Harbor Freight Tools Water Pump 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  
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  
 
ELECTRICAL SAFETY  
4.  
Avoid body contact with grounded surfaces such as pipes, radiators,  
ranges, and refrigerators. There is an increased risk of electric shock if your  
body is grounded.  
5.  
6.  
Do not expose Electric Pumps to rain or wet conditions. Water entering a  
Pump will increase the risk of electric shock.  
Do not abuse the Power Cord. Never use the Power Cord to carry the tools  
or pull the Plug from an outlet. Keep the Power Cord away from heat, oil,  
sharp edges, or moving parts. Replace damaged Power Cords immediately.  
Damaged Power Cords increase the risk of electric shock.  
7.  
8.  
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  
Stay alert. Watch what you 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 clothing or jewelry. Contain long hair.  
Keep your hair, clothing, and gloves away from moving 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.  
12.  
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.  
Disconnect the Power 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.  
15.  
Maintain Pumps with care. Keep them clean. Do not use a damaged Pump.  
Tag damaged Pumps “Do not use” until repaired.  
Check for, breakage of parts and any other condition that may affect 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.  
18.  
Pump service must be performed only by qualified repair personnel.  
Service or maintenance performed by unqualified personnel could result in a risk  
of injury.  
When servicing a Pump, use only identical replacement parts. Follow  
instructions in the “Inspection, Maintenance, And Cleaningsection of this  
manual. Use of unauthorized parts or failure to follow maintenance instructions  
may create a risk of electric shock or injury.  
SPECIFIC SAFETY RULES  
1.  
2.  
Maintain labels and nameplates on the Pump. These carry important  
information. If unreadable or missing, contact Harbor Freight Tools for a  
replacement.  
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.  
5.  
6.  
Avoid unintentional starting. Make sure you are prepared to begin work  
before turning on the Pump.  
All hydraulic hoses and hydraulic systems to be used with this pump must  
be rated at a working pressure of at least 2200 PSI.  
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.  
8.  
Make sure the OilTank (13) is completely filled with a high quality hydraulic  
oil prior to use.  
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 Power Cord. Never modify the Plug in any way. 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 Fault Circuit Interrupter (GFCI).  
SKU 92038 For technical questions, please call 1-800-444-3353.  
Page 5  
 
EXTENSION CORDS  
1.  
2.  
Grounded tools require a three wire extension cord.  
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.  
4.  
5.  
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.)  
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.)  
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.  
7.  
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.  
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)  
NAMEPLATE  
EXTENSION CORD LENGTH  
AMPERES  
(At Full Load)  
25 FEET  
50 FEET  
75 FEET  
100 FEET  
150 FEET  
0 - 2.0  
18  
18  
18  
18  
16  
14  
12  
18  
18  
18  
16  
14  
12  
10  
16  
16  
16  
14  
12  
10  
-
16  
14  
14  
12  
10  
-
16  
14  
12  
12  
-
2.1 - 3.4  
3.5 - 5.0  
5.1 - 7.0  
7.1 - 12.0  
12.1 - 16.0  
16.1 - 20.0  
-
-
-
*Based on limiting the line voltage drop  
to five volts at 150% of the rated amperes.  
FIGURE C  
SKU 92038 For technical questions, please call 1-800-444-3353.  
Page 6  
 
SYMBOLOGY  
Double Insulated  
Canadian Standards  
Association  
Underwriters  
Laboratories, Inc.  
Volts Alternating Current  
V ~  
A
Amperes  
n
No Load Revolutions  
per Minute (RPM)  
o
xxxx/min.  
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 Power Cord. Never modify the Plug in any way. 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 Fault Circuit Interrupter (GFCI).  
This pump can be used for a variety of applications. However,it must ALWAYS 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 Power Cord of the Pump is unplugged from its  
electrical outlet prior to installation.  
SKU 92038 For technical questions, please call 1-800-444-3353.  
Page 7  
 
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.  
4.  
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.  
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.  
2.  
Plug the Pump into an approved 220 Volt outlet.  
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 may 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.  
2.  
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.  
BEFORE EACH USE, inspect the general condition of the Pump. Check for  
loose screws, misalignment or binding of moving 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.  
4.  
5.  
Wipe the Pump clean with a lint free cloth.  
Check the hose connections prior to and following each use.  
Before each use, check that the Oil Tank (13) is full.  
SKU 92038 For technical questions, please call 1-800-444-3353.  
Page 9  
 
PARTS LIST  
Part No.  
1
Description  
Motor  
Qty.  
1
2
Nut M20x1.5  
1
3
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
Pressure Release Handle  
Release Valve Assembly  
Check Valve Assembly  
9-Gear Bearing Gap  
Safety Valve Nut Cap  
Safety Valve Assembly  
Valve Seat  
Gear Pump  
Bolt  
Oil Tank  
Bolt  
1
1
1
1
1
1
1
1
2
1
4
1
Bumper Assembly  
Input Oil Pipe  
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 ORWARRANTY OF ANY KINDTOTHE BUYERTHAT  
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 STATESTHAT 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 92038 For technical questions, please call 1-800-444-3353.  
Page 10  
 
ASSEMBLY DIAGRAM  
Lift Button  
Female Connection (3/8” NPT)  
Hydraulic Oil Fill  
NOTE: Some parts are listed and shown for illustration purposes only, and are not avail-  
able individually as replacement parts.  
SKU 92038 For technical questions, please call 1-800-444-3353.  
Page 11  
 

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