Perfomance Tool W1606 User manual

WARNING
It is the owner and/or operators’ responsibility to study all WARNINGS, operating, and
maintenance instructions contained on the product label and instruction manual prior to
operation of this service jack. The owner/operator shall retain product instructions for future
reference.
The owner and/or operator are responsible for maintenance, maintaining all decals or warning
labels and while in use, maintaining the unit in good working order. If the owner and/or operator
are not fluent in English, the product warnings and instructions shall be read and discussed with
the operators’ native language by the purchaser/owner or his designee. Make sure that the
operator comprehends its contents. Safety information shall be emphasized and understood prior
to usage. The service jack shall be inspected per the operating instructions.
Users of this service jack must fully understand these instructions. Each person operating this
service jack must also be of sound mind and body and must not be under the influence of any
substance that might impair their vision, dexterity, or judgment.
Protect yourself and others by observing all safety information.
Failure to comply with instructions could result in personal injury and/or property damage!
2 TON COMPACT
TROLLEY JACK
OWNERS MANUAL
Stock Number W1606
On occasion, after printing of our literature is completed, our manufacturers may make changes and/or
modifications to merchandise which will not be reflected in this manual. Although we strive to maintain
complete and accurate information, it is possible in some instances, that the product may differ slightly from
printed specifications. Illustrations are intended for reference only. Actual merchandise may vary. Wilmar is
not responsible for typographical errors.

2
DANGER Indicates an imminently hazardous situation that, if
not avoided, WILL result in death or serious injury.
WARNING Indicates a potentially hazardous situation that, if
not avoided, COULD result in death or serious injury.
CAUTION Indicates a potentially hazardous situation that, if
not avoided, MAY result in minor or moderate injury.
NOTICE Indicates important information, which if not followed,
MAY cause damage to equipment.
SAFETY GUIDELINES / DEFINITIONS
UNPACKING AND INSPECTION
SPECIFICATIONS
IMPORTANT SAFETY INFORMATION
Specifications are subject to change without notice.
WARNING
READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS ANDWARNINGS BEFORE OPERATINGTHIS
TOOL. FAILURETO DO SO MAY RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE AND WILL
VOIDWARRANTY.
1. Study, understand and follow all instructions before operating
this device.
2. DO NOT exceed rated capacity. Overloading can cause dam-
age to or failure of this product.
3. Use only on hard, level surface capable of sustaining the load.
Use of jack on other than hard level surfaces can result in jack
instability and possible loss of load.
4. Lifting device only. Immediately after lifting, support the vehicle
with appropriate means. Ensure that no personnel pass under-
neath load until load is securely supported by jack stands.
5. DO NOT adjust safety valve.
6. Wear ANSI approved safety goggles and heavy duty work
gloves during use.
7. Keep clear of load while lifting and lowering.
8. Lower load slowly.
9. DO NOT use for aircraft purposes.
10. Apply parking brake and chock tires before lifting vehicle.
11. Lift vehicle only at vehicle manufacturer recommended lift
locations.
12.Inspect before every use; do not use if parts are loose or
damaged.
13.Do not alter this product in any way.
14.Keep your work area clean and well lit.Cluttered work areas
invite accidents.
15.Keep bystanders, children, and visitors away while operating
this product. Distractions can cause you to lose control.
16. Stay alert.Watch what you are doing, and use common sense when
operating this product.Do not use this product while tired or under
the influence of drugs, alcohol or medication. A moment of inatten-
tion while operating this product may result in serious personal injury.
Warning: This is a lifting device only. Load must be supported immediately by Jack Stands.
WARNING: Read and understand this entire
instruction manual before attempting to assemble,
install, operate or maintain this product.Failure to com-
ply with the instructions may result in serious personal
injury and/or property damage!
The following signal words are used to emphasize
safety warnings that must be followed when using this
product:
This instruction manual is intended for your benefit. Please read and follow the safety, installation, maintenance and troubleshooting steps described within to ensure your
safety and satisfaction. The contents of this instruction manual are based upon the latest product information available at the time of publication. The manufacturer reserves
the right to make product changes at any time without notice.
After opening the carton, unpack your new product and related parts & accessories. Please inspect it carefully for
any damage that may have occurred during transit. Please check it against the photograph on carton.
WARNING DO NOT operate this product if damaged during shipment, handling or misuse. Do not operate the product until the
parts have been replaced or the fault rectified. Failure to do so may result in serious personal injury or property damage. All damaged
parts must be repaired or replaced as needed prior to operating this product. Check to see that all nuts, bolts and fittings are secure
before putting this product into service.
Capacity: ............................................................................................................. 4,000 lbs.
Minimum Lift Height:............................................................................................. 5 1/4 in.
Maximum Lift Height:................................................................................................ 13 in.
Base Length:.............................................................................................................. 17 in.
BaseWidth:.................................................................................................................. 8 in.

