Performance Tool W1651 User manual

10 TON HYDRAULIC RAM SYSTEM
OWNER’S MANUAL
Item Number W1651
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 product.
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 product shall be inspected per the operating instructions.
Users of this product must fully understand these instructions. Each person operating this product
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!
If you encounter any problems or difficulties, please contact our customer service department at:
1-800-426-1262 between 6:30 a.m. and 4:30 p.m. Pacific time.

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Capacity: ............................... 10 Ton (20,000 lbs.), 5 Ton (10,000 lbs.) with extensions
Ram Travel: .................................................................................................................. 6 in.
Extension Pole Length:............................................................................... 5 ft. Maximum
Spreader Wedge Capacity:.................................... 1/2 Ton, 3 3/4 in. Maximum Opening
Hose Length:................................................................................................................. 6 ft.
SAFETY GUIDELINES / DEFINITIONS
UNPACKING AND INSPECTION
SPECIFICATIONS
IMPORTANT SAFETY INFORMATION
Specifications are subject to change without notice
WARNING
READ, UNDERSTAND AND FOLLOW ALL INSTRUCTIONS AND WARNINGS BEFORE
OPERATING THIS TOOL. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY AND/OR
PROPERTY DAMAGE AND WILL VOID WARRANTY.
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. If any parts are missing, please call customer service at 1-800-426-1262
between 6:30 a.m. and 4:30 p.m. Pacific time.
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. If you have any
questions, or require assistance with damaged or missing parts, please contact our factory customer service
department at: 1-800-426-1262.
Please have the serial number, model number, and date of purchase available for reference when calling.
WARNING: Read and understand this entire instruction manual before attempting to assemble,
install, operate or maintain this product. Failure to comply 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:
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.

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2
3
1
IMPORTANT SAFETY INFORMATION
1. Study, understand, and follow all instructions
before operating this device.
2. DO NOT exceed rated capacity. Overloading
can cause damage to or failure of this tool.
3.Useonlyaccessoriesthatareidentiedbythe
manufacturerforthespecictoolmodel.Use
of an accessory not intended for use with the
specictoolmodel,increasestheriskofinjury
and/or property damage.
4. Wear ANSI approved safety goggles and
heavy duty work gloves during use.
5. Avoid off center loads. If the Pump (1) 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.
6. Protect the Hose. Do not drop heavy objects
on the Hose (P16). Avoid sharp kinks in the
Hose. Maintain proper clearance to avoid
damage to the Hose and Couplers.
7. Do not alter this product in any way.
8. Keep your work area clean and well lit. Clut-
tered work areas invite accidents.
9. Keep bystanders, children and visitors away
while operating this product. Distractions can
cause you to lose control.
10. 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inuenceofdrugs,alcoholor
medication. A moment of inattention while
operating may result in serious personal
injury.
11. Store tools/equipment out of reach of
children and other untrained persons. Tools
and equipment are dangerous in the hands
of untrained users.
12. Tool/equipment service must be performed
onlybyqualiedrepairpersonnel.Service
ormaintenanceperformedbyunqualied
personnel could result in a risk of injury.
13. When servicing this product, use only identi-
cal replacement parts - refer to attached,
product-specicpartslistanddiagram.Fol-
low instructions in the Care & Maintenance
section of this manual. Use of unauthorized
parts or failure to follow maintenance instruc-
tions may create a risk of injury and may void
any applicable warranty.
14. Maintain labels and nameplates on this
product. These carry important information. If
unreadable or missing, contact Performance
Tool® for a replacement.
15. Industrial applications must follow OSHA
requirements.
16. 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 con-
tain a chemical known to the State of California
to cause cancer, birth defects, or other reproduc-
tive harm.
PACKAGING CONTENTS

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Ram Attachments:
1. The Extensions (5-8) connect in different
combinations to reach desired lengths.
2. The Male Connector (14) is used to con-
nect the female end of the Ram (3) to a
Base.
3. The Flat Base (9) is typically used on the
stationary side to spread out the force of
the Ram (3).
4. The V-Base (13) is used to offset the
force of the Ram (3) when there is not a
straight line between the stationary side
and the damaged side, or to spread out
force on curved surfaces.
SETUP INSTRUCTIONS
PACKAGING CONTENTS
1 Pump 1
2 Spreader Wedge 1
3 Ram 1
4 Case 1
5 4 1/4 in. Extension 1
6 10 in. Extension 1
7 14 1/2 in. Extension 1
8 20 1/2 in. Extension 1
9 Flat Base 1
10 Ram Toe 1
11 Plunger toe 1
12 Wedge head 1
13 V-base 1
14 Male Connector 1
15 Cap Head 1
16 Rubber head 1
# Description Quantity # Description Quantity
45
6
7
10 12 13
8
9
14 15
16
11
5. The Cap Head (15) is typically used on
the pushing end to prevent slipping.
6. The Rubber Head (16) is typically used
for popping dents out of sheet metal such
as doors or body panels and to minimize
damage to the work surface.
7. The Wedge Head (12) is used to repair
small dents and areas located in angles
and tight spaces.
8. The Ram Toe (10) and Plunger Toe (11)
are used together to allow spreading in
areasthattheRamcannottinto.

