Central Hydraulics 7 Piece Porta Power Ram Kit 94681 Users Manual

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7 PIECE

PORTA-POWER RAM KIT

94681

ASSEMBLY AND OPERATION INSTRUCTIONS

Due to continuing improvements, actual product may differ slightly from the product described herein.

®

3491 Mission Oaks Blvd., Camarillo, CA 93011

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

TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND

ALL WARNINGS AND INSTRUCTIONS BEFORE USE.

Copyright© 2006 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 or replacement parts, please call 1-800-444-3353.

Page 2SKU 94681 For technical questions, please call 1-800-444-3353.

PRODUCT SPECIFICATIONS

2-Ton Hydraulic Push Ram (With Saddle) Height: 5.5” (Min.) / 9.5” (Max.)

Operating PSI: 5700 / Maximum Capacity: 4400 lb.

1-5/8” Diameter

4-Ton Hydraulic Push Ram Height: 1.6” (Min.) / 2.2” (Max.)

Operating PSI: 5700 / Maximum Capacity: 8800 lb.

2” Diameter

4-Ton Hydraulic Push Ram (With Spring) Height: 10.8” (Min.) / 16” (Max.)

Operating PSI: 8000 / Maximum Capacity: 8800 lb.

1-5/8” Diameter

10-Ton Hydraulic Push Ram

(With Saddle & Spring)

Height: 5.2” (Min.) / 7.5” (Max.)

Operating PSI: 8800 / Maximum Capacity: 22000 lb.

2-3/16” Diameter

10-Ton Hydraulic Push Ram (With Spring) Height: 13.7” (Min.) / 19.6” (Max.)

Operating PSI: 8800 / Maximum Capacity: 22000 lb.

2-1/8” Diameter

2-Ton Hydraulic Pull Ram (With Spring) Height: 16.6” (Min.) / 21.6” (Max.)

Operating PSI: 7800 / Maximum Capacity: 4400 lb.

1-1/2” Diameter

5-Ton Hydraulic Pull Ram (With Spring) Height: 20.4” (Min.) / 25.5” (Max.)

Operating PSI: 8800 / Maximum Capacity: 11000 lb.

2-3/8” Diameter

Accessories 2-Ton Pull Hooks (1 Set) / 5-Ton Pull Hooks (1 Set) / Metal Carrying Case

Unit Weight 40 Pounds

This equipment requires the addition of a Hydraulic Pump (such as Harbor Freight Sku 40611), hydraulic hoses, and hydraulic

fittings to operate properly. None of this equipment is provided, and all of it must be properly rated for use with this kit.

SAVE THIS MANUAL

You will need this manual for the safety warnings and precautions, assembly, oper-

ating, inspection, maintenance and cleaning procedures, parts list and assembly diagram.

Keep your invoice with this manual. Write the invoice number on the inside of the front

cover. Keep this manual and invoice in a safe and dry place for future reference.

UNPACKING

When unpacking, check to make sure all the parts shown in the Parts Lists on

pages 8 through 14 are included. If any parts are missing or broken, please call Harbor

Freight Tools at the number shown on the front cover of this manual as soon as possible.

GENERAL SAFETY RULES

WARNING!

READ AND UNDERSTAND ALL INSTRUCTIONS

Failure to follow all instructions listed below may result in

electric shock, fire, and/or serious injury.

SAVE THESE INSTRUCTIONS

Page 3SKU 94681 For technical questions, please call 1-800-444-3353.

WORK AREA

Keep your work area clean and well lit. Cluttered and dark work areas invite

accidents.

Keep bystanders, children, and visitors away while using this product. Dis-

tractions can cause you to lose control.

PERSONAL SAFETY

Stay alert. Watch what you are doing, and use common sense during use. Do not

use this product while tired or under the influence of drugs, alcohol, or medication.

A moment of inattention while operating power tools may result in serious personal

injury.

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.

Do not overreach. Keep proper footing and balance at all times. Proper footing

and balance enables better control in unexpected situations.

