Manual For The 61946 2.5 Ton Pallet Jack
User Manual: Manual for the 61946 2.5 Ton Pallet Jack 2.5 Ton Pallet Jack
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Page Count: 12
Page 2 For technical questions, please call 1-888-866-5797. Item 61946
SAFETY OPERATION MAINTENANCESETUP
Table of Contents
Safety ......................................................... 2
Specifications ............................................. 3
Setup .......................................................... 4
Operation .................................................... 6
Maintenance ................................................ 7
Parts Lists and Diagrams ............................ 8
Warranty .................................................... 12
WARNING SYMBOLS AND DEFINITIONS
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that
follow this symbol to avoid possible injury or death.
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Addresses practices not related to personal injury.
IMPORTANT SAFETY INFORMATION
Read all safety warnings and instructions.
Failure to follow the warnings and instructions may result in serious injury and/or property damage.
Save all warnings and instructions for future reference.
1. Do not exceed 5,000 lb. capacity. Be
aware of dynamic loading! Sudden load
movement may briefly create excess
load causing product failure.
2. Wear ANSI-approved safety
goggles, heavy-duty work gloves,
and non-skid footwear during
assembly and use.
3. Use as intended only. Do not use
to support people or animals.
4. Do not use for aircraft purposes.
5. Keep clear of fork and load when
lifting, moving, and lowering.
6. Only use on flat, level surface able to
withstand weight of Jack and load.
7. Do not leave unattended while under load.
8. Only use with balanced, properly secured load.
9. Inspect before every use; do not use
if parts loose or damaged.
10. This product is not a toy. Do not allow
children to play with or near this item.
11. Keep work area clean and well lit. Cluttered
or dark areas invite accidents.
12. Stay alert, watch what you are doing
and use common sense when using this
Jack. Do not use while you are tired or
under the influence of drugs, alcohol or
medication. A moment of inattention while
using may result in serious personal injury.
Page 3For technical questions, please call 1-888-866-5797.Item 61946
SAFETYOPERATIONMAINTENANCE SETUP
13. Check for misalignment or binding of parts,
cracks and/or breakage of parts, and any other
condition that may affect safe operation. Many
accidents are caused by poorly maintained tools.
14. Jack service must be performed only by
qualified repair personnel. Service or
maintenance performed by unqualified
personnel could result in a risk of injury.
15. When servicing a jack, use only identical
replacement parts. Use of unauthorized
parts or failure to follow maintenance
instructions may create a risk of injury.
16. Maintain labels and nameplates on the
Pallet Jack. These carry important safety
information. If unreadable or missing, contact
Harbor Freight Tools for a replacement.
17. The brass components of this product contain lead,
a chemical known to the State of California to cause
cancer, birth defects (or other reproductive harm).
(California Health & Safety code § 25249.5, et seq.)
18. The warnings, precautions, and instructions
discussed in this instruction 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.
IMPORTANT! Before first use:
Check hydraulic fluid level and fill to the level of the fill
hole as needed. Thoroughly test the Jack for proper
operation. If it does not work properly, bleed air from
its hydraulic system – see instructions on page 6.
SAVE THESE INSTRUCTIONS.
Specifications
Capacity 2-1/2 Tons (5000 lb.)
Maximum Fork Height 7-1/2"
Minimum Fork Height 3"
Fork Length 48"
Fork Width 6-1/4"
Width over Forks 27"
Page 4 For technical questions, please call 1-888-866-5797. Item 61946
SAFETY OPERATION MAINTENANCESETUP
Set Up
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product
Note: For additional information regarding the parts listed in the following pages,
refer to Parts Lists and Diagrams on page 8.
Tool Set Up
Handle Assembly
1. Remove the three Screws (D611)
from the Handle Bracket (D151).
2. Set the Handle (D610) on the Handle
Bracket. Make sure the Chain (D612),
Chain Bolt (D614) and Nut (D615) pass
through the large opening in the center
of the Handle Bracket and the hole in the
center of the Handle Bracket Shaft (D153).
3. Slide a Washer (D616) onto each Screw.
Insert the Screws through the base of
the Handle into the Handle Bracket and
tighten securely with a torque wrench
(sold separately) to no more than 43 ft-lb.
4. Raise the Pump Lever (D132) on the
Pump and insert the Chain Bolt into the
slotted open end, keeping the Nut on the
underside of the Pump Lever.
Chain
Chain Attachment Detail
Chain
Bolt Pump
Lever
Nut
Chain
Screw
Handle
Washer
Handle
Bracket
Pump
Chain
Bolt
Pump
Lever
Nut
Figure A
Page 5For technical questions, please call 1-888-866-5797.Item 61946
SAFETYOPERATIONMAINTENANCE SETUP
Control Lever
The Control Lever on the Handle has three
operating positions: Lift, Drive and Lower.
a. Lift – Move the Control Lever down to its
lowest position. Pump the Handle frame
up and down to lift the Jack Forks.
b. Drive – Move the Control Lever to the center
position. The Jack Forks do not change position
when in drive. This position is used when the
load is moved from one location to another.
c. Lower – Hold the Control Lever up in its highest
position. This position automatically moves the
Forks to their lowest level. This position is only
in place as long as the Control Lever is held up.
