Service Manual Big Joe/Lift-Rite
Contents
1. Jack fails to lower e Look for any bent frame parts lifting link push rod etc Bent frame parts need to be replaced e The hand control may be out of adjustment see Control Rod Adjustment under section heading Handle Removal and Installation e Debris blocking an oil channel in the hydraulic unit Contact us for our hydraulic core exchange program Jack lifts in short increments e Lack of oil pressure see to Low Fluid Level e Reservoir filler plug leaking Replace the washer and filler plug and replenish oil if necessary see to Low Fluid Level One fork lifts the other does not Check for damage in the following areas and their attached parts e Lifting link lifting link pin and traverse shoulder pin e Pushrod e Load roller bracket pivot axle GENERIC PARTS SERVICE 11 CALL 1 800 331 0839 GPS Inc Hydraulic Unit Service Hints e Tampering and abuse are two of the most common problems In most cases minor repairs become major when inexperienced people attempt to rebuild a hydraulic unit If you come across a unit that looks like it has been tampered with or modified inspect the unit carefully to be sure it can be rebuilt or call Generic Parts Service for technical assistance e The ram is chromed and the pump piston polished to a fine finish for maximum seal life and minimum oil leakage If you see these surfaces nicked or pitted this will cause the unit to fail in a short time Replace any rusty or dam2. GENRO ERVICE INC AAN ps z Service Manual Big Joe Lift Rite Models L 50 and L 50 CHEP 4 way gt d pes X DUm na Developed by Generic Parts Service This manual is intended for basic service and maintenance of the Big Joe Lift Rite pallet jack The pallet jacks you are servicing are tools that make moving products easier Operating pallet jacks with rusty broken or worn parts makes usage and maintenance more difficult Pallet jack parts are inexpensive and easy to replace To ensure maximum life from the jack always replace the parts that are broken or worn Remember that all parts on a pallet jack depend on the adjoining parts to work properly and to perform to their full potential When used in conjunction with our catalog this service manual will explain how and when to replace a pallet jack part Remember when in doubt replace it If you have any questions just call us We make it easy US 19 95 Fax 1 800 366 5939 CAN 29 95 CALL 1 800 331 0839 GENERIC PARTS SERVICE GPS Inc Contents 2 Suggested Assemblies 3 Commonly Used Tools 3 Helpful Reminders 4 Axles Bushings 5 Load Rollers and Load Roller Brackets 6 Steer Wheels and Axle Traverse 8 Push Rods 9 Lifting Link 10 Handle Removal and Installation Hydraulic Unit 1l Inspection 12 Service Hints 12 Removal 12 Installation 13 Diagram Copyright 1999 by GPS Inc All rights reserved Lift
3. Roll Washer Washer ia Snap Washer Ring Hub Cap Axle KO CALL 1 800 331 0839 6 GENERIC PARTS SERVICE GPS Inc Traverse Inspection There are few things that can be wrong with the traverse Wear can occur on the bearing shoulder or where the shoulder bolts attach to the lifting link If these areas are egg shaped or out of round replace the traverse Removal Turn the jack onto its side and remove the steer wheel assembly see Steer Wheels and Axle Remove the snap ring under the traverse and turn the jack upright Be careful lowering the stem of the hydraulic unit onto the ground Pump the jack up to gain access to and remove the bolt that fastens the lift ram to the frame Pull the hydraulic unit away from the frame and out of the traverse Remove the shoulder bolts and the traverse 25 minutes Installation Attach the traverse to the lifting link with its shoulder bolts Slide the hydraulic unit into the traverse with the washers and lower thrust bearing already in position on the stem of the hydraulic unit Position the lift ram and ball under the A Frame Tighten the bolt onto the ram to secure the ram in place Turn the jack onto its side and install the snap ring onto the stem of the hydraulic unit to hold the traverse in place Install the steer wheel assembly see Steer Wheels and Axle 25 minutes Lower Thrust Bearing Washer Snap Ring GENERIC PARTS SERVICE CALL 1 800 331 0839 GPS Inc Push
