porta power

PORTABLE PULLER 4 TON

SET UP ANd OPERATiNg iNSTRUcTiONS

Visit our website at: http://www.harborfreight.com

Read this material before using this product. Failure to do so can result in serious injury. SAVE ThiS mANUAL.

Copyright© 2009 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.

44900

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

SAVE ThiS mANUALKeep 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.

Safety Alert Symbol and Signal Words

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.

imPORTANT SAFETY iNSTRUcTiONS

iNSTRUcTiONS PERTAiNiNg TO A RiSk OF iNjURY TO

PERSONSThe 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.

WARNiNg – When using tools, basic precautions should always be followed, including the following:

Work areaTurn off the engine, set the parking 1. brake, and block the tires before working on a vehicle.

keep the work area clean and well 2. lighted. Cluttered benches and dark areas increase the risk of injury to persons.

Keep bystanders and children 3. away while operating the tool. Distractions can result in loss of control of the tool.

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

Personal safetyStay alert. Watch what you are 1. 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.

dress properly. do not wear loose 2. 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.

do not overreach. keep proper 3. footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations.

Use safety equipment.4. Wear ANSI-approved safety goggles and heavy-duty work gloves during use.

Tool use and caredo not force the tool.1. 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.

Store the tool when it is idle out 2. of reach of children and other untrained persons. A tool is dangerous in the hands of untrained users.

check for misalignment or binding 3. 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.

Use only accessories that are 4. 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.

Avoid off-center loads. 5. If the Pump (6) seems unusually hard to operate, immediately stop. Adjust the Ram to eliminate or diminish an off-center load. The Flange Base and Flange Head must only be used together to prevent an off-center load.

Protect the hose. 6. Do not drop heavy objects on the Hose (4). Avoid sharp kinks in the Hose. Maintain proper clearance to avoid damage to the Hose and Couplers.

inspect repair after use.7. 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.

ServiceTool service must be performed 1. only by qualified repair personnel.

When servicing a tool, use only 2. identical replacement parts. Use only authorized parts.

SAVE ThESE iNSTRUcTiONS.


SPEciFicATiONS

Ram Capacity 10-Tons5-Tons w/ extensions

Ram Travel 6”Extension Pole Length 5’ MaximumSpreader Wedge Capacity

1/2-Ton3-3/4” Maximum Opening

Hose Length 6’

UNPAckiNgWhen unpacking, make sure all

parts listed on the Main Parts List and Assembly Diagram are included. If any parts are missing or broken, please call Harbor Freight Tools at 1-800-444-3353 as soon as possible.

Note: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagrams near the end of this manual.

SETUP

Ram AttachmentsThe 1. Extensions (16 – 19) connect in different combinations to reach desired lengths.

The 2. Male Connector (7) is used to connect the female end of the Ram (5) to a Base.

The 3. Flat Base (12) is typically used on the stationary side to spread out the force of the Ram (5).

The 4. 90° V Base (11) is used to offset the force of the Ram (5) when there is not a straight line between the stationary side and the damaged side, or to spread out force on curved surfaces.

The 5. Cap Head (15) is typically used on the pushing end to prevent slipping.

The 6. Rubber Head (13) is typically used for popping dents out of sheet metal such as doors or body panels and to minimize damage to the work surface.

The 7. Wedge Head (10) is used to repair small dents and areas located in angles and tight spaces.

The 8. Flange Base and Flange Head (9, 8) are used together to allow spreading in areas that the Ram cannot fit into.

Note: The Flange Base and Flange Head must only be used together to prevent an off-center load.


Ram SetupNote: When positioning the Ram (5) 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 (12) to distribute pressure over a greater area.

Clean the end of the Hose (4) and the 1. inlet on the Ram (5). Unscrew and save the End Plugs located on the end of the Hose (4) and Ram (5).

Attach the Hose to the Ram.2.

Assemble attachments as shown 3. below:

male connector

(7)

Ram (5)90° V Base (11)

orFlat Base (12)

(install Extension Bars here

as needed)

cap head (15), Rubber head (13),

or Wedge head (10)

Ram (5)

Flange Base (9)

(install Extension Bars here as needed)

Flange head (8)

Note: If using the Flange Base and Flange Head, thread the Flange Base onto the Ram completely and align the Flange Head to it.

Spreader Wedge SetupThe Spreader Wedge (14) is used

when the Ram (5) is too long to fit between the stationary side and the damaged area.

Clean the end of the Hose (4) and the 1. inlet on the Spreader Wedge (14).

Unscrew and save the End Plugs 2. located on the end of the Hose (4) and Spreader Wedge (14).

Attach the Hose (4) to the Spreader 3. Wedge (14), as shown below:

Pump (6)

Spreader Wedge (14)

hose (4)


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.

Check the Hydraulic Fluid Level, 1. following the instructions in the Cleaning and Maintenance section.

Determine which direction the frame 2. needs to be bent.

Remove any obstructions that could 3. be damaged or are in the way.

Note: When using the Pump (6) in a vertical position, keep the Hose (4) end of the Pump downward.

USiNg RAm (5):4A. Connect the appropriate Base a. (11,12,13) to the stationary side of the Ram (5), and connect the appropriate head to the pushing end of the Ram.