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Ram Setup:
Note: When positioning the Ram (3) use a
smaller attachment on the side that
is to be bent instead of the stationary
side. If the stationary side is in dan-
ger of being bent or damaged, place
a block of wood or other material
behind the Flat Base (9) to distribute
pressure over a greater area.
1. Clean the end of the Hose and the inlet
on the Ram (3). Unscrew and save the
End Plugs located on the end of the hose
and Ram (3).
2. Attach the Hose to the Ram.
3. Assemble attachments as shown in
gure1and2.
Note: If using the Plunger Toe and Ram
Toe, thread the Ram Toe onto the
Ram completely and align the
Plunger Toe to it.
Spreader Wedge Setup:
The Spreader Wedge (2) is used when the
Ram(3)istoolongtotbetweenthestation-
ary side and the damaged area.
1. Clean the end of the hose and the inlet on
the Spreader Wedge (2).
2. Unscrew and save the End Plugs located
on the end of the hose and Spreader
Wedge (2).
3. Attach the Hose to the Spreader Wedge
(2),asshowningure3.
SETUP INSTRUCTIONS
Note: The Flange Base and Flange Head must only be used together to prevent an off
center load.
Note: When positioning the Ram (3) 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 (9) to
distribute pressure over a greater area.
Fig. 1
Fig. 2
Fig. 3
Ram (3)
Ram (3)
Spreader
Wedge (2)
Male
Connector (14)
Extension Bars (5-8)
as needed
Extension Bars (5-8)
as needed
Pump (1)
V-base (13) or
Flat Base (9)
Cap Head (15)
Rubber Head (16)
or Wedge Head (12)
Plunger
Toe (11)
Ram
Toe (10)

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1. Check the Hydraulic Fluid Level, following
the instructions in the Bleeding the pump
section, if needed.
2. Determine which direction the frame
needs to be bent.
3. Remove any obstructions that could be
damaged or are in the way.
Note: When using the Pump (1) in a verti-
cal position, keep the Hose (3) end
of the Pump downward.
4A. Using Ram (2):
a. Connect the appropriate Base
(13,15,17) to the stationary side of
the Ram (2), and connect the ap-
propriate head to the pushing end of
the Ram.
GENERAL OPERATION
NOTICE During shipment or handling, air in the pump can become trapped in the
hydraulic system causing the pump to malfunction.
BEFORE USE
Bleeding The Pump:
1. SetPump(1)atonalevelsurface.
2. Remove the Fill Screw (A). The O-ring (B) should come off with it.
3. Theuidlevelshouldbenearthebottomoftheopening.Ifrequired,addhighgrade
hydraulicuid.
4. Make sure the O-ring (B) is still in place around the Fill Screw (A) and thread the Fill
Screw into the Pump securely. Do not use thread seal tape.
5. Firmly close the Release Valve (C) by turning it clockwise.
6. Press the tip of the Coupling (D) against a hard surface and pump the pump handle.
7. Continuepumping,untilthehydraulicuidcomingouttheendofthecouplertipisfree
of air bubbles.
8. Rechecktheuidlevelandadduidif
necessary.
9. Turn the Release Valve counterclock-
wise to release the pressure in the pump
and hose.
10.Changethehydraulicuidyearly.
Remove the Fill Screw (A) and tilt the
Pump(1)todrainouttheolduid.Rell
thehydraulicuidandbleedthesystem
several times to ensure all air is out of
the system.
A
B
C
D
Fig. 4
WARNING: Read and understand all the previous sections before use of this product. Failure to
comply with those sections may result in serious personal injury and/or property damage!
Note: When repairing larger body panel
dents such as a dented door, fender
or quarter-panel use the Rubber
Head (11) on the pushing end.
b. If using the Flange Base (15) or
Flange Head (14): 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.
c. Position the Ram (2) so that the 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