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NOTICE During shipment or handling, air in the jack can become trapped in the hydraulic system
causing the jack to malfunction.
IMPORTANT SAFETY INFORMATION
OPERATION
BEFORE USE
17.Store idle jacks out of reach of children and other untrained
persons.Jacks are dangerous in the hands of untrained users.
18.Tool/equipment service must be performed only by qualified
repair personnel. Service or maintenance performed by
unqualified personnel could result in a risk of injury.
19.When servicing this product, use only identical replacement
parts - refer to attached, product-specific parts list and dia-
gram.Follow instructions in the Care & Maintenance section
of this manual.Use of unauthorized parts or failure to follow
maintenance instructions may create a risk of injury and may
void any applicable warranty.
20.Maintain labels and nameplates on this product.These carry
important information. If unreadable or missing, contact
Performance Tool for a replacement.
21.Before use, read manufacturer’s instruction manual for the
vehicle (or object) you will lift.
22.When lifting only one wheel, support the load immediately
with one jack stand (not included) placed under the side of the
vehicle being lifted.Align the saddle of the jack stand directly
under the vehicle’s frame or recommended lifting point.
23.When lifting the entire front end or rear end of a vehicle,
support the load immediately with two jack stands. Align the
saddles of the jack stands directly under the vehicle’s frame or
recommended lifting points.Also, adjust the jack stands to the
same height.
24.Do not work under the vehicle without properly supporting the
vehicle with jack stands.
25.Avoid dangerous oncoming traffic.Use the Jack as far away
from the roadside as possible.
26.Industrial applications must follow OSHA requirements.
27.Do not allow anyone inside the vehicle while using the Jack.
Keep all bystanders a safe distance away from the vehicle.
28.Do not support both ends of the vehicle at the same time.
29.Before lowering the jack, remove all tools and equipment from
under the vehicle.
30.The warnings, precautions, and instructions discussed in this
manual cannot cover all possible conditions and situations
that may occur.The operator must understand that common
sense and caution are factors, which cannot be built into this
product, but must be supplied by the operator.
WARNING: This product and its packaging contain a chemical
known to the State of California to cause cancer, birth defects, or
other reproductive harm.
To raise:
1. Park vehicle on a hard level surface safely
away from oncoming traffic.
2. Turn off the vehicle’s engine.
3. Place the vehicle’s transmission in PARK, if
equipped with an automatic, or in its lowest
gear, if equipped with a manual transmission.
4. Set the vehicle’s emergency brake and block
the wheels that are not being lifted.
5. Refer to vehicle owner’s manual for proper
jacking procedures. Lift only on areas of
vehicle as specified by manufacturer.
6. Make certain that load is centered on saddle.
7. Place pump handle over release valve and
turn clockwise to close.
8. Insert handle into handle socket and pump to
raise load to desired height.
9. ALWAYS support load with jack stands. (See
figure 2) Place jack stands of appropriate
Figure 1
Figure 2
Before using your jack:
1. Place pump handle over release valve and
turn counter-clockwise no more than two turns
to open.
2. Pump jack about 6 full strokes to ensure
complete distribution of hydraulic fluid.
(See Figure 1)
3. Repeat above steps as needed.