Always wear eye and hand protection. Wear ANSI-approved safety

impact goggles, non-skid safety shoes, and heavy duty work gloves when

using this product.

TOOL USE AND CARE

Store idle tools and equipment out of reach of children and other untrained

people. Tools and equipment are dangerous in the hands of untrained users.

Maintain this product with care. Keep this product clean. A properly maintained

tool is easier to control. Do not use damaged tools and equipment. Tag damaged

tools and equipment “Do not use” until repaired.

Check for misalignment or binding of moving parts, loose or broken parts, and

any other condition that may affect this product’s operation. If damaged, have

the tool serviced before using. Many accidents are caused by poorly maintained

tools and equipment.

Use only accessories that are recommended by the manufacturer for your

model. Accessories that may be suitable for one product may become hazardous

when used on another product.

SERVICE

Tool service must be performed only by qualified service technician. Service

or maintenance performed by unqualified personnel could result in a risk of injury.

1.

2.

1.

2.

3.

4.

1.

2.

3.

4.

1.

Page 4SKU 94681 For technical questions, please call 1-800-444-3353.

When servicing this product, use only identical replacement parts. Follow

instructions in the “Inspection, Maintenance, And Cleaning” section 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

WARNING! Do not exceed the maximum PSI capacity of each Hydraulic Ram in

this Kit. Also, do not operate a Ram beyond its maximum range of travel. Exceeding

the maximum PSI and travel capacity of a Ram can cause personal injury and/or

property damage.

IMPORTANT! Refer to the “Product Specifications” Table on page 2 of this

manual to determine the maximum PSI and range of travel for each Hydraulic Ram

included in this Kit.

Prior to using the Auto Body/Frame Repair Kit, make sure to read

and understand all instructions and safety precautions as outlined

in the auto manufacturer’s manual. Make sure the Auto Body/Frame

Repair Kit is fully compatible with each specific vehicle. It is beyond the

scope of this manual to discuss body/frame repair guidelines, and instead is the

responsibility of the product user to consult a body/frame repair technical manual

for full instructions.

Maintain labels and nameplates on the Auto Body/Frame Repair Kit. These

carry important information. If unreadable or missing, contact Harbor Freight Tools

for a replacement.

Use the right product for the job. There are certain applications for which this

product was designed. Do not use this product for a purpose for which it was not

intended. Never use this item to raise or move a vehicle.

Stay clear of an Hydraulic Ram when using the tool. Position your body as far

away from the Ram as is practical when the Ram is under a load. It is possible

for a Ram to slip under a load, possibly resulting in serious injury and/or property

damage.

Industrial applications must follow OSHA requirements.

Before working on a vehicle, always set the parking brake and block the tires.

Never attempt a repair while the engine is running or the vehicle is moving.

Avoid off-center loads. If the Hydraulic Pump (not included) unit seems unusu-

ally hard to pump, immediately stop the operation. Adjust the Hydraulic Ram unit

to eliminate or diminish an off-center load.

2.

1.

2.

3.

4.

5.

6.

7.

8.

Page 5SKU 94681 For technical questions, please call 1-800-444-3353.

Keep the Hose Couplers protected when the Hydraulic Rams are not in use.

Dust Caps are included for all Hose Couplers and should be screwed in when not

in use to keep the internal mechanisms of the Rams clean.

WARNING! Prior to using the Auto Body/Frame Repair Kit, make sure to read

and understand all instructions and safety precautions as outlined in the Hydraulic

Pump (not included) manufacturer’s manual.

The results you achieve with these tools will depend upon your skills and ex-

perience at using tools of this type. Harbor Freight Tools is not responsible

for damage to vehicles caused by misuse of these tools.

WARNING! This product will exert thousands of pounds of force when in use

and can be dangerous. Use extreme caution when using this product.

Use compressed hydraulic fluid only. Do not use any other power source or fluid

to operate this product.

WARNING! The warnings and cautions 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.

SAVE THESE INSTRUCTIONS

9.

10.

11.

12.

13.

14.