4. handle replacement Also inspect the roller for flat areas and wear If any of the above parts are worn more than 16 replace them Removal Loosen adjustment nut on lower control rod and slide the control rod off the release lever Remove the shoulder bolts from the handle bracket and the handle is now ready to come off 10 minutes Installation Set the handle on the hydraulic unit The roller should be placed on top of the pump piston Push down on the handle to compress the spring under the pump piston Line up the holes and install the shoulder bolts Tip You may need someone to help you hold the handle in place in order to keep the pump piston compressed while you install the shoulder bolts Insert the lower control rod into the release lever and tighten the adjustment nut 15 minutes Control Rod Adjustment Control Lever Hold the release lever up and insert the lower con SS trol rod with the adjusting nut already on it into PMP SION the slot of the release lever Place the control lever a into raise mode and pump the handle The jack Should rise If it doesn t lift unthread the adjusting nut until pumping the handle raises the jack Place the control lever into neutral mode and pump the handle The jack should not lift If it does the Control Rod adjusting nut needs to be tightened until the jack no longer rises If the jack lowers when the control lever is placed in neutral the adjusting nut needs to be loosened
5. Rods Inspection When inspecting the push rods look for broken or cracked welds bends missing roll pins and worn bushings It is best to mark the position of the eyebolt and nut in relation to the push rod to ensure proper adjustment during installation Removal Turn the jack over so that the undercarriage is facing up Remove the load roller brackets see Load Roller Brackets Loosen the nut on the push rod and then the push rod can be threaded off of the eyebolt The eyebolt can be removed with the push rod by using a hammer and pin punch to drive the roll pin out of the pin that fastens the eyebolt to the lifting link Remove the pin and the push rod The eye bolt can then be removed from the jack 20 minutes Installation Turn the jack over so that the undercarriage is facing up Fasten the eyebolt to the lifting link with its pin and secure the pin with its roll pins Thread the nut onto the eyebolt with enough room to thread the push rod on also Thread the push rod onto the eyebolt until it approximately matches the other push rod Assemble the load roller brackets and the load roller onto the push rod Line up the pivot axle hole on the brackets to the axle hole on the frame Slide the pivot axle through the frame brackets and exit roller if it has one Secure the pivot axle to the frame with its roll pin Tighten the nut on the eyebolt against the push rod Note The nut on the eyebolt is primarily a marker for proper adjustment
6. floor Check for out of round axle holes and inspect the bushings closely see Bushing Inspection If any of the above conditions exist replace the brackets Removal Tip We recommend servicing one load roller assembly at a time using the other assembly as a reference Load roller Remove the nut and washer from the axle bolt Slide the axle bolt out of the brackets and remove the load roller Remove the load roller axle sleeve from the load roller 10 minutes Load roller bracket Remove the load roller With a pin punch and hammer drive out the roll pin that fastens the pivot axle to the frame then drive the pivot axle out of the frame exit roller and brackets Pull the push rod away from the frame and slide the brackets off the push rod 15 minutes Installation Load roller brackets Slide the brackets onto the push rod and insert the pivot axle through the frame brackets and the exit roller the 4 way does not use an exit roller Secure the pivot axle to the frame with its roll pin and install the load roller 15 minutes Load roller Insert the load roller axle sleeve into the load roller and place the load roller between the brackets Install the axle bolt through the brackets and load roller The use of washers differs from one style to the other Use the diagrams below or the other load roller bracket assembly on the jack as a reference Secure the axle bolt with its nut 10 minutes Nut L 50 Mini L 50 L 50 C
7. the undercarriage is facing up Disconnect the eyebolts from the lifting link by removing the pins that secure the two pieces together Drive the roll pins out that fasten the lifting link pins to the frame Pull the lifting link pins out using vise grips or pliers This is easier to do if you support the lifting link while pulling the pins out 45 minutes Installation Turn the jack over so that the undercarriage is facing up Position the lifting link in the frame Insert the lifting link pins and the roll pins that fasten the lifting link pins to the frame Attach the push rods to the lifting link by inserting the pin through the eyebolt and the ears of the lifting link Secure the pin with its roll pins Turn the jack over and place the traverse and hydraulic unit assembly into position Insert the lift ram into the frame Thread the shoulder bolts through the ears of the lifting link and into the traverse to secure it Fasten the lift ram to the frame with the bolt 45 minutes cx A a Ak Oy Lifting Link Pin Bushings Shoulder Bolt Push Rod Traverse GENERIC PARTS SERVICE 9 CALL 1 800 331 0839 GPS Inc Handle Removal and Installation Inspection Inspect handle for cracks and structural integrity There should be minimal side play in the handle socket Check for worn bushings If bushings are not replaced regularly the handle bracket holes can become worn Damaged holes cause pin failure and may require complete