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1. Before each use, inspect the general condition
of the jack.Check for broken, cracked, or bent
parts, loose or missing parts, and any condition
that may affect the proper operation of the
product. Any jack that appears damaged in
anyway must be removed from service.Have
the problem corrected before further use. DO
NOT use damaged equipment.
2. Replace worn or damaged parts with Perfor-
mance Tool replacement parts. Be sure that
only qualified personnel perform repairs.
3. Before each use, thoroughly test the jack for
proper operation prior to its actual use.If the
jack appears not to be working properly, follow
bleeding instructions on page 3.
4. When jack is not in use, ram and pump piston
should be in fully down position to keep their
machined surfaces free from corrosion.
5. Keep jack clean and well lubricated at points
illustrated in figure 3.
6. For best results, use only hydraulic fluid with a
rating of SAE 20 for refills.Check fluid level with
jack in fully down position. Fluid level should be
up to bottom of oil fill port.(See figure 4)
7. Change the hydraulic oil at least once every
three years:
a. With the jack fully lowered, remove the oil
filler plug on the side of the Housing.
b. Tip the jack to allow the old hydraulic oil
to drain out of the Housing completely, and
dispose of the old hydraulic oil in accordance
with local regulations.
c. With the jack upright, completely fill the
housing with a high quality hydraulic oil (not
included) until the oil just begins to run out of
the oil fill hole.Be VERY CAREFUL not to allow
dirt or foreign matter into the system.
d. Then, reinstall the oil filler plug.
e. Clean with a clean cloth using a detergent or
mild solvent.Then, store the jack in a safe, dry
location with the ram and pump piston in fully
down position.Keep out of reach of children
and other non-authorized people.
Figure 3
Pump feels "spongy" under load
OPERATION
CARE & MAINTENANCE
capacity (not included) beneath the vehicle
at locations recommended by the vehicle
manufacturer. DO NOT Get under the vehicle
without jack stands. J acks are not designed to
maintain heavy loads for long periods of time.
DO NOT attempt to put jack stands simultane-
ously under both ends of vehicle or under one
side of vehicle. NOTE:When using two jack
stands, they must be at the same height.
10. SLOWLY turn the release valve counterclock-
wise to lower vehicle onto jack stands and
remove jack.
IMPORTANT: NEVER MOVE JACK WHEN
THE HANDLE IS IN OPERATING LEVER
OR THE VALVE SLEEVE. DAMAGE TO
THE PUMPING UNIT MAY OCCUR.
To lower:
1. Remove all tools, parts, etc. from under the vehicle.
2. Position the saddle under the lifting point.
Place pump handle over release valve and
turn clockwise to close the valve release
screw, and pump the upper/lower handle to
raise the vehicle slightly above the saddle(s)
of the jack stands.Then, collapse and remove
jack stand(s).
3. SLOWLY turn the release valve counterclock-
wise with the handle just enough to allow
controlled descent of the vehicle onto the
ground.(Never more than two full turns).
4. Lower the jack completely.Then, store in a
safe, dry location out of reach of children.
Monthly maintenance is recommended. Lubrication is critical to jacks as they support
heavy loads. Any restriction due to dirt, rust, etc. can cause either slow movement or
cause extremely rapid jerks, damaging the internal components.The following steps are
designed to keep the jack maintained and operational.

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WARNING: Remove jack from service before making adjustments
NOTE:
Problems listed above with more than one
solution may have a combination of
causes.Please be sure that all solutions
listed for each problem have been checked
to eliminate possibility of further trouble.
Sometimes solutions may need to be
●●●
●
● ●
● ●
●
●
Power unit may be
low in fluid.With
jack on level
surface and in
down position,
remove filler plug
and add clean
hydraulic jack fluid
to level of filler.
Power unit may be
air bound. Open
the release valve
a minimum of 2
full turns. Pump
the handle a
minimum of 20 full
strokes to purge
air from the
system.
Valve may not be
closing
completely.
To seat valves:
a.) Close release
valve.
b.) With jack in
fully lowered
position,
manually raise
lifting arm as
high as
possible.
c.) Open release
valve and
allow jack to
descend to
lowered
position
Will not lift load
Will not hold load
Will not lift to full height
Pump feels "spongy" under load
Handle raises under load
Handle lowers under load
TROUBLESHOOTING
Your PerformanceTool® product was constructed with quality materials and workmanship
and will give you many years of trouble free use when cared for as described in the "Care
& Maintenance" section on page 4. However, as with any mechanical device, periodic
adjustments are necessary to maintain a peak level of performance. Should your jack be
displaying any of the following symptoms, the simple procedures shown below will correct
the problem.

