Doosan FJ4B User manual

Instruction Manual
# FJ4B 8800 lb. CAPACITY
FORKLIFT JACK
CAPACITY: 4000kgs
NOTE: Owner / Operator must read and
understand this instruction manual
before using the forklift jack.
NOTE: IT IS THE OWNER/OPERATOR’S
RESPONSIBILITY TO READ AND UNDERSTAND
THIS INSTRUCTION MANUAL BEFORE USING
THESE FORKLIFT JACKS. FAILURE TO DO SO
MAY CAUSE SERIOUS INJURY.

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CONTENTS
1. SPECIFICATIONS-----------------------------------2
2. IMPORTANT------------------------------------------2
3. FEATURES--------------------------------------------3
4. OPERATING INSTRUCTIONS------------------4
5. SAFETY TIPS-----------------------------------------7
6. MAINTENANCE INSTRUCTIONS--------------10
7. PUMP PRRMING INSTRUCTIONS-----------10
8. PLACARD PARTS LIST--------------------------11
9. PARTS LIST ﹠EXPLODED FIGURE-------12

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SPECIFICATIONS
Rated capacity………………………………,,,4000kg/8800lbs
Starting pad height (notch) ……………... 65mm/2-1/2inches
Raised height—maximum………………….406mm/16inches
Width………………………………………200mm/7-4/5inches
Weight………………………………………….…….33kg/77lbs
IMPORTANT:
Owner and/or Operator Responsibilities:
1. The use of this jack is subject to certain hazards that can only
precluded by the exercise of intelligence, care and common sense. It
is therefore essential to have competent and careful personnel
involved in the use and operation of this equipment.
Before using the jack, you must read and understand all the
instructions, warnings and precautions contained in this manual as
well those affixed to the jack in the form of decals.
2. Warning symbol:
This symbol is used to warn you of
specific situations which may occur and must be avoided when using
the FJ4B jack. Failure to observe these warnings may result in personal
injury and/or property damage.
3. You must refer this manual to all operators, using the FJ4B jack.
They must read and understand the contents of this manual. This
manual is written in English. If the equipment is to be used by
operators who cannot read or understand English, it is the

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responsibility of the owner (or his designated representative) to
instruct these people in the use of the jack. To avoid unnecessary risk
of bodily injury or property damage, the operator MUST understand
and observe these instructions and warnings.
4. The owner must inspect, or appoint a knowledgeable person, to
inspect the jack at regular intervals.
Each jack must be inspected immediately if subjected to an abnormal
load or shock. Regular inspection should be made weekly for daily
use and monthly for intermittent use.
Damaged jacks-any jack which appears to be damaged in any way or
deemed badly worm or operates abnormally-MUST BE REMOVED
FROM SERVICE UNTIL NECESSARY REPAIRS ARE MADE.
5. You must retain this manual and make it available to all persons
in need of the information contained herein.
6. For additional copies, please contact our dealer.
FEATURES:
Here is an abbreviated list of features:
o1.Low starting height
o2. Easy portability
o3.Two-position lift pad
o4. Simple, rugged design
o5.Lift pad swivels with load as jack is raised and lowered.
o6.Safety valve

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OPERATING
INSTRUCTIONS:
1. To raise: close the release valve (turn the knob clockwise) then pump
the handle.
2. To lower: turn the release valve SLOWLY counter-clockwise. When
lowering the jack lift truck. It is important to keep the rate of lowering
under your control. Do not lower the fork lift until the area is free of
personnel, tools and equipment. Keep all body parts away from the
area wheels of the jack because they move backwards when
lowering.
3. We recommend that a vehicle be
raised by cradling a support
point in the notch at the end of
the lift arm. (Fig. 1-B) To
accomplish this , it is advisable
to attach a steel bar to the lower
surface capable of supporting
the load. The serrated pad can
be used to raise a vehicle with
flat underside. See Fig. 1-A (flat
surface must be parallel to the
floor before lifting)
4. Always position lift pad least 76mm inward toward the center of
vehicle from the beginning of the flat surface (See Fig. 1-A). Never
push jack under the fork lift beyond the “red line” marked on decal
located on top of the lift arm (see NOTICE ②in PLACARD).
a. When lifting from the
side the jack should be
located nearer to the rear
wheels than the front. If
the fork lift seems to be
heavier at one end, lower
the jack and move it closer
to the heavy end to obtain
suitable balance.
A B
Fig.1
Fig.2