TOOLS AND ACCESSORIES

CARRYING CASE

5-TON PULL RAM WITH SPRING

4-TON PUSH RAM

2-TON PULL RAM WITH SPRING

10-TON PUSH RAM

WITH SADDLE & SPRING

FIGURE A 2-TON

HOOKS

5-TON

HOOKS

4-TON PUSH RAM

WITH SPRING

2-TON PUSH RAM

WITH SADDLE

10-TON PUSH RAM

WITH SPRING

Page 6SKU 94681 For technical questions, please call 1-800-444-3353.

ASSEMBLY INSTRUCTIONS

Refer to instructions provided with pump, hoses, and fittings for proper hydraulic

line purging, preparation, and connection procedures.

OPERATING INSTRUCTIONS

WARNING! Before starting work, read and thoroughly understand all warnings and pre-

cautions in this manual and all documentation provided with the hydraulic pump

and hoses used.

Product Overview:

The Auto Body/Frame Repair Kit is designed for bending frames and repairing

dents in vehicle body panels. In most cases, the Push and Pull Hydraulic Rams in

this Kit will only be capable of returning vehicle body and frame parts to their ap-

proximate, original position. Additional work may be required to completely repair

the vehicle part.

The Hydraulic Push Rams:

Included in this Kit are five Hydraulic Push Rams. The larger Push Rams are used

in larger spaces where greater force is needed and where there is sufficient room

to operate. The smaller Push Rams are used in tighter spaces where less force is

required. (See Figure B.)

The Push Rams require a solid, non-movable base directly across from the dam-

aged area and in line with the direction the damaged area needs to be bent. When

positioning the Push Ram, place a block of wood or other material behind the base

of the Push Ram and on the side that is to be bent for protection and to spread the

Push Ram pressure over a greater area. (See Figure B.)

CONNECT TO HYDRAULIC PUMP HOSE

(NOT INCLUDED)

HERE

NON-MOVABLE

AREA

DAMAGED

AREA

WOOD

BLOCK

WOOD

BLOCK

FIGURE B

HYDRAULIC PUSH RAM

The Hydraulic Pull Rams:

Included in this Kit are two Hydraulic Pull Rams. The larger Pull Ram is used in

larger spaces where greater force is needed and where there is sufficient room to

operate. The smaller Pull Ram is used in tighter spaces where less force is required.

(See Figure C, next page.)

1.

2.

1.

Page 7SKU 94681 For technical questions, please call 1-800-444-3353.

INSPECTION, MAINTENANCE, AND CLEANING

Before each use, inspect the general condition of the Auto Body/Frame Repair

Kit. Check for bent, cracked, worn or damaged parts, loose or missing parts, and

any other condition that may affect the Kit’s safe operation. If a problem occurs,

have the problem corrected before further use.

Do not use damaged equipment.

To clean, use a damp cloth and a mild detergent or mild solvent. Do not use

flammable or corrosive agents.

When storing, keep the Auto Body/Frame Repair Kit in its Carrying Case and

in a clean, dry, safe location out of reach of children and other unauthorized

people.

CAUTION! All maintenance, service, and repairs not discussed in this manual

should only be performed by a qualified service technician.

1.

2.

3.

4.

TROUBLESHOOTING

Problem Possible Cause Possible Solution

Hydraulic Ram will not push or

pull the load.

Release Valve on Hydraulic Pump (not

included) not tightly closed.

Overload condition.

Air trapped in Hydraulic Pump system.

Hydraulic Pump oil level low.

Loose connection from Hydraulic Pump to

Hydraulic Ram.

1.

2.

3.

4.

5.

Close Release Valve tightly.

Do not exceed maximum PSI or range of

travel for Hydraulic Ram.

Purge air from Hydraulic Pump system.

Add oil to proper level.

Make sure connection from Hydraulic

Pump to Hydraulic Ram is secure.

1.

2.

3.

4.

5.

Hydraulic Ram will push or pull,

but will not maintain pressure.

Release Valve on Hydraulic Pump (not

included) not tightly closed.

Overload condition.

Hydraulic Pump or Hydraulic Ram mal-

function.

1.

