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44900
Set up and Operating Instructions
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.
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.
Work area
1. Turn off the engine, set the parking brake, and block the tires before working on a vehicle. Keep the work area clean and well lighted. Cluttered benches and dark areas increase the risk of injury to persons. Keep bystanders and children away while operating the tool. Distractions can result in loss of control of the tool. SKU 44900
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Personal safety
1. Stay alert. Watch what you are 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 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 footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations. Use safety equipment. Wear ANSIapproved safety goggles and heavyduty work gloves during use.
that affects the tools operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools. 4. Use only accessories that are 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. 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. 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. 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.
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Service
Tool service must be performed only by qualified repair personnel. When servicing a tool, use only identical replacement parts. Use only authorized parts.
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SPECIFICATIONS
10-Tons 5-Tons w/ extensions Ram Travel 6 Extension Pole Length 5 Maximum Spreader Wedge 1/2-Ton Capacity 3-3/4 Maximum Opening Hose Length 6 Ram Capacity
Setup
Ram Attachments
1. The Extensions (16 19) connect in different combinations to reach desired lengths. The Male Connector (7) is used to connect the female end of the Ram (5) to a Base. The Flat Base (12) is typically used on the stationary side to spread out the force of the Ram (5). The 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 Cap Head (15) is typically used on the pushing end to prevent slipping. The 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 Wedge Head (10) is used to repair small dents and areas located in angles and tight spaces. The Flange Base and Flange Head (9, 8) are used together to allow spreading in areas that the Ram cannot fit into.
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UNPACKING
When 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. 3.
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Note: The Flange Base and Flange Head must only be used together to prevent an off-center load.
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Ram Setup
Note: 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. 1. Clean the end of the Hose (4) and the 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. Assemble attachments as shown below:
Ram (5) 90 V Base (11) or Flat Base (12)
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Cap Head (15), Rubber Head (13), or Wedge Head (10) Flange Head (8)
Ram (5)
Note: If using the Flange Base and Flange Head, thread the Flange Base onto the Ram completely and align the Flange Head to it. SKU 44900 For technical questions, please call 1-800-444-3353. Page 5
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. 1. Check the Hydraulic Fluid Level, following the instructions in the Cleaning and Maintenance section. Determine which direction the frame needs to be bent. Remove any obstructions that could be damaged or are in the way.
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. d. Aim the pushing end towards the area that needs to be repaired, and slowly apply pressure with the Pump (6). Note: To prevent damage, do not overextend the Ram. 4b. Using Spreader Wedge (14): a. Place the Spreader Wedge (14) 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. b. Carefully hold the Spreader Wedge in position and apply the Pump (6) 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. 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 (5) or Spreader Wedge (14). Clean all hydraulic ports and cover them with clean End Plugs to prevent contamination and damage.
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Note: When using the Pump (6) in a vertical position, keep the Hose (4) end of the Pump downward. 4a. Using Ram (5): a. Connect the appropriate Base (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. b. If using the Flange Base (9) or 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. c. Position the Ram (5) 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 Page 6
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e. Firmly close the Release Valve (10C) by turning it clockwise. f. Press the tip of the Coupling (16C) against a hard surface and pump the pump handle. g. Continue pumping, until the hydraulic fluid coming out the end of the coupler tip is free of air bubbles. h. Recheck the fluid level and add fluid if necessary. i. Turn the Release Valve counterclockwise to release the pressure in the pump and hose. 6. Change the hydraulic fluid yearly. 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.
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Description
Qty
1 1 1 1 1 1 1 1 1
Part
12 13 14 15 16 17 18 19
Flat Base Rubber Head Spreader Wedge Cap Head 5 Extension 10 Extension 18 Extension 27 Extension
Description
Qty
1 1 1 1 1 1 1 1
3 19 4 6 18 16 12
11 5 15 17
10
14
13
Note: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. Page 8 For technical questions, please call 1-800-444-3353. SKU 44900
Description
4A 18A
6A
7A 11A 10A 19A 9A 17A 5A 8A 16A 15A 13A 14A 13A 12A 8A 3A 2A 1A
20A
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Description
Part
8B 9B 10B 11B 12B 13B
Description
11B
10B 12B
9B 13B
8B
7B
6B
5B
4B
3B
2B
1B
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Description
Part
15C 16C 17C 18C 19C 20C 21C 22C 23C 24C 25C 26C 27C 28C
End Plug Coupling Spring Hose Fluid Fitting Grip Handle Circle Clip Pivot Pin Arm Pivot Pin Arm Pivot Pin Arm Plunger Washer Seal
Description
Part
29C 30C 31C 32C 33C 34C 35C 36C 37C 38C 39C 40C 41C 42C
Filter Ring Cylinder Washer Seal Spacer O-ring O-ring Bolt Pump Foot Screw Reservoir Seal Filter Housing
Description
22C 25C 21C 2C 3C 4C 20C 5C 6C 7C 1C 42C 39C 14C 40C 13C 34C 36C 35C 37C 38C 41C 27C 29C 31C 9C 8C
23C 26C 28C 30C 32C 17C 18C 24C 19C 16C 15C
12C
11C
33C 10C
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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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