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b. When lifting from the end
place the FJ4B at the center of
the fork lift truck. Always chock
the wheels at the opposite end
of the fork lift. When lifting 3
wheeled lift trucks, never lift the
2 wheeled end.
WARNING: Do not lift from the
end of the fork lift if the contact
surface is sloped or rounded
(See Fig.4)
WARNING: This is a lifting device
only ！After lifting, load must be
immediately supported by adequate stands. Failure to do so may result
in personal injury and/or property damage.
Fig.3
Fig.4

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WARNING: Care must be taken not to tilt the vehicle more than 15°
when using the serrated pad. Excessive tilting can cause the jack to
kick out suddenly and drop the load. See instruction 3 page 7.
5. Select the lifting point on the fork lift with care. It must be strong
enough to resist the lifting force without damaging the fork lift. It is
desirable to cradle the lifting point in the arm notch when
possible(See Fig.1-B).
6. Use only the serrated lifting
pad, or the notch at the end of
the lifting arm as the lifting
contact. Do not attempt to use
any other part of the FJ4B
lack as a lifting contact point.
7. Raise a fork lift with the FJ4B only when:
a. The forks are in a lowered position
b. There is no load of any kind on the forks
c. There are no personnel on the jacks
8. If the fork lift truck is to be lifted, lowered and re-lifted, the following
procedure is to be followed.
a. Lift and lower in accordance with the instructions in this manual
b. Before using a second jack, make certain that the jack is
replaced in full accordance with the initial instructions in this
manual. (See Paragraph 4 of Operating Instructions)
Fig.5

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SAFETY TIPS
WARNING:The warnings and
instructions listed and described hereafter must be followed at all times.
If there is any uncertainty regarding an intended use of the FJ4B,
contact your supervisor. Failure to observe these warnings and
instructions may result in injury and/or property damage.
1.Both the FJ4B jack and the fork lift must be on a firm lever surface
capable of supporting the load. Do not attempt to lift from a polished
or greasy floor.
2.The FJ4B may be used to lift from either side or end of the fork lift
truck. However, 2 wheels of the lift truck must remain firmly on the
floor.
3.Use extreme caution when lifting narrow fork lift trucks (less than
1016mm Wide) from the sides. Always make sure that the height
between the floor and the bottom of the raised tire is never more than
one fourth (1/4th) of the vehicle’s tread width. See Fig.6. (Tread width
is measured from center line to center line of the tire treads.) If the
one forth figure is exceeded, the fork lift truck could reach the point of
instability and tip over or the angularity of the forklift truck frame could
cause the jack to kick out and drop the load.
Example: If treadwith=914.40mm,then never lift the bottom of the
vehicle tire more than 228.60mm off the floor.
ht
TREAD WIDTH
Fig.6

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4.Never use more than one jack to lift the fork lift truck. Failure to
observe this instruction may lead to unstable conditions and could
cause failure of one of the jacks.
5.Do not use the FJ4B to raise all for 4 wheels of the fork lift from the
floor. Two wheels of the lift truck must remain in contact with the floor
at all times.
6.Do not push the jack under the
fork lift beyond the red line
marked on the decal on the top
of the lift arm. This will maintain
at least one inch clearance
between the body of the jack
and the fork lift in its raise
position. Failure to observe
these instructions could result in
damage to the FJ4B and/or loss
of load.
7.Do not use any kind of
“cribbing” under the FJ4B, or on
top of the lift pad area. The jack
must always remain in direct
contact with the floor, and the
lifting pad or notch must be in
direct contact with the fork lift.
8. Keep hands, feet and all other body parts out of the area of the
scissors mechanism at all times. This instruction applies to handling
and carrying as well as lifting and lowering the jack. The scissors
action of the lifting mechanism can cause serious injury.
Fig.7
Fig.8

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9. Do not drop, throw, drive over or
otherwise abuse the FJ4B. The jack
must be treated with the same care as
any other precision tool upon which
your safety and the safety of your co-
workers depends.
10. Do not drive the lift truck off the
jack or attempt to move the
forklift at any time when it is supported by the FJ4B.
11.Do not work on the fork lift, or get under it for any reason until it is
properly supported by means of adequate stands. When the stands
are in place and are supporting the fork lift truck, remove the FJ4B
from the working area before beginning work.Fig.9
12. The FJ4B jack is designed solely for the lifting of fork lift trucks.
Use of the jack for any other purpose constitutes misuse of the jack.
Users of the jack hereby warned of this misuse, which can result in
physical injury and/or property damage.
13. Damaged jacks-Any jack which appears to be damaged in any way,
is found to be badly worn, or operates abnormally MUST BE
REMOVED FROM SERVICE until necessary repairs are made.
14. Do not modify the FJ4B jack in any manner.
15.Do not exceed the rated capacity of the FJ4B,which is 4000kg.
Fig.9