2.

3.

Close Release Valve tightly.

Do not exceed maximum PSI or range of

travel for Hydraulic Ram.

Have a qualified service technician check

out the Hydraulic Pump and/or Hydraulic

Ram.

1.

2.

3.

The Hydraulic Pull Rams may be used in either horizontal or vertical positions.

The Hooks will turn to accept hooking from different angles. Hook one end of the

Pull Ram to the object to be moved and the other end of the Pull Ram to a stable,

unmovable base. A chain or strap may be used on either end to provide a hooking

surface. Make sure the chain or strap is rated to support the pulling weight.

(See Figure C.)

HOOK

TO CHAIN

OR STRAP

CONNECT TO HYDRAULIC PUMP HOSE

(NOT INCLUDED)

HERE

HOOK

TO CHAIN

OR STRAP

FIGURE C

HYDRAULIC PULL RAM

2.

Page 8SKU 94681 For technical questions, please call 1-800-444-3353.

PARTS LIST A - ASSEMBLY DIAGRAM A

(2-TON HYDRAULIC PUSH RAM WITH SADDLE)

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

1A

2A

3A

4A

5A

6A

7A

8A

9A

10A

11A

13A

12A

14A

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 OR WARRANTY OF ANY KIND TO THE BUYER THAT

HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFAC-

TURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS

SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER.

THE BUYER ASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE

ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER IN-

STALLATION OF REPLACEMENT PARTS THERETO.

Part Description Qty.

1A Nut 1

2A Seal Ring 1

3A O-Ring 1

4A Ram 1

5A O-Ring 1

Part Description Qty.

6A Cylinder 1

7A Spindle Screw 1

8A Spring 1

9A Spindle 1

10A Oil Ring 1

Part Description Qty.

11A Connection Nut 1

12A Hose Coupler 1

13A O-ring 1

14A Dust Cap 1

Page 9SKU 94681 For technical questions, please call 1-800-444-3353.

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

PARTS LIST B - ASSEMBLY DIAGRAM B

(4-TON HYDRAULIC PUSH RAM)

1B

2B

3B

4B

5B

6B

7B

8B

9B

10B

11B

12B

13B

14B

Part Description Qty.

1B Nut 1

2B Seal Ring 1

3B O-ring 1

4B Ram 1

5B O-ring 1

Part Description Qty.

6B Cylinder 1

7B Spindle Screw 1

8B Spring 1

9B Spindle 1

10B Oil Ring 1

Part Description Qty.

11B Connection Nut 1

12B Hose Coupler 1

13B O-ring 1

14B Dust Cap 1

Page 10SKU 94681 For technical questions, please call 1-800-444-3353.

PARTS LIST C - ASSEMBLY DIAGRAM C

(4-TON HYDRAULIC PUSH RAM WITH SPRING)

1C

2C

3C

4C

5C

6C

7C

8C

9C

10C

11C

12C

13C

14C

15C

16C

17C

18C

19C

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Part Description Qty.

1C Collar 1

2C Snap Ring 1

3C Piston Rod 1

4C Snap Ring 1

5C Bushing 1

6C U-Cup 1

7C O-ring 1

Part Description Qty.

8C Snap Ring 2

9C Spring 1

10C Screw 1

11C Cylinder Base 1

12C O-ring 1

13C Cylinder 1

14C Cylinder Collar 1

Part Description Qty.

15C Cylinder Screw 1

16C Thread Protector Ring 1

17C Hose Coupler 1

18C Dust Cover 1

19C Spring Pin 1

Page 11SKU 94681 For technical questions, please call 1-800-444-3353.

PARTS LIST D - ASSEMBLY DIAGRAM D

(10-TON HYDRAULIC PUSH RAM WITH SADDLE & SPRING)

1D

2D

3D

4D

5D

6D

7D

8D

9D

10D

11D

12D

13D

14D

15D

16D

17D

18D

19D

20D

21D

22D

23D

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Part Description Qty.

