POWER FIST 9188988 6 600 lb Heavy Duty Pallet Jack

 Please read and understand all instructions before use. Retain this manual for future reference.

SPECIFICATIONS

INTRODUCTION

This pallet jack is designed to help you easily transport loads around warehouses, loading docks, and other facilities, It’s made from durable powder-coated steel with a rubber-coated handle and corrosion-resistant, non- damaging polyurethane wheels that offer a tight, convenient turning radius.

SAFETY

• WARNING! Read and understand all instructions before using this tool. The operator must follow basic precautions to reduce the risk of personal injury and/or damage to the equipment.

• Keep this manual for safety warnings, precautions, operating or inspection and maintenance instructions.

• HAZARD DEFINITIONS
  Please familiarize yourself with the hazard notices found in this manual. A notice is an alert that there is a possibility of property damage, injury or death if certain instructions are not followed.

• DANGER!
  This notice indicates an immediate and specific hazard that will result in severe personal injury or death if the proper precautions are not taken.

• WARNING!
  This notice indicates a specific hazard or unsafe practice that could result in severe personal injury or death if the proper precautions are not taken.

• CAUTION!
  This notice indicates a potentially hazardous situation that may result in minor or moderate injury if proper practices are not taken.

• NOTICE!
  This notice indicates that a specific hazard or unsafe practice will result in equipment or property damage, but not personal injury.

WORK AREA

1. Operate in a safe work environment. Keep your work area clean, well-lit and free of distractions. Place lights so you are not working in a shadow.
2. Keep anyone not wearing the appropriate safety equipment away from the work area.
3. Store unused tools properly in a safe and dry location to prevent rust or damage. Lock tools away and keep out of the reach of children.
4. Do not use in areas or spaces where the jack can come into contact with electrical sources.

PERSONAL SAFETY
WARNING! Wear personal protective equipment approved by the Canadian Standards Association (CSA) or American National Standards Institute (ANSI).

PERSONAL PROTECTIVE EQUIPMENT

1. Always wear impact safety goggles that provide front and side protection for the eyes. Eye protection equipment should comply with CSA Z94.3-07 or ANSI Z87.1 standards based on the type of work performed.
2. Wear the appropriate type of full-face shield when needed.
3. Wear gloves that provide protection based on the work materials.
4. Wear protective clothing designed for the work environment and tool.
5. Non-skid footwear is recommended to maintain footing and balance in the work environment.
6. Wear steel toe footwear or steel-toe caps to prevent a foot injury from falling objects.

PERSONAL PRECAUTIONS
Control the tool, personal movement and the work environment to avoid personal injury or damage to tool.

1. Do not operate any tool when tired or under the influence of drugs, alcohol or medications.
2. Avoid wearing clothes or jewelry that can become entangled with the moving parts of a tool. Keep long hair covered or bound.
3. Do not overreach when operating a tool. Proper footing and balance enable better control in unexpected situations.
4. Securely hold this tool using both hands. Using a tool with only one hand can result in loss of control.

SPECIFIC SAFETY PRECAUTIONS
WARNING! DO NOT let comfort or familiarity with product (gained from repeated use) replace strict adherence to the tool safety rules. If you use this tool unsafely or incorrectly, you can suffer serious personal injury.

1. Use the correct tool for the job. This tool was designed for a specific function. Do not modify or alter this tool or use it for an unintended purpose.
2. Check the pallet jack before each operation. Do not use the tool if any parts are damage broken or misplaced. Repair or replace the parts.
3. Always ensure all guards or safety features are engaged before using.
4. Do not force this tool. It will perform better and more safely when used for it intended purpose.
5. Only use this device on a surface that is stable, level, dry and not slippery, and capable of sustaining the load. Ensure that the load is center-loaded and secure.
6. Do not exceed the overall maximum load capacity. The weight rating is based on an evenly distributed load.
7. Do not allow children to use this device without supervision. This device is not a toy.
8. Do not use this device to transport passengers.
9. Always keep your hands and feet clear from under the fork or the load. Do not place your hands on the side of the pallet jack while lifting.
10. Be sure your load is stable and secured before transporting.
11. Do not operate on ramps or inclines or on surface that are soft or graded.
12. Operate the pallet jack only from the designed operating position.
13. Ensure that the lengths of the fork match the length of the load or pallet.
14. Lower the fork to the lowest possible height and remove any loads when it is not in use.
15. Operators must be able to physically maneuver and handle the pallet jack when it is fully loaded.
16. Always use the end of the forks when lifting.
17. When lifting, the hydraulics may retract the wheels into the frame of the forks, crushing fingers and feet.