8. until the jack stops lowering Place the control lever into release mode and the jack should lower If not the adjusting nut needs Z _ Bolt f yo Lock Washer Chain Adjustment to be tightened Nut Roller 10 minutes Bushing Shoulder Bolt Release Lever CALL 1 800 331 0839 10 GENERIC PARTS SERVICE GPS Inc Hydraulic Unit Inspection Inspect the outside of the pump for oil leaks Test the unit under a load to determine if there is a problem This can be done by lifting a heavy pallet and letting it stand for 15 20 minutes Below are symptoms and solutions to common hydraulic unit failures If the following solutions fail to correct the problem a complete rebuild of the malfunctioning unit may be necessary Please refer to our catalog for information about ordering the appropriate seal kit or take advantage of our hydraulic unit exchange program Jack fails to lift load e Air Lock in Pump Place the control lever into release position then pump the handle rapidly about 10 15 times 5 minutes e Low Fluid Level With the jack in a lowered position remove filler plug Using UNI HO oil fill the reservoir until the oil is level with the fill plug hole Bleed the unit see Air Lock in Pump Replace the filler plug creating a snug fit Do not over tighten 5 minutes e Hand Control Out of Adjustment See Control Rod Adjustment under section heading Handle Removal and Installation 10 minutes
9. 1 0839 12 GENERIC PARTS SERVICE GPS Inc Hydraulic Unit Diagram Control Rod RO ie Plug Washer Adjusting Nut Note Newer style jacks have a recess on the top of the a traverse which requires a spacer Models with the older style traverse do not require this part Washer Traverse Bearing Se _ a A Washer Traverse Snap Ring GENERIC PARTS SERVICE 13 CALL 1 800 331 0839 GPS Inc
10. HEP Push Rod 4 way Axle Bolt Push Rod GENERIC PARTS SERVICE 5 CALL 1 800 331 0839 GPS Inc Steer Wheels and Axle Inspection Steer wheels should not have flat spots or large pieces of metal imbedded in them i e tacks nails or metal shavings Chips in the wheel which keep it from rolling smoothly indicate the need for replacement Steer wheels should turn freely They should not rub the bottom of the traverse If they do check for the correct installation of the snap ring under the traverse If the wheel is worn more than 4 from the normal outside diameter replacement is necessary Removal Steer wheels Turn the jack onto its side and then remove the hubcap Remove the snap ring for the newer style or the roll pin for the older style that fastens the steer wheels to the axle 10 minutes Steer wheel axle Turn the jack onto its side and remove the steer wheels Drive out the roll pin that fastens the axle to the stem of the hydraulic unit and slide the axle out 15 minutes Installation Steer wheel axle Slide the axle into the stem of the hydraulic unit and fasten with its roll pin Install the steer wheels 10 minutes Steer wheels Slide the wheels onto the axle and secure with its fasteners snap rings for the newer style or roll pins for the older style 10 minutes Older Style I I D Bearing Newer Style Washer a 25mm D Bearing Washer Roll Bearing Pin Axle ds Roll Pin a C Bearing
11. It also keeps the eyebolt or push rod from spinning out of adjustment when working on the load roller brackets or the lifting link It is easiest to adjust the push rod correctly if both push rod and bracket assemblies are in a fully lowered position before installing the pivot axle To ensure that the push rods are adjusted correctly pump the jack up then place the jack into release If both forks bottom out at the Same time the push rods are adjusted correctly If one fork hits bottom before the other it needs to be adjusted You can either lengthen the push rod that hit first or shorten the push rod that hit second Loosen the nut on the eyebolt and turning the eyebolt one way or the other to achieve the correct length 20 minutes Push Rod Bushing Bushing Bracket Bushing Eye Bolt CALL 1 800 331 0839 8 GENERIC PARTS SERVICE GPS Inc Lifting Link Inspection Check lifting link for out of round holes cracks in welds or bent ears If any of these conditions exist replace the lifting link Also look for worn bushings missing shoulder bolts missing lifting link pins or the roll pins that fasten these parts to their mating parts Removal Pump the jack up to make the bolt that fastens the lift ram to the frame more accessible Then remove the bolt Remove the shoulder bolts that fasten the traverse to the lifting link Pull the hydraulic unit and traverse assembly away from the frame Turn the frame over So that