The Lever moves back to the Drive position
when released.
If the Control Lever Does Not Function Properly
Make adjustments as described in the following chart by loosening the Lock Nut (D134) and
turning the Control Adjustment Screw (D133). After each adjustment, tighten the Lock Nut and
check that all positions of the Control Lever function properly and re-adjust if needed.
Control
Position Problem Turn Adjustment Screw (D133):
Drive Forks rise instead of
staying in neutral.
Clockwise until pumping action
does not raise forks.
Drive Forks lower when Control
Lever is in drive position. Counterclockwise until forks do not lower.
Lower Forks do not lower. Clockwise until raising the Control Lever
to the lower position lowers the Forks.
Lift Forks do not elevate. Counterclockwise until the Forks elevate
while pumping in the lift position.
Figure C
Components and Controls
Steering
Wheels
Load Rollers
Control Lever
ForksHandle
Handle
Control Lever
lower
drive
lift
Figure B
Pump
Lock Nut
Control
Adjustment
Screw
Figure D
Page 6 For technical questions, please call 1-888-866-5797. Item 61946
SAFETY OPERATION MAINTENANCESETUP
Operating Instructions
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
Bleeding
IMPORTANT! Before first use and before each use thereafter, check for proper hydraulic
fluid level in the Pump and add fluid to the level of the fill hole if necessary.
Then thoroughly test the Jack for proper operation prior to its actual use.
If the Jack appears not to be working properly, it may be necessary
to bleed its hydraulic system of excess air.
1. Hold the Control Lever (D608) in the
lower position to lower the Forks.
2. Remove the Fluid Fill Plug (D149)
from the side of the Pump.
3. Pump the Handle (D610) up and down several
times while holding the Control Lever in the lower
position to purge excess air from the system.
4. Check the fill hole (where the Fluid Fill Plug
was removed from) and, if necessary, add
hydraulic fluid up to the level of the fill hole.
5. Replace the Fluid Fill Plug.
6. Test the Jack several times for proper operation
before attempting to lift a load. If the Jack still
does not appear to be working properly after
bleeding, do not use the Jack until it has been
repaired by a qualified service technician.
General Operating Instructions
1. Hold the Control Lever in the lower position to
lower the Forks, then release the Control Lever.
2. Slide the Pallet Jack under the load, being
careful to center the load over the Forks.
Have the main weight of the load resting as
near as possible to the Steering Wheels.
3. Push the Control Lever down to the lift position,
then pump the Handle until the load is raised
off the floor and is resting on the Forks.
WARNING! To prevent serious injury from tipping,
raise the load as little as possible before moving.
4. Move the Control Lever to the drive position
and roll the load to the desired location.
5. Hold the Control Lever in the lower position to
lower the Forks, then release the Control Lever.
6. Slide the Forks out from under the load.
7. When finished using the Jack, hold the Control Lever
in the lower position to lower the Forks completely.
8. Store in a safe, dry location out of reach of children.
Page 7For technical questions, please call 1-888-866-5797.Item 61946
SAFETYOPERATIONMAINTENANCE SETUP
Maintenance and Servicing
Procedures not specifically explained in this manual must
be performed only by a qualified technician.
TO PREVENT SERIOUS INJURY FROM TOOL FAILURE: Do not use damaged equipment. If
abnormal noise or vibration occurs, have the problem corrected before further use.
Cleaning, Maintenance, and Lubrication
1. BEFORE EACH USE, inspect the general
condition of the Pallet Jack. Check for:
• cracked, broken or bent parts
• loose or missing parts
• misalignment of parts
• any other condition that may
affect its safe operation.
If a problem occurs, have the problem
corrected before further use. Do not
use damaged equipment.
2. 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 6.
3. Periodically inject grease into the grease fittings.
4. AFTER USE, lower Jack completely to help
prevent rusting of the Piston Rod. Clean external
surfaces with clean cloth. Store the Jack in a
safe, dry location out of reach of children.
Troubleshooting
TO PREVENT SERIOUS INJURY: Use caution when troubleshooting a malfunctioning jack.
Stay well clear of the supported load. Completely resolve all problems before use.
If the solutions presented in the Troubleshooting guide do not solve the problem, have a qualified technician
inspect and repair the Jack before use. After the Jack is repaired: Test it carefully without a load by raising
it and lowering it fully, checking for proper operation, BEFORE RETURNING THE JACK TO OPERATION.
DO NOT USE A DAMAGED OR MALFUNCTIONING JACK!
Problem Possible Causes Likely Solutions
The Forks do not
raise completely.
Insufficient hydraulic fluid. Refill Pump with hydraulic fluid.
The Forks will not raise. 1. Insufficient hydraulic fluid.
