Harbor Freight Tools 1/2 Ton Capacity Pickup Truck Crane with Cable Winch Product manual
Contents
1. 6 to Lower Post Bracket using Pin 13 and R Pin 10 See Figure C Bolts i 15 Pin Mounting Washers males 16 19 16 Lower Post Lock k Bracket Washers 17 amp p Figure C Nuts 18 Figure A Page 4 For technical questions please call 1 800 444 3353 Item 61522 6 Attach Boom 3 Bracket facing down to Upper Note You may need to pull out cable from Winch Post Bracket using Pin 13 and R Pin 10 reel to expose bolt holes on Winch base 7 Connect Boom Bracket to Ram using Pin 12 9 Attach Winch 5 to Boom with Bolts 7 and R Pin 10 See Figure D and Lock Washers 8 10 Thread Grease Fitting 21 into Post See Figure F Pin UpperPost R Pin Boom 3 1 Bracket 10 amp T Bolt 7 4 4 Lock Washer 8 Boom VC Bracket Pin 12 Figure D 8 Slide Boom Extension 4 into Boom Secure with Boom Pin 11 and R Pin 10 See Figure E KRL Pin x 10 Boom Figure F Note Tighten ALL Bolts before initial operation Boo Extension 4 Ow Boom Pin 11 Figure E Item 61522 For technical questions please call 1 800 444 3353 Page 5 ie m S m le zZ Operating Instructions Read ENTIRE IMPORTANT SAFETY INFORMATION section at beginning of this manual including all text under subheadings therein before setup or use of this product Note Once Assem2. support any part of load Do not apply load to the point of the Hook Do not operate Crane with twisted kinked or damaged cable Inspect cable carefully before every use A SAVE THESE INSTRUCTIONS Specifications Rated Capacity Boom Length max 3 1 2 Boom Length min 33 000 Ib Winch Cable Item 61522 For technical questions please call 1 800 444 3353 13 64 steel 25 L with 7 8 locking hook Page 3 Assembly Instructions Read ENTIRE IMPORTANT SAFETY INFORMATION section at beginning of this manual including all text under subheadings therein before setup or use of this product Note Remove Post 2 and Boom 3 4 Slide Post 2 onto Base and secure using before mounting Base Post Pin 14 and R Pin 10 See Figure B 1 Locate a mounting position so the Crane will be near end of truck bed and can be attached to frame WARNING The Base must be securely bolted to the Post P frame of the truck bed Bolting the Base to the truck Pin 14 S bed will not provide necessary support and could result in product failure and serious bodily injury Post Note Verify that installation surface has no hidden 2 components or brake lines before drilling or driving screws 2 Use Base to mark drilling holes Drill holes 3 Mount Base to frame using Nuts 18 Lock Washers 17 Washers 16 Base Mounting Plates 19 and Bolts 15 See Figure A Figure B 5 Attach Ram
3. technical questions please call 1 800 444 3353 6 Before lifting load make sure Cable is not kinked or twisted WARNING Do not lift load with Winch Winch is for adjusting slack only Lift load with hydraulic Ram only T Tolift load a Make sure Release Valve is closed by turning clockwise with Ram Handle b Pump Ram Handle until load has been lifted high enough to clear truck bed 8 To move load Swivel Boom until the load is directly over the truck bed WARNING Do not lower load with Winch Winch is for adjusting slack only Lower load with hydraulic Ram only 9 Tolowerload Slowly open Release Valve by turning counterclockwise with Ram Handle 10 Retract Winch Cable and remove Hook only after load has been lowered completely 11 Before driving vehicle retract Winch Cable completely lower Boom and position over truck s wheel well then insert Post Pin to prevent Boom from swiveling 6 Before lifting load make sure Cable is not kinked or twisted WARNING Do not lift load with Winch Winch is for adjusting slack only Lift load with hydraulic Ram only T Tolift load a Make sure Release Valve is closed by turning clockwise with Ram Handle b Pump Ram Handle until load has raised high enough to just clear truck bed 8 To move load Swivel Boom until load is safely away from truck bed and over a level flat surface WARNING Do not lower load with Winch Winch is for adjusting slack onl
4. ISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO Parts List 1 Description k Pin 0 0 0 0 0 0 0 0 0 Pin 1 Grease Fitting tt Record Products 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 1 800 444 3353 Item 61522 Assembly Diagram MAINTENANCE 16 S D 17 17 a se Item 61522 For technical questions please call 1 800 444 3353 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
5. Owner s Manual amp Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference ITEM 61522 1 2 Ton Capacity Haul Master Pickup ilir Vehicle Not Included Visit our website at http www harborfreight com Email our technical support at tech harborfreight com When unpacking make sure that the product is intact and undamaged If any parts are missing or broken A WARNING please call 1 800 444 3353 as soon as possible Copyright 2013 by Harbor Freight Tools All rights reserved No portion of this manual or any artwork contained herein may be reproduced in Read this material before using this product any shape or form without the express written consent of Harbor Freight Tools Failure to do so can result in serious injury Diagrams within this manual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included o gt Rn m j lt Table of Contents DANGLY RR 2 Specifications esssssssssss 3 Assembly eee 4 Operation i