UNPACKING

WARNING! Do not operate the tool if any part is missing. Replace the missing part before operating. Failure to do so could result in a malfunction and personal injury.

Remove the parts and accessories from the packaging and inspect for damage. Make sure that all items in the parts list are included. Make sure that all items in the contents are included.

Contents:

• Frame assembly
• Handle

ASSEMBLY & INSTALLATION

Numbered references in parenthesis (#1) refer to the included Parts List. Dashed numbers in parenthesis (Fig. 1-1) refer to a specific point in an illustration or image.

1. Insert the base of the handle (#1) into the pump bracket (Fig. 1-1) on the pump housing (#28) (Fig. 1).
2. Align the holes at the base of the handle with the hole in the bracket (Fig. 1-2).
3. Insert the handle pin (#15) into the holes 15 of the pump bracket and the handle (Fig. 2).
4. Tap gently and firmly into place with a hammer (not included).
5. Use pliers (not included) to turn the handle pin until its holes (Fig. 2-1) align with the holes in the spring pins (#16) (Fig. 2).
6. Feed the screw head (Fig. 3-1) through the center hole in the handle pin (Fig. 3).
7. Using a screwdriver (not included), pry up the cam (Fig. 3-2) and then slip the screw head under the notch in the cam (Fig. 3).
8. Use a hammer to tap the spring pins into the holes on the pump bracket and handle pin.
9. Tap out the pump retainer pin (#67) (Fig. 1).

OPERATION

1. Position the pallet jack in front of the load you wish to transport.
2. Insert the fork (#68) into the pallet.
3. To raise the fork, push the control lever (#8) all the way downwards (Fig. 4-3) and pump the Fig. 4 handle until the fork reaches the desired height.
4. Place the handle in the center neutral position (Fig. 4-2). This allows you to move the handle without affecting the height of the jack.
5. Use the handle to maneuver the pallet jack to the desired location.
6. Lower the fork by pulling the lever upwards (Fig. 4-1). Allow the load to descend slowly in a controlled manner.
7. Once the load is lowered, release the lever. It is spring-loaded and will return automatically to the neutral position.

ADJUSTING THE CONTROL HANDLE

The positions described in the Operation section have been set at the factory to allow for immediate operation upon proper assembly. These positions can be changed if the forks do not raise or lower as expected.

To adjust, accomplish the following:

1. Use a wrench and a flat screwdriver (not included) to loosen the hex nut (#19) (Fig. 5).
2. Turn the socket head cap screw (#20) both clockwise and counterclockwise (Fig. 5).
3. Check to see if the pallet jack works well in the control positions. If more adjustments are necessary, proceed to the following steps.
4. Place the control handle in the neutral position.
5. If the fork does not rise when you pump the handle, skip to step 7.
6. If the fork does rise, turn the socket head cap screw clockwise until the fork does not rise.
7. Keep the control handle in the neutral position.
8. If the fork does not move when the handle is pumped, skip to step 6.
9. If the fork lowers, turn the socket head cap screw counterclockwise until it does lower.
10. Pull the control lever upward to the lower position.
11. If the fork lowers, skip to step 7.
12. If the fork does not lower, turn the socket head cap screw clockwise until the fork lowers.
13. Push the control lever down to the lift position.
14. If the fork elevates when you pump the truck, go back and check steps 1 through 5 until the pallet jack works in all 3 control positions.
15. If the fork does not elevate, turn the socket head cap screw counterclockwise until the fork elevates.
16. Repeat steps 1 through 5 until the pallet jack works in all 3 control positions.

