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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Table of Contents SAFETy 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. SETUp 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. OpERATION 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. MAINTENANCE 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. Page 2 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. For technical questions, please call 1-888-866-5797. Item 61946 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.) 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. 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. 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. SAFETy 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. 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. SETUp SAVE THESE INSTRUCTIONS. 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" MAINTENANCE Capacity OpERATION Specifications Item 61946 For technical questions, please call 1-888-866-5797. Page 3 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 SAFETy 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). SETUp 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). Handle 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. Screw OpERATION 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. Washer Chain Chain Bolt Nut Chain Chain Bolt pump Lever Handle Bracket pump MAINTENANCE Nut pump Lever Chain Attachment Detail Figure A Page 4 For technical questions, please call 1-888-866-5797. Item 61946 Control Lever Control Lever The Control Lever on the Handle has three operating positions: Lift, Drive and Lower. 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. Handle SAFETy a. Lift – Move the Control Lever down to its lowest position. Pump the Handle frame up and down to lift the Jack Forks. lower drive lift 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. Figure B SETUp 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. problem Turn Adjustment Screw (D133): Drive Forks rise instead of staying in neutral. Clockwise until pumping action does not raise forks. Drive Pump Control Adjustment Screw Forks lower when Control Counterclockwise until forks do not lower. Lever is in drive position. 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. OpERATION Control position Lock Nut Figure D Figure C Components and Controls Control Lever Forks MAINTENANCE Handle Steering Wheels Load Rollers Item 61946 For technical questions, please call 1-888-866-5797. Page 5 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. SAFETy 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. SETUp 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 OpERATION 1. Hold the Control Lever in the lower position to lower the Forks, then release the Control Lever. 4. Move the Control Lever to the drive position and roll the load to the desired location. 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. 5. Hold the Control Lever in the lower position to lower the Forks, then release the Control Lever. 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. 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. WARNING! To prevent serious injury from tipping, raise the load as little as possible before moving. MAINTENANCE Page 6 For technical questions, please call 1-888-866-5797. Item 61946 Maintenance and Servicing SAFETy 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 • cracked, broken or bent parts • loose or missing parts 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. • misalignment of parts 3. Periodically inject grease into the grease fittings. • any other condition that may affect its safe operation. 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. If a problem occurs, have the problem corrected before further use. Do not use damaged equipment. SETUp 1. BEFORE EACH USE, inspect the general condition of the Pallet Jack. Check for: DO NOT USE A DAMAGED OR MALFUNCTIONING JACK! problem possible Causes The Forks do not Insufficient hydraulic fluid. raise completely. The Forks will not raise. 1. Insufficient hydraulic fluid. 2. Air in valve chamber. 3. Control Lever out of adjustment. 4. Old/contaminated fluid. The Forks will 1. Control Lever out of adjustment. not descend. 2. Piston Rod rusted. 3. Deformed Piston Rod. 4. Control Lever, Chain, Chain Bolt, or Nut broken or missing. Fluid leak. Component, likely seal, worn or damaged. Forks descend without 1. Control Lever out of adjustment. operating release valve. 2. Contaminated hydraulic fluid clogging valve. 3. Hydraulic component damaged. Likely Solutions Refill Pump with hydraulic fluid. 1. 2. 3. 4. 1. 2. 3. 4. Refill Pump with hydraulic fluid. Bleed hydraulic system – see page 6. Adjust Control Lever – see page 5. Change fluid and replace Seals. Adjust Control Lever – see page 5. Lubricate/replace Rod. Replace Piston Rod and cylinder. Replace the Handle Assembly. Inspect and replace worn or damaged parts. 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. Item 61946 For technical questions, please call 1-888-866-5797. Page 7 MAINTENANCE 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. OpERATION Troubleshooting parts Lists and Diagrams pLEASE READ THE FOLLOWING CAREFULLy SAFETy 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 SETUp D601 D602 D603 D604 D605 D606 D607 D608 Description Spring Blade Spring Roller Spring Pin Spring Pin Spring Pin Spring Pin Control Lever Qty 1 1 1 1 1 1 1 1 part D609 D610 D611 D612 D613 D614 D615 D616 Description Pull Board Handle Screw Chain Pin Chain Bolt Nut Washer Qty 1 1 3 1 1 1 1 3 OpERATION MAINTENANCE Page 8 For technical questions, please call 1-888-866-5797. Item 61946 Fork Frame parts List and Diagram Description Qty 1 1 1 1 2 2 2 2 2 2 1 2 2 2 part D215 D216 D218 D219 D220 D223 D224 D225 D226 D227 D228 D229 D230 D231 D232 Description Roller Frame Spring Pin Fork Frame Washer Bearing Spring Pin Bushing Bushing Bolt Entry Roller Nut Load Roller Roller Shaft Washer Washer Qty 2 2 1 4 4 4 4 2 2 2 2 2 2 2 4 MAINTENANCE OpERATION SETUp Screw Oil Fitting Rocker Arm Spring Pin Retaining Ring Joint Shaft Push Rod Nut Pin Shaft Roller Frame Shaft Spring Pin Push Rod Shaft SAFETy part D201 D202 D203 D204 D205 D206 D207 D208 D209 D210 D211 D212 D213 D214 Item 61946 For technical questions, please call 1-888-866-5797. Page 9 pump parts List part SAFETy SETUp D101 D102 D103 D104 D105 D106 D107 D108 D109 D110 D111 D112 D113 D115 D116 D117 D118 D119 D120 D121 D122 D123 D124 D125 D126 D127 D129 D130 Description Pump Piston Rod Washer Spring Dust Ring Y-Seal Screw O-Ring Spring Pump Valve Spindle Pump Valve Seat O-Ring Steel Ball Pump Body Spring Pin Steering Wheel Wheel Shaft Thrust Plate Oil Fitting Retaining Ring Bearing Cover Bearing Spring Pin Dust Cover Retaining Ring Washer Bearing Spring Release Valve Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 2 2 4 1 1 part D131 D132 D133 D134 D135 D136 D137 D139 D140 D141 D142 D143 D144 D145 D146 D147 D148 D149 D150 D151 D152 D153 D154 D155 D156 D157 D158 Description O-Ring Pump Lever Control Adjustment Screw Lock Nut O-Ring Axle Sleeve Adjusting Bolt Safety Valve Spindle Spring O-Ring Screw O-Ring Y-Seal Spring Pin Steel Ball Piston Rod Dust Ring Fluid Fill Plug Shaft Handle Bracket Pressure Roller Handle Bracket Shaft Spring Pin Spring Pin Bushing Seal Washer Bushing Qty 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 OpERATION MAINTENANCE 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. Page 10 For technical questions, please call 1-888-866-5797. Item 61946 MAINTENANCE OpERATION SETUp SAFETy pump Diagram Item 61946 For technical questions, please call 1-888-866-5797. Page 11 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. 3491 Mission Oaks Blvd. • pO Box 6009 • Camarillo, CA 93011 • 1-888-866-5797
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