6. Ram is attempting a solution capacity spongy under load Check that Release Valve is closed fully Bleed air from the system Valve may be blocked and may not close fully To flush the valve Lower the Boom and securely close the Release Valve Manually lift the Boom several inches Open the Release Valve and force the Boom down as quickly as possible Ram may be low on fluid Check the fluid level and refill if needed Ram may require bleeding see Bleeding Instructions on page 6 Unit may have too much hydraulic fluid inside check fluid level and adjust if needed MAINTENANCE Item 61522 For technical questions please call 1 800 444 3353 Page 9 m gt Z Oo m Parts List and Diagram 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 AR
7. bly is complete tighten ALL Bolts before initial operation Bleeding Instructions IMPORTANT Before first use check for 4 Check fluid level and if necessary proper hydraulic fluid level and thoroughly test top off with hydraulic fluid the Crane If it does not work properly bleed T air from its hydraulic system as follows 5 Close Release Valve and replace Fluid Fill Plug 1 Remove Fluid Fill Plug Fill with hydraulic fluid 6 Test Crane several times for proper operation sold separately to full level if necessary before attempting to lift a load 2 Open Release Valve by turning T f after bleeding the Crane still does not counterclockwise with Ram Handle appear to be working properly do not use until repaired by a qualified service technician 3 Insert Ram Handle into Fulcrum apply downward pressure to Boom and pump Handle quickly several times Operating Instructions WARNING The Boom Extension has four positions Do not lift more than rated capacity Be aware of dynamic loading Sudden load movement may briefly create excess load causing product failure and serious bodily injury Boom Extension Ram Handle Ram Handle Storage VA Release Valve Fluid AAK Fill Plug N Figure G Page 6 For technical questions please call 1 800 444 3353 Item 61522 Loading WARNING Engage parking brake before use Do not move vehicle with load attached to Crane 1 Remove Post Pin and s
8. city greater than the weight of the load being lifted Do not allow load to swing or drop violently while lowering or moving 10 11 For technical questions please call 1 800 444 3353 Lift and lower load with hydraulic ram only Use winch to extend or retract cable while unloaded only No alterations shall be made to this product Do not adjust safety valve Keep clear from underneath suspended load Do not lift people or lift load over people Capacity decreases as boom lengthens Follow capacities marked on boom Replacement ram must have same rating mounting points and maximum length Item 61522 12 Wear ANSI approved safety goggles heavy duty work gloves and steel toed work boots during installation and use 13 Do not use for aircraft purposes 14 Inspect before every use do not use if parts loose or damaged 15 Before driving vehicle retract Winch Cable completely lower boom and position over truck s wheel well then insert Post Pin to prevent boom from swiveling 16 Stay alert Watch what you are doing and use common sense when operating Crane 17 Do not use Crane while tired or under the influence of drugs alcohol or medication A moment of inattention may result in serious personal injury Ram Safety Warnings 1 Attach securely to Crane before use 2 Do not exceed rated capacity 3 Do not adjust safety valve 4 Keep clear of load while lifting and lowering Winch Saf
9. 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 Haul Master 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353
10. ety Warnings 1 USE TO EXTEND OR RETRACT CABLE WHILE UNLOADED ONLY 2 Keep clear of mechanism when operating 3 Keep atleast 4 full turns of cable on reel 4 Before driving vehicle retract winch cable completely position boom over truck s wheel well and insert Post Pin to prevent boom from swiveling 18 19 20 21 Keep children and bystanders away while operating the Crane Distractions can cause you to lose control Have Crane serviced by a qualified repair person using only identical replacement parts This will ensure that the safety of the Crane is maintained Maintain labels and nameplates These carry important information If unreadable or missing contact Harbor Freight Tools for a replacement SAFETY The warnings precautions and instructions discussed in this manual cannot cover all possible conditions and situations that may occur The operator must understand that common sense and caution are factors which cannot be built into this product but must be supplied by the operator Lower load slowly Be aware of dynamic loading Sudden load movement may briefly create excess load causing product failure Attach load to Hook securely by properly rated suitable means such as chains shackles hooks lifting slings etc Load must be attached to prevent accidental disconnection Properly seat sling or other device in Hook and fully close Hook s safety clasp Do not allow Hook hitch to
