
wet areas.

RECOMMENDED MINIMUM WIRE GAUGE FOR EXTENSION CORDS*

(220 VOLT)

NAMEPLA TE
AMPERES
(At Full Load)

25 FEET 50 FEET 75 FEET 100 FEET 150 FEET

0 - 2.0 18 18 16 16 16

2.1 - 3.4 18 18 16 14 14

3.5 - 5.0 18 18 16 14 12

5.1 - 7.0 18 16 14 12 12

7.1 - 12.0 16 14 12 10 -

12.1 - 16.0 14 12 10 - -

16.1 - 20.0 12 10 - - -

FIGURE C

EXTENSION CORD LENGTH

*Based on limiting the line voltage drop
to five volts at 150% of the rated amperes.

SKU 92038 For technical questions, please call 1-800-444-3353. Page 6

SYMBOLOGY

Double Insulated

Canadian Standards
Association

Underwriters
Laboratories, Inc.

V ~

A

n

o

xxxx/min.

V olts Alternating Current

Amperes

No Load Revolutions
per Minute (RPM)

UNPACKING

When unpacking, check to make sure all the parts shown on the Parts List on page 11
are included. If any parts are missing or broken, please call Harbor Freight Tools at the
number shown on the cover of this manual as soon as possible.

ASSEMBLY AND OPERATING INSTRUCTIONS

NOTE: For additional information regarding the parts listed in the following pages, refer
to the Assembly Diagram on page 12.

WARNING!

The Power Cord requires the attachment of a 220 volt, grounded, 3-Prong Plug
(not included). For safety purposes, only a qualified, certified, electrician should
attach a Plug to the Po wer Cord. Ne v er modify the Plug in any w a y. To comply with
the National Electric Code, and to provide additional protection from the risk of
electrical shock, this product should only be connected to a 220 volt electrical outlet
that is protected by a Ground F ault Circuit Interrupter (GFCI).

This pump can be used for a v ariety of applications. Howe ver, it must AL W A YS be mounted

vertically to a stable, secure surface at least 18” from the floor and can only be used
with hydraulic systems and hoses rated at a working pressure of at least 2200 PSI.

1. CAUTION: Always make sure the Po w er Cord of the Pump is unplugged from its
electrical outlet

SKU 92038 For technical questions, please call 1-800-444-3353. Page 7

prior

to installation.

OPERATING INSTRUCTIONS (continued)

2. Read all of the directions and safety instructions in the manual for the product
used with this Pump.

Mounting the Pump

3. Use the proper hardware (capable of supporting the weight of the pump fully; not
included) to mount the Pump vertically to a secure mounting location
(also capable of supporting the pump properly), making sure that the Pump is at
least 18” from the ground.

4. Fill the unit with 4.5 gallons of high quality hydraulic oil.

Attaching Hydraulic Hoses
Note: All hydraulic hoses must be rated at a working pressure of at least 2200 PSI.

5. With pipe thread seal tape (not included), wrap the threads on both ends of a
NPT 3/8” male connector (not included). Tighten one end of the male connector
(not included) into the female connection (see Assembly Drawing on page 12).

6. Securely attach the other end of the connector to the hydraulic system.

Operation

1. Plug the Pump into an approved 220 Volt outlet.

2. Press down on the Pressure Release Handle (3) to completely release hydraulic
pressure.

3. To pressurize the system, press the Lift Button (see the Assembly Drawing on
page 12).

WARNING!! Allow the pump 2 seconds to rest between motor starts.
Failure to comply ma y burn out the motor .

4. When finished operating the Pump, unplug the unit.
NOTE: If the Pump fails to operate, check the hose connections to make sure

fluid is pumping through the hoses. Then, check the fluid level. If the unit still fails
to operate, stop using it and have it repaired by a qualified technician.

SKU 92038 For technical questions, please call 1-800-444-3353. Page 8

INSPECTION, MAINTENANCE, AND CLEANING

1. WARNING! Make sure the Power Button of the Pump is in its “OFF” position
and that the Pump is unplugged from its electrical outlet before performing any
inspection, maintenance, or cleaning procedures.

2. BEFORE EACH USE, inspect the general condition of the Pump. Check for
loose screws, misalignment or binding of mo ving parts, cracked or broken parts,
leaking hydraulic fluid, damaged electrical wiring, and any other condition that
may affect its safe operation. If abnormal noise or vibration occurs, have the
problem corrected by a qualified technician before further use.

Do not use damaged equipment.

3. Wipe the Pump clean with a lint free cloth.

4. Check the hose connections prior to and following each use.

5. Before each use , chec k that the Oil Tank (13) is full.

SKU 92038 For technical questions, please call 1-800-444-3353. Page 9

PARTS LIST

Part No. Description Qty.
1 Motor 1
2 Nut M20x1.5 1
3 Pressure Release Handle 1
5 Release Valve Assembly 1
6 Chec k Valve Assembly 1
7 9-Gear Bearing Gap 1
8 Safety Valve Nut Cap 1
9 Saf ety Valve Assembly 1
10 Valve Seat 1
11 Gear Pump 1
12 Bolt 2
13 Oil Tank 1
14 Bolt 4
15 Bumper Assembly 1
16 Input Oil Pipe 1

PLEASE READ THE FOLLOWING CAREFULLY

THE MANUF A CTURER AND/OR DISTRIBUT OR HAS PR O VIDED THE PARTS LIST AND ASSEMBLY
DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR
DISTRIBUTOR MAKES ANY REPRESENTA TION OR W ARRANTY 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 ST ATES THA T ALL REPAIRS AND P ARTS REPLA CEMENTS SHOULD
BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NO T 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 92038 For technical questions, please call 1-800-444-3353. Page 10

Lift Button

ASSEMBLY DIAGRAM

Female Connection (3/8” NPT)

Hydraulic Oil Fill

NOTE: Some parts are listed and shown for illustration purposes only, and are not avail­able individually as replacement parts.

SKU 92038 For technical questions, please call 1-800-444-3353. Page 11