CARE & MAINTENANCE

1. Maintain the tool with care. A tool in good condition is efficient, easier to control and will have fewer problems.
2. Inspect the tool components periodically. Repair or replace damaged or worn components. Only use identical replacement parts when servicing.
3. Follow instructions for lubricating and changing accessories.
4. Only use accessories intended for use with this tool.
5. Keep the tool handles clean, dry and free from oil/grease at all times.
6. Inspect the wheels and axles, removing any threads, rags or other items are inhibiting movement or operation.
7. Maintain the tool’s labels and nameplates. These carry important information. If unreadable or missing, contact Princess Auto Ltd. for replacements.

WARNING! Only qualified service personnel should repair the tool. An improperly repaired tool may present a hazard to the user and/or others.

OIL

Remove the oil plug (#52) on top of the pump housing and check the oil. To change or add oil, accomplish the following: \

1. Fill the tank through the oil plug hole to about 80% capacity, which is about 2-1/2 in. deep (Fig. 6-1), with hydraulic jack oil.
2. Replace the oil plug.

SEAL AND O-RING REPLACEMENT

1. Raise the pallet jack.
2. Remove the spring pin. This will free the pump and the handle assembly from the pallet jack.
3. Remove the oil plug.
4. Turn the pump over and empty the oil into an appropriate container.
5. Pump the handle until all the oil is drained.
6. Dispose of the used hydraulic oil in accordance with local regulations (see Disposal).
7. Pull out the plunger piston (#60) and/or the ram piston (#54).
8. Remove O-rings (#51) and dust seal (#63)
9. Insert a new O-ring or seal one at a time, making sure the replacement parts are the same size.
10. Reassemble and add oill appropriately (see Fig. 7 instructions outlined in Oil).

UP-DOWN CAM ADJUSTMENT

When pumping the handle with the lever in the neutral position, there should be movement of the fork. If there is no movement, accomplish the following to adjust:

1. Place the lever in the neutral position.
2. Loosen the hex nut.
3. Adjust the socket head cap screw while pumping the handle until there is no longer any movement of the ram.
4. Tighten the hex nut.

BLEEDING AIR
There may be times when the forks do not riser while the handle is being pumped in the lift position. This is most likely due to air being in the hydraulic system.

To bleed the air from the system accomplish the following:

1. Place the handle in the lower position.
2. Pump the handle up and down several times.
3. Test the function of the hydraulic system.
4. If trouble persists, repeat steps 1 through 3.

CLEANING

Regularly inspect and clean the wheels and other moving elements of the pallet jack to ensure they operate smoothly and properly.

LUBRICATION
Inspect and lubricate the tool when required. This excludes the wheel bearings, which are sealed and require no lubrication, and the crankshaft, which features oil lite bushings and also requires no lubrication. Only use light oil to lubricate the tool. Other lubricants may not be suitable and could damage the tool or cause a malfunction during use.

NOTICE! NEVER use a penetrating oil to lubricate the tool. Penetrating oil may act as a solvent that can break down the grease and cause the tool to seize up.

STORAGE
When not in use for an extended period, apply a thin coat of lubricant to the steel parts to avoid rust. Remove the lubricant before using the tool again. Only store in places that are dry, secure locations.

DISPOSAL
Recycle a tool damaged beyond repair at the appropriate facility. Contact your local municipality for a list of disposal facilities or by-laws for electronic devices, batteries, oil or other toxic liquids.

IMPORTANT! DO NOT pollute the environment by allowing uncontrolled discharge of waste oil.

TROUBLESHOOTING

Visit a Princess Auto Ltd. location for a solution if the tool does not function properly or parts are missing. If unable to do so, have a qualified technician service the tool.