Note: When repairing larger body panel dents such as a dented door, fender or quarter-panel use the Rubber Head (13) on the pushing end.

if using the Flange Base (9) or b. Flange head (8): Thread the Flange Base onto the Ram completely and align the Flange Head to it. The Flange Base and Flange Head must only be used together to prevent off-center load.Position the Ram (5) so that the c. 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.Aim the pushing end towards the d. area that needs to be repaired, and slowly apply pressure with the Pump (6).

Note: To prevent damage, do not overextend the Ram.

USiNg SPREAdER WEdgE (14):4B. Place the Spreader Wedge (14) so a. that the hinged (pushing) arm is resting against the part to be moved and the stationary arm is resting against a non-movable base.Carefully hold the Spreader Wedge b. in position and apply the Pump (6) pressure.

Once both ends have made contact, 5. 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.

When the damaged area has been 6. bent to the desired position, slowly turn the Release Valve (10C) counterclockwise to release the hydraulic pressure and remove the Ram (5) or Spreader Wedge (14).

Clean all hydraulic ports and cover 7. them with clean End Plugs to prevent contamination and damage.


cLEANiNg ANd mAiNTENANcE

Keep the surface of this tool and its 1. 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.

Before each use, examine the 2. 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.

Keep hydraulic connections clean. 3. Clean all hydraulic ports and replace end plugs immediately after use.

Store the Pump (6) with the Release 4. Valve (10C) open.

hydraulic Fluid Fill and Bleeding -5. If the Pump (6) operation feels spongy, or the Ram (4) lowers while the Release Valve (10C) is closed, there may be air in the Pump. Bleed the Pump as follows:Set Pump (6) flat on a level surface.a. Remove the Fill Screw (13C). The b. O-ring (34C) should come off with it.The fluid level should be near the c. bottom of the opening. If required, add high grade hydraulic fluid.Make sure the O-ring (34C) is still d. in place around the Fill Screw (13C) and thread the Fill Screw into the Pump securely. Do not use thread seal tape.

Firmly close the Release Valve e. (10C) by turning it clockwise.Press the tip of the Coupling (16C) f. against a hard surface and pump the pump handle.Continue pumping, until the g. hydraulic fluid coming out the end of the coupler tip is free of air bubbles.Recheck the fluid level and add fluid h. if necessary.Turn the Release Valve i. counterclockwise to release the pressure in the pump and hose.

Change the hydraulic fluid yearly. 6. Remove the Fill Screw (13C) and tilt the Pump (6) to drain out the old fluid. Refill the hydraulic fluid and bleed the system several times to ensure all air is out of the system.

PLEASE REAd ThE FOLLOWiNg cAREFULLY

THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEI-THER 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 DISTRIBU-TOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UN-DERTAKEN BY CERTIFIED AND LICENSED TECH-NICIANS 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.


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

PARTS LiSTS ANd ASSEmBLY diAgRAmS

main Parts List and Assembly diagramPart description Q’ty

3 Pump Handle 14 Hose 15 Ram 16 Pump 17 Male Connector 18 Flange Head 19 Flange Base 1

10 Wedge Head 111 90° V Base 1

Part description Q’ty12 Flat Base 113 Rubber Head 114 Spreader Wedge 115 Cap Head 116 5” Extension 117 10” Extension 118 18” Extension 119 27” Extension 1

19

18

16

5

17

13147109

15

11

12

8

4

3

6


Parts List and Assembly diagram A - Ram (5)Part description

1A Dust Cap2A Coupling3A Coupling Ring4A C Snap Ring 5A Bushing6A Protecting Cap7A Ring8A Screw9A Spring

10A C Clip11A Washer12A Spreader13A Cap 14A Cap 15A Cap 16A Bushing17A Bearing18A Washer19A Ram20A Cylinder

4A

18A

6A

7A

19A

17A

16A

15A

13A

14A

13A

12A

1A

20A

8A

5A

9A

10A

11A

2A3A

8A


Parts List and Assembly diagram B - Spreader Wedge (14)

11B10B

9B

12B

13B8B 7B 6B 5B 4B 3B 2B 1B

Part description1B Dust Cap2B O-ring3B Coupler4B Coupler Ring5B End Plug6B Washer7B Cup Seal

Part description8B Piston9B C-clip

10B Pivoting Pin11B Pushing Arm12B Spring13B Stationary Arm


Part description1C Screw (Safety Valve)2C Plastic Cap3C Screw4C O-ring Seal5C Spring6C Stem7C Ball Valve8C Washer9C Valve

10C Release Valve11C Spring12C Ball Valve13C Fill Screw14C Ball Valve

Part description15C End Plug16C Coupling17C Spring18C Hose19C Fluid Fitting20C Grip21C Handle22C Circle Clip23C Pivot Pin Arm24C Pivot Pin Arm25C Pivot Pin Arm26C Plunger27C Washer28C Seal

Part description29C Filter Ring30C Cylinder31C Washer32C Seal33C Spacer34C O-ring35C O-ring36C Bolt37C Pump Foot38C Screw39C Reservoir40C Seal41C Filter42C Housing

Parts List and Assembly diagram c - Pump

20c

38c13c

34c

42c1c

7c6c

4c3c

2c

25c

22c

27c

29c

9c

37c

32c

30c

28c

26c

18c

24c

8c

5c

39c

36c

35c

41c40c

14c

33c10c

11c12c

17c

31c

19c

15c

16c

21c

23c


LimiTEd 90 dAY WARRANTYHarbor 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.

3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 •

(800) 444-3353

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