11. iien 6 A DANGER AWARNING ACAUTION NOTICE Maitena E ennan 8 Parts List and Diagram 10 Warranty sssssssssssseeseeeeeennne 12 HaulfWMaster 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 CAUTION 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 AWARNING Read all safety warnings and instructions Failure to follow the warnings and instructions may result in serious injury Save all warnings and instructions for future reference General Safety Warnings 1 Page 2 Study understand and follow all instructions before installing or operating this device Attach to frame of truck bed according to manual instructions only Verify that installation surface has no hidden components or brake lines before drilling or driving screws Engage parking brake before use Do not move vehicle with load attached to Crane Do not exceed rated capacity Use only slings or chains with a rated capa
12. se Screw and pump the 2 Lubricate the Grease Fitting with a grease Handle to bleed air from the system gun once a month or when the Boom VE becomes difficult to swivel on the Post g Reinstall Fluid Fill Plug h Reinstall Ram to Crane 3 Clean and lubricate all moving parts of Winch including gears ratchets shafts 5 Top assembly may be removed and stored indoors and cable to insure safe operation in a dry safe place out of the reach of children Note If Crane will be exposed to wet conditions more frequent lubrication may be necessary to prevent buildup of rust m gt Z Oo m Page 8 For technical questions please call 1 800 444 3353 Item 61522 Troubleshooting AWARNING TO PREVENT SERIOUS INJURY Use caution when troubleshooting malfunctioning Crane Stay clear of supported load Completely resolve all problems before use If solutions presented in Troubleshooting guide do not solve the problem have a qualified technician inspect and repair Crane before use After Crane is repaired Test it carefully without a load by raising and lowering it fully checking for proper operation BEFORE RETURNING CRANE TO OPERATION DO NOT USE A DAMAGED OR MALFUNCTIONING CRANE POSSIBLE SYMPTOMS PROBABLE SOLUTION Ram will not FOOR Pump Flandle Fluid leaking Mak rtain that the C ake certain that the Crane lift at its lowers UR MAVES LP from Fill is not supporting a load while weight under feels when
13. wivel Boom so Hook is over load If necessary remove Boom Pin adjust Boom Extension then replace Boom Pin WARNING Do not attempt to extend or retract Boom while load is attached 2 Make sure Boom will handle load when itis extended See Figure H Capacity Lb Boom Length 53 1 2 am NM a CNNUN 40 112 Figure H 3 Lower Boom to bottom of its movement range 4 Attach Hook to properly secured load giving specific attention to load balancing 5 Adjust slack on Winch Cable until no slack remains a To tighten push Pawl forward and turn Handle clockwise b To loosen pull Pawl back and turn Handle counterclockwise Unloading WARNING Engage parking brake before use Do not move vehicle with load attached to Crane 1 Remove Post Pin 2 Lift Boom to just below the top of its movement range and swivel Boom so Hook is over load If necessary remove Boom Pin adjust Boom Extension then replace Boom Pin WARNING Do not attempt to extend or retract Boom while load is attached 3 Make sure Boom will handle load when itis extended See Figure I Capacity Lb Boom Length 53 1 2 AAT Figure 4 Attach Hook to properly secured load giving specific attention to load balancing 5 Adjust slack on Winch Cable until no slack remains a To tighten push Pawl forward and turn Handle clockwise b To loosen pull Pawl back and turn Handle counterclockwise Item 61522 For
14. y Lower load with hydraulic Ram only 9 Tolower load Slowly open Release Valve by turning counterclockwise with Ram Handle 10 Release Winch Cable and remove Hook only after load has been lowered completely 11 Before driving vehicle retract Winch Cable completely lower Boom and position over truck s wheel well then insert Post Pin to prevent Boom from swiveling Page 7 Z O H lt nc Lu ou ie Maintenance and Servicing Procedures not specifically explained in this manual must be performed only by a qualified technician AWARNING TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION 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 4 Change the hydraulic fluid at least once every year condition of the tool Check for a Remove Ram from Crane Lower ram completely loose hardware b Remove Fluid Fill Plug misalignment or binding of moving parts c Tip Ram to allow old hydraulic fluid cracked or broken parts to completely drain out proper ram and winch operation d Dispose of old hydraulic fluid in accordance with local regulations e With the Ram upright fill with hydraulic fluid sold separately to full level frayed kinked or damaged winch cable and any other condition that may affect its safe operation f Open Valve Relea
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