2.         Air in pump

3.          Worn O-ring in ram cylinder

| 1.         Add oil is needed and ensure there is no leakage from the release screw, pressure adjustment screw or valve area

2.         Reference the instructions outlined in Bleeding Air

3.          Reference the instructions outlined in Seal and O-Ring Replacement for Ram and Plunger Piston

Once lifted, the pallet jack then lowers by itsett| 1.          Air in the oil

2.         Worn O-ring in ram cylinder

| 1.         Reference the instructions outlined in Bleeding Air

2.         Reference the instructions outlined in Seal and O-Ring Replacement

 | 3.         Release valve not seated properly

4.        Pallet jack loaded beyond capacity

5.      Release valve not adjusted properly

6.         Oil leakage from release screw or pressure adjustment screw

| 3.         Reference the instructions outlined in Bleeding Air

4.        Reduce load to proper capacity

5.      Adjust valve with the pressure adjustment screw and release screw

6.         Tighten release screw and replace O-rings on release screw and/or pressure adjustment screw

---|---|---
Fork does not lower| 1.         Cam requires adjustment

2.         Cam is damaged

3.          Damaged push rods and/or linkages

| 1.         Reference the instructions outlined in Up-Down Cam Adjustment

2.         Replace the cam

3.          Replace damaged parts

Lever does not

set at a neutral position

| Cam requires adjustment| Reference the instructions

outlined in Up-Down Cam Adjustment

PARTS BREAKDOWN

PARTS LIST

| DESCRIPTION| QTY

---|---|---
1| Handle| 1
2| Spring pin| 1
3| Block spring| 1
4| Spring| 1
5| Spring pin| 2
6| Roller| 1
7| Lever mat| 1
8| Control lever| 1
9| Spring pin| 1
10| Release rod| 1
11| Oil lite bushing| 2
12| Pressure roller| 1
13| Shaft| 1
14| Oil lite bushing| 2
15| Handle pin| 1
16| Spring pin| 2
17| Pump retainer pin| 1
18| Spring pin| 1
19| Hex nut| 1
20| Socket head cap screw| 1
21| Table pin| 2
22| Spring pin| 2
23| Table| 1
24| Snap ring| 1
25| Ball bearing| 1
26| Bearing base| 1
27| Spring pin| 1
28| Pump housing| 1
29| Wheel shaft| 1
30| Ball bearing| 4
31| Steering wheel| 2
---|---|---
32| Snap ring| 2
33| Dust seal cap| 2
34| Release nozzle housing| 1
35| O-ring| 1
36| O-ring| 2
37| Release nozzle| 1
38| Release nozzle spring| 1
39| Mid-valve base| 1
40| Steel ball| 1
41| Oil baffle washer| 2
42| O-ring| 2
43| Front valve base| 1
44| Tapered column| 1
45| Oil baffle washer| 1
46| O-ring| 1
47| Front valve base| 1
48| Needle valve| 1
49| Needle valve spring| 1
50| Valve cap| 1
51| O-ring| 1
52| Oil plug| 1
53| Steel ball| 1
54| Ram piston| 1
55| Dust seal ring| 1
56| O-ring| 1
57| Li-packing| 1
58| Steel ball| 1
59| Spring base| 1
60| Plunger piston| 1
61| Spring cap| 1
62| Spring| 1
---|---|---
63| Dust seal ring| 1
64| Li-packing| 1
65| Plunger housing| 1
66| Washer| 1
67| Pump retainer pin| 1
68| Fork frame| 1
69| Spring washer| 1
70| Socket head cap screw| 1
71| Oil lite bushing| 2
72| Oil lite bushing| 2
73| Lifting yoke| 1
74| Snap ring| 2
75| Push rod| 2
76| Oil lite bushing| 2
77| Crank pin| 2
78| Spring pin| 1
---|---|---
79| Crank shaft| 1
80| Spring pin| 2
81| Arm pin| 2
82| Load wheel frame| 2
83| Spring pin| 2
84| Flat washer| 4
85| Ball bearing| 4
86| Load wheel| 2
87| Load wheel axle| 2
88| Rod pin| 2
89| Spring pin| 2
90| Hex cap screw| 2
91| Guide roller| 2
92| V nut| 2

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