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1. Before each use, inspect the general
condition of the product. Check for
broken, cracked, or bent parts, loose or
missing parts, and any condition that
may affect the proper operation of the
product. Any equipment that appears
damaged in anyway must be removed
from service. Have the problem cor-
rected before further use. DO NOT use
damaged equipment.
2. Replace worn or damaged parts with
Performance Tool® replacement parts.
Besurethatonlyqualiedperson-
nel perform repairs. DO NOT attempt
to weld, rivet or otherwise repair this
device.
CARE & MAINTENANCE
Monthly maintenance is recommended. Lubrication is critical to the ram and
pump 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 com-
ponents. The following steps are designed to keep the pump and ram maintained
and operational.
GENERAL OPERATION
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.
d. Aim the pushing end towards the
area that needs to be repaired,
and slowly apply pressure with
the Pump (1).
Note: To prevent damage, do not overex-
tend the Ram.
4B. Using Spreader Wedge (10):
a. Place the Spreader Wedge (10) so
that the hinged (pushing) arm is rest-
ing against the part to be moved and
the stationary arm is resting against a
non-movable base.
b. Carefully hold the Spreader Wedge
in position and apply the Pump (1)
pressure.
5. Once both ends have made contact, 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.
6. When the damaged area has been bent to
the desired position, slowly turn the Release
Valve (10C) counterclockwise to release the
hydraulic pressure and remove the Ram (2)
or Spreader Wedge (10).
7. Clean all hydraulic ports and cover them
with clean End Plugs to prevent contamina-
tion and damage.
3. Before each use, thoroughly test the
equipment for proper operation prior to
its actual use. If the equipment appears
not to be working properly, follow bleed-
ing instructions on page 6.
4. When the product is not in use, ram and
pump piston should be in fully down
position to keep their machined surfaces
free from corrosion.
5. Keep the surface of this equipment and
itsaccessoriesfreeofhydraulicuid
and grease. Use only a mild detergent
and damp cloth when cleaning. Do not
useaammableorcombustiblesolvent
to clean this tool or its accessories.

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6. For best results, use only hydraulic
uidwitharatingofSAE20forrells.
Checkuidlevelwithpumpinfullydown
position.
7. Change the hydraulic oil at least once
every three years:
a.SetPump(1)atonalevelsurface.
b. Remove the Fill Screw (A). The O-
ring (B) should come off with it.
c. Tip the pump to allow the old hy-
draulic oil to drain out of the housing
completely, and dispose of the old
hydraulic oil in accordance with local
regulations.
d. With the Pump upright, completely
llthehousingwithahighquality
hydraulic oil (not included) until the
oil just begins to run out of the oil
llhole.BeVERYCAREFULnotto
allow dirt or foreign matter into the
system.
CARE & MAINTENANCE
A
B
C
D
Fig. 5
e. Make sure the O-ring (B) is still in
place around the Fill Screw (A) and
thread the Fill Screw into the Pump
securely. Do not use thread seal
tape.
f. Firmly close the Release Valve (C) by
turning it clockwise.
g. Clean with a clean cloth using a
detergent or mild solvent.

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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 repeated for best results.
TROUBLESHOOTING
This Performance Tool® 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 7-8. However, as with any mechanical device, periodic
adjustments are necessary to maintain a peak level of performance. Should this product
be displaying any of the following symptoms, the simple procedures shown below will
correct the problem.
WARNING: Remove all equipment from service before making adjustments
●●●
●
● ●
● ●
●
●
Power unit may
be low in fluid.
With pump 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 pump in
fully lowered
position,
manually raise
lifting arm as
high as
possible.
c.) Open release
valve and
allow pump 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

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REPLACEMENT PARTS LIST
P01 Valve Block 1
P02 Oil Filter 1
P03 O-ring 1
P04 Reservoir 1
P05 Tie Rod 1
P06 Nylon Ring 1
P07 Fill Plug 1
P08 Sealing Ring 1
P09 Air Valve 1
P10 Screw 1
P11 O-ring 1
P12 Pump Leg 1
P13 Ball 2
P14 O-ring 1
P15 Release Valve 1
P16 Hydraulic Hose 1
P17 Coupler 1
P18 Dust Proof Cover 1
P19 Ball 1
P20 Ball Cup 1
P21 Spring 1
P22 Safety Valve screw 1
P23 O-ring 2
P24 Screw 1
P25 Plastic Cup 1
P26 Screw 1
P27 Nylon Ring 1
P28 Sealing Ring 1
P29 O-Ring 1
P30 Nylon Ring 1
P31 Screw 1
P32 O-Ring 1
P33 Nylon Ring 1
P34 Piston 1
P35 Pin 1
P36 Circlip 2
P37 Pin 1
P38 Handle Bracket 1
P39 Handle 1
P40 Handle Sleeve 1
P41 Screw 1
P42 Valve Base 1
P43 Spring 1
P44 Ball 1
P45 Nylon Washer 1
# Description Qty # Description Qty
PUMP