6
REPLACEMENT PARTS LIST
# Description Qty. # Description Qty. # Description Qty.
39 Return Spring *1 54 Front Wheel Spindle 1 69 Snap Ring 2
40 Lock Washer 4 55 Body Spindle 1 70 Pump Handle *1
41 Nut 6 58 Left Side Member 1 72 Cover Plate 1
44 Caster Wheel Assy. *2 60 Radius Link 2 73 Support Bar 1
47 Right Side Member 1 61 Retaining Ring 2
48 Flat Washer 2 62 Lifting Arm 1
49 Lock Washer 2 63 Cross Head Pin 1
50 Nut 2 64 C 19 Retaining Ring 1
51 Front Wheel Spacer 2 65 Lifting Arm Spindle 1
52 Front Wheel 2 67 Saddle Assembly 1
53 Flat Washer 2 68 Radius Link Pin 1
Replacement Parts
W1605CK Ram Repair Kit
W1605-39 Return Spring
W1605-44 Caster Assembly
W1605-70 Pump Handle
* Notes the replacement parts
Figure 5

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REPLACEMENT PARTS LIST - RAM ASSEMBLY
# Description Qty. # Description Qty. # Description Qty.
1 Hydraulic Unit Body 1 13 Fiber Washer (A) 1 27 Connecting Pin 1
2 3/16” Steel Ball 2 14 Top Nut 1 28 Retaining Pin 2
3 Filter Body Screen 1 15 Top Nut O-Ring 1 30 5/16” Steel Ball 1
4 Copper Washer 1 16 1/4” Steel Ball 1 31 Release Valve Spacer 1
5 Pump Cylinder O-Ring 1 17 Pump Cylinder 1 32 Release Valve O-Ring 1
7 Ram Collar 1 19 Pump Cylinder O-Ring 1 33 Release Valve 1
8 Ram 1 20 Back Up Ring 1 34 Spring Guide 1
9 Cylinder 1 21 Pump Piston 1 35 Overload Valve Spring 1
10 Fiber Washer (B) 1 22 Piston Clamp 1 36 O-Ring 1
11 Oil Chamber 1 24 Handle Sleeve 1 37 Adjusting Screw 1
12 Oil Fill Plug 1 26 Piston Pin 1 38 Cap 1
Figure 6

LIMITED WARRANTY
PERFORMANCE TOOL® extends only the following warranties, and only to original retail purchasers. These warranties
give specific legal rights. Except where prohibited by local law, the law of the State of Washington governs all
warranties and all exclusions and limitations of warranties and remedies. There may be other rights which vary from
state to state.
PERFORMANCE TOOL® warrants the product to be free from defects in materials and workmanship under normal
use and service. A defective product may be returned for a free replacement within 90 days from the date of purchase,
provided that product is returned to place of purchase immediately after discovery of defect. After 90 days and up to
one year from date of purchase, PERFORMANCE TOOL® will replace at no charge any parts which our examination
shall disclose to be defective and under warranty. These warranties shall be valid only when a sales receipt showing
the date of purchase accompanies the defective product or defective part (s) being returned.
These warranties exclude blades, bits, punches, dies, bulbs, fuses, hoses, and other consumables which must be
replaced under normal use and service. These warranties shall not apply to any product or part which is used for a
purpose for which it is not designed, or which has been repaired or altered in any way so as to affect adversely its
performance or reliability, nor shall these warranties apply to any product or part which has been subject to misuse,
neglect, accident or wear and tear incident to normal use and service.
PERFORMANCE TOOL® does not authorize any other person to make any warranty or to assume any liability in
connection with its products.
Except for warranties of title and the limited express warranties set forth above, PERFORMANCE TOOL® makes no
express or implied warranties of any kind with respect to its products. In particular, PERFORMANCE TOOL® makes no
implied warranty of merchantability and no implied warranty of fitness for any particular purpose, except that for goods
purchased primarily for personal, family or household use and not for commercial or business use, PERFORMANCE
TOOL® makes an implied warranty of merchantability (and, if otherwise applicable, an implied warranty of fitness for a
particular purpose), but only for the particular qualities or characteristics, and for the duration, expressly warranted
above.
The laws on limitation of implied warranties may differ from state to state, so the above limitations may not apply in all
cases.
PERFORMANCE TOOL® shall not be liable for consequential, incidental or special damages resulting from or in any
manner related to any product, or to the design, use, or any inability to use the product. The sole and exclusive
remedy for a defective product or part shall be the repair, or replacement thereof as provided above. The laws on
limitation of remedies or on consequential, incidental or special damages may vary from state to state, so the above
limitations may not apply in all cases.
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