PT W1650 User manual

1 YEAR 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. For
part (s) after 90 days, please remit your request, postage prepaid to:
PERFORMANCE TOOL, P.O. Box 88259 Tukwila, WA 98138
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.
© Copyright 2021 WILMAR CORPORATION, P.O. Box 88259 Tukwila, WA 98138

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.
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.
OWNER'S MANUAL
4 TON
HYDRAULIC RAM SYSTEM
Item Number W1650

2
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.
SAFETY GUIDELINES / DEFINITIONS

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.
NOTE: Indicates important information, which if not
followed, MAY cause damage to equipment.
UNPACKING AND INSPECTION
After opening the carton, unpack your new product and related parts and 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 a.m. and 5 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 customer service department at 1-800-426-1262. Please have the serial number, model
number, and date of purchase available for reference when calling.
Capacity:............... 4 Ton (8,000 lbs.), 2 Ton (4,000 lbs.) with extensions
Ram Travel: ....................................................................................... 5 in.
Extension Pole Length:...................................... 5 ft. 10-1/2 in. Maximum
Spreader Wedge Capacity: ............ 1/2 Ton, 3-3/4 in. Maximum Opening
Hose Length: ....................................................................................... 6 ft.
SPECIFICATIONS:
Specifications are subject to change without notice.
PACKAGING CONTENTS
23
1

11

10

3
45
6
7
10 12 13
8
9
14 15 16 11
PACKAGING CONTENTS
1 Pump .................................. 1
2 Spreader Wedge ................. 1
3 Ram..................................... 1
4 Case.................................... 1
5 3-3/4 in. Extension.............. 1
6 5 in. Extension .................... 1
7 8-1/2 in. Extension.............. 1
8 16-1/2 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
No. Description Qty. No. Description Qty.
RAM ATTACHMENTS:
1. The Extensions (5-8) connect in different combinations to reach desired lengths.
2. The Male Connector (14) is used to connect the female end of the Ram (3) to a
base (9 or 13).
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.
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.
SETUP INSTRUCTIONS

4
SETUP INSTRUCTIONS
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 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.
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 (11) and
Ram Toe (10), 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 stationary 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.
8. The Ram Toe (10) and Plunger Toe (11) are used together to allow spreading
in areas that the Ram cannot t into.
Note: The Ram Toe (10) and Plunger Toe (11) 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)

9
SPREADER WEDGE EXPANDED PARTS LIST
1 Pin....................................... 1
2 Circlip.................................. 1
3 Moveable Jaw..................... 1
4 Spring ................................. 1
5 Fixed Jaw............................ 1
6 Piston.................................. 1
7 Cup Seal ............................. 1
8 O-ring................................. 1
9 End Cap ............................. 1
10 Coupling Ring .................... 1
11 Coupling Bolt ..................... 1
12 O-ring................................. 1
13 Dust Cap............................ 1
No. Description Qty. No. Description Qty.
RAM EXPANDED PARTS LIST
1 Cover ..................................1
2 Circlip..................................1
3 Piston Rod ..........................1
4 Circlip..................................1
5 Bushing...............................1
6 Nylon Ring ..........................1
7 Sealing Ring........................1
8 Circlip..................................1
9 Nut ......................................1
10 Spring .................................1
11 Screw..................................1
12 Protection Cup....................1
13 Ring.....................................1
14 Cylinder...............................1
15 Screw..................................1
16 Coupling Ring .....................1
17 Coupling Ring .....................1
18 O-ring..................................1
19 Dust Cap.............................1
No. Description Qty.

8
24
25
23
26
27
22
21
37
38
36
37
39
34
35
20
18
17
16
15
14
13
12
11
10
32
31
30
29
28
10
19
9
33
8
4
7
6
25
5
4
3
2
1
PUMP EXPANDED PARTS LIST
1 Screw.................................. 1
2 O-ring.................................. 1
3 Cap ..................................... 1
4 O-ring.................................. 2
5 Pull Rod .............................. 1
6 Oil Tank ............................... 1
7 Screw.................................. 1
8 Filter ................................... 1
9 Pump ................................. 1
10 Steel Ball............................ 3
11 Steel Ball............................ 1
12 Spring ................................ 1
13 Washer............................... 2
14 Screw................................. 1
15 Copper Washer.................. 1
16 Piston Seat......................... 1
17 Dust Cap............................ 1
18 U-ring................................. 1
19 Screw................................. 1
20 Piston................................. 1
21 Steel Ball............................ 1
22 Steel Ball Seat.................... 1
23 Spring ................................ 2
24 Screw................................. 1
25 O-ring................................. 2
26 Screw................................. 1
27 Cap Nut.............................. 1
28 O-ring................................. 1
29 Release Valve..................... 1
30 Oil Hose ............................. 1
31 Connector .......................... 1
32 Dust Cap............................ 1
33 Steel................................... 1
34 Handle................................ 1
35 Handle Sleeve.................... 1
36 Pin...................................... 1
37 Retainer Ring ..................... 2
38 Pin...................................... 1
39 Connector .......................... 1
No. Description Qty. No. Description Qty.

5
GENERAL OPERATION
BEFORE USE
1. Check the hydraulic uid 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
vertical position, keep the hose end of
the Pump (3) downward.
4A. Using Ram:
a. Connect the appropriate Base
(9 or 13) to the stationary side
of the Ram (3), and connect the
appropriate head to the pushing end
of the Ram.
WARNING: Read and understand all the previous sections before use of this
product. Failure to comply with those sections may result in serious personal inju-
ry and/or property damage!
NOTE: When repairing larger body
panel dents such as a dented door,
fender or quarter-panel use the Rubber
Head (16) on the pushing end.
b. If using the Ram Toe (10) or Plunger
Toe (11): Thread the Ram Toe onto
the Ram completely and align the
Plunger Toe to it. The Ram Toe
and Plunger Toe must only be used
together to prevent off-center load.
Operation continued on page 6...
NOTE: During shipment or handling, air in the pump can become trapped in the
hydraulic system causing the pump to malfunction.
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.
A
B
C
D
Fig. 4
8. Recheck the uid level and add
uid if necessary.
9. Turn the Release Valve counter-
clockwise 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.

6
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 components. The following steps are designed to keep the pump and
ram maintained and operational.
c. Position the Ram (3) 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 must be stronger than the
area to be bent or it may be dam-
aged. 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
overextend the Ram.
4B. Using Spreader Wedge:
a. Place the Spreader Wedge (2) so
that the hinged (pushing) arm is
resting against the part to be moved
and the stationary arm is resting
against a non-movable base.
GENERAL OPERATION
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 (C)
counterclockwise to release the
hydraulic pressure and remove the
Ram (3) or Spreader Wedge (2).
7. Clean all hydraulic ports and cover
them with clean end plugs to prevent
contamination and damage.
CARE & MAINTENANCE
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 corrected 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 personnel perform
repairs. DO NOT attempt to weld,
rivet or otherwise repair this device.
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 bleeding
instructions on page 5.
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.
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
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
hydraulic 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
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 6-7. 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.
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
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
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.