1D Saddle 1

2D Steel Sphere 1

3D Spring 1

4D Screw 1

5D Ram 1

6D Pin 1

7D Guiding Collar 1

8D Cap (Nylon) 1

Part Description Qty.

9D O-ring 1

10D Spring 1

11D Nut 1

12D Cylinder 1

13D O-ring 1

14D Cover Nut 1

15D Pin 1

16D Spindle Screw 1

Part Description Qty.

17D Spring 1

18D Spindle 1

19D Oil Ring 1

20D Connection Nut 1

21D Hose Coupler 1

22D O-ring 1

23D Dust Cap 1

Page 12SKU 94681 For technical questions, please call 1-800-444-3353.

PARTS LIST E - ASSEMBLY DIAGRAM E

(10-TON HYDRAULIC PUSH RAM WITH SPRING)

1E

2E

3E

4E

5E

6E

7E

8E

9E

10E

11E

12E

13E

14E

15E

16E

19E

18E

17E

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Part Description Qty.

1E Collar 1

2E Snap Ring 1

3E Piston Rod 1

4E Snap Ring 1

5E Bushing 2

6E U-Cup 1

7E O-ring 1

Part Description Qty.

8E Snap Ring 2

9E Spring 1

10E Screw 1

11E Cylinder Base 1

12E O-ring 1

13E Cylinder 1

14E Cylinder Collar 1

Part Description Qty.

15E Cylinder Screw 1

16E Thread Protector Ring 1

17E Hose Coupler 1

18E Dust Cover 1

19E Spring Pin 1

Page 13SKU 94681 For technical questions, please call 1-800-444-3353.

PARTS LIST F - ASSEMBLY DIAGRAM F

(2-TON HYDRAULIC PULL RAM WITH SPRING)

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

1F

2F

3F

4F

5F

6F

7F

8F

9F

10F

11F

12F

13F

14F

15F

16F

17F

18F

19F

20F

21F

22F

1F

24F

23F

25F

26F

27F

28F

29F

30F

Part Description Qty.

1F Hook 2

2F Axle Pin 2

3F Coupling 2

4F Collar 2

5F Split Pin 2

6F Nut 1

7F Screw 1

8F Ram 1

9F Closing Ring 2

10F Carrier Ring 1

Part Description Qty.

11F O-ring 1

12F U-Type Packing 1

13F Guiding Collar 1

14F Nut 1

15F Spring 1

16F Shaft 1

17F O-ring 2

18F Nut 1

19F O-ring 1

20F Cylinder 1

Part Description Qty.

21F Nut 1

22F Screw Coupler 1

23F Spindle Screw 1

24F Spring 1

25F Spindle 1

26F Oil Ring 1

27F Connection Nut 1

28F Hose Coupler 1

29F O-ring 1

30F Dust Cap 1

Page 14SKU 94681 For technical questions, please call 1-800-444-3353.

PARTS LIST G - ASSEMBLY DIAGRAM G

(5-TON HYDRAULIC PULL RAM WITH SPRING)

1G

2G

3G

4G

5G

6G

7G

8G

9G

10G

11G

12G

13G

14G

15G

16G

17G

18G

19G

20G

21G

22G

23G

24G

25G

NOTE:

Some parts are listed and shown for illustration purposes only,

and are not available individually as replacement parts.

Part Description Qty.

1G Top Hook 1

2G Nut 1

3G Hex Screw 1

4G Ram 1

5G Bushing 1

6G Closing Ring 2

7G O-ring 1

8G U-Type Packing 1

9G Collar 1

Part Description Qty.

10G Nut 1

11G Spring 1

12G Shaft 1

13G O-ring 2

14G Nut 1

15G O-ring 1

16G Cylinder 1

17G Bottom Hook 1

18G Spindle Screw 1

Part Description Qty.

19G Spring 1

20G Spindle 1

21G Oil Ring 1

22G Connection Nut 1

23G Hose Coupler 1

24G O-ring 1

25G Dust Cap 1

Page 15SKU 94681 For technical questions, please call 1-800-444-3353.

Harbor 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 ninety 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, 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

LIMITED 90 DAY WARRANTY