2. Air in valve chamber.
3. Control Lever out of adjustment.
4. Old/contaminated fluid.
1. Refill Pump with hydraulic fluid.
2. Bleed hydraulic system – see page 6.
3. Adjust Control Lever – see page 5.
4. Change fluid and replace Seals.
The Forks will
not descend.
1. Control Lever out of adjustment.
2. Piston Rod rusted.
3. Deformed Piston Rod.
4. Control Lever, Chain, Chain
Bolt, or Nut broken or missing.
1. Adjust Control Lever – see page 5.
2. Lubricate/replace Rod.
3. Replace Piston Rod and cylinder.
4. Replace the Handle Assembly.
Fluid leak. Component, likely seal,
worn or damaged.
Inspect and replace worn or damaged parts.
Forks descend without
operating release valve.
1. Control Lever out of adjustment.
2. Contaminated hydraulic
fluid clogging valve.
3. Hydraulic component damaged.
1. Adjust Control Lever – see page 5.
2. Clean valve with kerosene and
change hydraulic fluid.
3. Replace damaged part.
Follow safety precautions whenever diagnosing or servicing the tool.
Page 8 For technical questions, please call 1-888-866-5797. Item 61946
SAFETY OPERATION MAINTENANCESETUP
Parts Lists and Diagrams
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 MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE
ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER 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 RISK AND LIABILITY
ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS
THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
Handle Parts List and Diagram
Part Description Qty
D601 Spring 1
D602 Blade Spring 1
D603 Roller 1
D604 Spring Pin 1
D605 Spring Pin 1
D606 Spring Pin 1
D607 Spring Pin 1
D608 Control Lever 1
Part Description Qty
D609 Pull Board 1
D610 Handle 1
D611 Screw 3
D612 Chain 1
D613 Pin 1
D614 Chain Bolt 1
D615 Nut 1
D616 Washer 3
Page 9For technical questions, please call 1-888-866-5797.Item 61946
SAFETYOPERATIONMAINTENANCE SETUP
Fork Frame Parts List and Diagram
Part Description Qty
D201 Screw 1
D202 Oil Fitting 1
D203 Rocker Arm 1
D204 Spring Pin 1
D205 Retaining Ring 2
D206 Joint 2
D207 Shaft 2
D208 Push Rod 2
D209 Nut 2
D210 Pin 2
D211 Shaft 1
D212 Roller Frame Shaft 2
D213 Spring Pin 2
D214 Push Rod Shaft 2
Part Description Qty
D215 Roller Frame 2
D216 Spring Pin 2
D218 Fork Frame 1
D219 Washer 4
D220 Bearing 4
D223 Spring Pin 4
D224 Bushing 4
D225 Bushing 2
D226 Bolt 2
D227 Entry Roller 2
D228 Nut 2
D229 Load Roller 2
D230 Roller Shaft 2
D231 Washer 2
D232 Washer 4
Page 10 For technical questions, please call 1-888-866-5797. Item 61946
SAFETY OPERATION MAINTENANCESETUP
Pump Parts List
Part Description Qty
D101 Pump Piston Rod 1
D102 Washer 1
D103 Spring 1
D104 Dust Ring 1
D105 Y-Seal 1
D106 Screw 1
D107 O-Ring 1
D108 Spring 1
D109 Pump Valve Spindle 1
D110 Pump Valve Seat 1
D111 O-Ring 1
D112 Steel Ball 1
D113 Pump Body 1
D115 Spring Pin 1
D116 Steering Wheel 2
D117 Wheel Shaft 1
D118 Thrust Plate 1
D119 Oil Fitting 1
D120 Retaining Ring 1
D121 Bearing Cover 1
D122 Bearing 1
D123 Spring Pin 2
D124 Dust Cover 2
D125 Retaining Ring 2
D126 Washer 2
D127 Bearing 4
D129 Spring 1
D130 Release Valve 1
Part Description Qty
D131 O-Ring 2
D132 Pump Lever 1
D133 Control Adjustment Screw 1
D134 Lock Nut 1
D135 O-Ring 1
D136 Axle Sleeve 1
D137 Adjusting Bolt 1
D139 Safety Valve Spindle 1
D140 Spring 1
D141 O-Ring 1
D142 Screw 1
D143 O-Ring 1
D144 Y-Seal 1
D145 Spring Pin 1
D146 Steel Ball 1
D147 Piston Rod 1
D148 Dust Ring 1
D149 Fluid Fill Plug 1
D150 Shaft 1
D151 Handle Bracket 1
D152 Pressure Roller 1
D153 Handle Bracket Shaft 1
D154 Spring Pin 1
D155 Spring Pin 1
D156 Bushing 1
D157 Seal Washer 1
D158 Bushing 2
Record Product’s Serial Number Here:
Note: If product has no serial number, record month and year of purchase instead.
Note: Some parts are listed and shown for illustration purposes only,
and are not available individually as replacement parts.
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SAFETYOPERATIONMAINTENANCE SETUP
Pump Diagram
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797
Limited 90 Day Warranty
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 90 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, criminal activity, improper
installation, normal wear and tear, 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.