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MAINTENANCE
INSTRUCTIONS:
1. Apply several drops of a grade machine oil to the stem of the pump
plunger.
2. Oil the handle joints while operating the pump handle to work the oil
in.
3. Although the hydraulic unit on the FJ4B is a sealed unit and will
probably never need fluid adding to the reservoir, the following
instructions should be followed in the event fluid is needed:
To refill the reservoir, place the jack in normal upright position, and
completely lower jack by opening release knob. Carefully clean dirt
and contaminants form around the fill plug and the remove the plug.
Add Mobile DTE#13 hydraulic oil to reservoir until fluid runs out the fill
plug hole. Do not use brake fluid. (Extreme care should be taken to fill
plug the fluid contaminant free and keep dirt and contaminants out of
the reservoir of the jack.) Reinstall fill plug.
PUMP PRIMING
INSTRUCTIONS:
To prime the model FJ4B actuator, in the event that it inadvertently
becomes unprimed, proceed as follows:
1.Open release valve (large red knob on top) approximately 2 full tuns.
2.Stroke handle through 2 full turns, slowly.
3.Raise handle fully up, turnover jack on left side, as viewed from rear.
Push handle “down”.
4.Stand jack upright again, raise handle to up, lay over on left side
and push handle “down” again.
5.Stand jack upright, stroke handle while closing release valve and
jack should operate satisfactorily.

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FJ4B PLACARD
PARTS LIST
ITEM NO.
DESCRIPTION
NO.REQ’D
1
Warning Label (Use Stands to Support Vehicle)
1
2
Jack Position Plate
1
3
Lift Pad Instructions
1
4
Identification Piacard,FJ4B
1
5
Warning Label(Do Not Adjust)
1
WARNING
1
2
NOTICE
4
HFJ-400
3TWO
POSITION
LIFT PAD
WARNING 5

Part No Description App Qty Part No Description App Qty
FJ4B-01 SCREW 2FJ4B-38 LINK ROD 2
FJ4B-02 LOCK WASHER 4FJ4B-39 PIN 2
FJ4B-03 TRUNION 2FJ4B-40 RETAINING RING 2
FJ4B-04 FRAME 1 1FJ4B-41 PIN 1
FJ4B-05 SCREW 2FJ4B-42 HANDLE 1
FJ4B-06 WASHER 2FJ4B-43 O-RING 2
FJ4B-07 AXLE 1FJ4B-44 OIL TANK 1
FJ4B-08 SNAP RING 2FJ4B-45 O-RING 2
FJ4B-09 WASHER 2FJ4B-46 PORT RING 1
FJ4B-10 WHEEL 2FJ4B-47 CYLINDER 1
FJ4B-11 FRAME 2 1FJ4B-49 PISTON 1
FJ4B-12 SCREW 2FJ4B-50 VALVE SEAT 1
FJ4B-13 LOCK WASHER 2FJ4B-51 O-RING 1
FJ4B-14 NUT 2FJ4B-52 RELEASE ROD 1
FJ4B-15 SPACER 2FJ4B-53 RELEASE KNOB 1
FJ4B-16 PIN 1FJ4B-54 PIN 1
FJ4B-17 SADDLE 1FJ4B-55 CHAIN HOOK 1
FJ4B-18 PIN 1FJ4B-56 CHAIN HOOK 1
FJ4B-20 SCREW 2FJ4B-57 HANDLE BASE 1
FJ4B-21 SEAL RING 2FJ4B-58 RING 1
FJ4B-23 SPRING 1FJ4B-59 PIN 1
FJ4B-24 BALL SEAT 1FJ4B-60 HANDLE 1
FJ4B-25 BALL SEAT 1FJ4B-61 GRIP 1
FJ4B-26 VALVE BLOCK 1FJ4B-62 PIN 1
FJ4B-27 MAGNET STEEL 1FJ4B-63 O-RING 2
FJ4B-28 BALL 3FJ4B-64 BACK-UP RING 1
FJ4B-29 SPRING 1FJ4B-65 SEAL RING 1
FJ4B-30 SCREW 1FJ4B-66 SNAP RING 1
FJ4B-31 SEAL RING 1FJ4B-67 SCREW 1
FJ4B-32 PUMP 1FJ4B-70 PISTON ROD 1
FJ4B-33 O-RING 1FJ4B-71 WIPER 1
FJ4B-34 BACK-UP RING 1FJ4B-72 Y-RING 1
FJ4B-36 PLUNGER 1FJ4B-73 SCREW 1
FJ4B-37 RETAINING RING 6

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