12. Rite pallet jacks all models are products of Lift Rite Inc GENERIC PARTS SERVICE l CALL 1 800 331 0839 GPS Inc Suggested Assemblies to Save Repair Time e LF 10278 Super Super Seal Kit e LF 10236 B A D Ultra Poly Steer Wheel e LF 10210 P A D Ultra Poly Load Roller Assembly e LF 10210 P A D Super Super Ultra Poly Load Roller Assembly e LF C 10210 A Super Super Steel Load Roller Assembly e LF 10234 H D Heavy Duty Thrust Bearing e LF 10276 A Handle Assembly CALL 1 800 331 0839 GENERIC PARTS SERVICE GPS Inc Commonly Used Tools e Hammer e Jack stand e 45 Snap ring pliers large and small e 1 2 Wrench e 3 4 Wrench e 7 8 Wrench e 1 2 Allen wrench e 1 4 Pin punch e 3 16 Pin punch e 1 4 Pin punch e 3 Pin punch e Soft hammer nylon mallet e Anti seize compound e Lubricant i e WD40 may be necessary to remove rusted parts PIN PUNCH SNAP RING PLIERS Helpful Reminders e Never hammer directly on an axle always use a pin punch e Always replace old roll pins and snap rings e Replace accessible bushings whenever the jack is disassembled e Newer style serial numbers are 62500 and higher Older style serial numbers are 62499 and lower GENERIC PARTS SERVICE 3 CALL 1 800 331 0839 GPS Inc Axles Inspection If the axle is bent out of round or shows signs of wear replace it Check for worn roll pin holes If these are damaged or worn replace the a
13. aged parts that will cause premature wear on their mating parts or the body of the hydraulic unit e Use UNI HO hydraulic oil Do not use automotive oil or hydraulic brake fluid Removal Pump the jack to its maximum height and turn the jack onto its side Remove the steer wheels and axle see Steer Wheels and Axle Removal and the snap ring under the traverse on the stem of the hydraulic unit Turn the jack upright be careful no to damage the stem of the hydraulic unit while lowering Remove the bolt that fastens the top of the ram to the frame Lift the frame off of the ram tip the handle and hydraulic unit away from the frame and rest both pieces on the ground Remove the ball on top of the ram and pull the hydraulic unit out of the traverse Remove the handle and handle bracket if necessary see Handle Removal 45 minutes Installation Slide the stem of the hydraulic unit into the traverse with the traverse bearing already in place on the stem Insert the ram into the A Frame with the ball positioned on the top of the ram and secure the ram to the A Frame with the bolt Carefully turn the jack onto its side keeping the hydraulic unit in the traverse and frame Attach the snap ring to the stem of the hydraulic unit under the traverse Install the steer wheel assembly see Steer Wheel and Axle Installation and the handle if necessary see Handle Installation Bleed the hydraulic unit see Air Lock and Pump 45 minutes CALL 1 800 33
14. xle Bushings Bushings are designed to wear out sooner than the mating parts They are made of softer material and are expendable It is recommended that anytime the jack is torn down to a point where the bushings are accessible they be replaced This will ensure longer life of the jack and will reduce the amount of downtime Bushings are very inexpensive and it is cost effective to change them regularly Inspection If bushings are cracked broken egg shaped or worn more than 16 from the original size replace them Remember If the jack is already disassembled replace all accessible bushings Tip Coating axles and bushings with anti seize compound before installation makes maintenance easier CALL 1 800 331 0839 4 GENERIC PARTS SERVICE GPS Inc Load Rollers and Load Roller Brackets Inspection Load roller Load rollers should not have flat spots or large pieces of metal imbedded in them i e tacks nails or metal shavings Any chips in the wheel that keep it from rolling smoothly indicate the need for replacement If the wheel has cracks loose tread or does not turn freely replace both wheels Always change the wheels in pairs to reduce uneven wear New load rollers have an outside diameter of 3 L 50 2 L 50 mini and 1 3 4 L 50 CHEP If the diameter is worn more than 4 from its normal size replacement is necessary Load roller brackets Inspect the brackets for cracks or wear from prolonged rubbing on the
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