IRONguard PowerTower Hitch Hauler Instruction Manual

OPERATOR’S
SAFETY MANUAL
P/N 4026613
Hitch Hauler
www.ironguardsafety.com

PowerTower Hitch Hauler by IRONguard Safety Products
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It is very important that you read, understand and obey the contents of
this manual! Keep it easily accessible for reference at all times.
The purpose of this manual is to provide safe and proper operating procedures
for anyone utilizing the benefits of the Hitch Hauler.
Because we at IRONguard Safety Products are always working to improve our
products, processes and procedures, we reserve the right to make changes
without prior notice. Please contact us at IRONguard Safety Products for
updated information.
This is the Safety Alert Symbol. It is used throughout this manual and on the
machine to alert you to potential personal injury hazards. Understand and obey all
safety messages that correspond with this symbol to avoid possible injury or death.
INDICATES AN IMMINENTLY HAZARDOUS SITUATION AND IF NOT AVOIDED
WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED
BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED,
COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE
AN ORANGE BACKGROUND.
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS.
CONTACT IRONGUARD SAFETY PRODUCTS OR THE LOCAL AUTHORIZED
IRONGUARD SAFETY PRODUCTS REPRESENTATIVE FOR INFORMATION
REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED
FOR THIS PRODUCT.
DANGER
NOTICE
CAUTION
WARNING
DANGER
NOTICE
CAUTION
WARNING
DANGER
NOTICE
CAUTION
WARNING
SAFETY ALERT SYMBOLS AND
SAFETY SIGNAL WORDS
Hitch Hauler
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INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT IF NOT AVOIDED,
MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST
UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.
IRONGUARD SAFETY PRODUCTS SENDS SAFETY RELATED BULLETINS
TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT IRONGUARD
SAFETY PRODUCTS TO ENSURE THAT THE CURRENT OWNER RECORDS ARE
UPDATED AND ACCURATE.
IRONGUARD SAFETY PRODUCTS MUST BE NOTIFIED IMMEDIATELY IN
ALL INSTANCES WHERE OUR PRODUCTS HAVE BEEN INVOLVED IN AN
ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR
WHERE SUBSTANTIAL PERSONAL PROPERTY DAMAGE OR DAMAGE TO THE
IRONGUARD SAFETY PRODUCTS PRODUCT HAS OCCURRED.
DANGER
NOTICE
CAUTION
WARNING
FOREWORD
DANGER
NOTICE
CAUTION
WARNING
FOR:
• Accident Reporting
• Product Safety Publications
• Current Owner Updates
• Product Safety Questions
• Standards and Regulations Compliance Information
• Questions Regarding Special Applications
• Questions Regarding Product Modifications
CONTACT:
Technical Safety and Engineering Department
181 Regina Road
Vaughan, ON L4L 8M3 Canada
In USA
Toll Free: 866-828-6737
E-mail: [e-mail]

PowerTower Hitch Hauler by IRONguard Safety Products
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REVISION LOG
Original issue of Manual........................................May 11, 2012
TABLE OF CONTENTS
SECTION - INFORMATIONAL
FOREWORD ........................................................................................................ 2
SAFETY ALERT SYMBOLS AND SAFETY WORDS ....................................... 2-3
CONTACT ........................................................................................................... 3
REVISION LOG ................................................................................................... 4
SECTION - 1 - SAFETY PRECAUTIONS ............................................................ 6
1.1 GENERAL.................................................................................................... 6
1.2 PRE-USE ..................................................................................................... 6
User Preparedness .......................................................................... 6
Transport Vehicle Inspection ........................................................... 7
Hitch Hauler Inspection ................................................................... 7
1.3 USER GUIDELINES.................................................................................... 8
General ............................................................................................. 8
Fall Hazard........................................................................................ 8
Lifting Instructions........................................................................... 9
Tipping Hazards ..............................................................................10
Crushing and Collision Hazards ....................................................10
Additional Safety Information .......................................................11
SECTION - 2 - PREPARATION AND INSPECTION .......................................... 12
2.1 PERSONNEL REQUIREMENTS ............................................................... 12
User Requirements........................................................................ 12
User Responsibilities..................................................................... 12
2.2 PREPARATION, INSPECTION AND MAINTENANCE ............................. 13
2.3 PRE-USE INSPECTION .............................................................................14
Pre-Use Inspection..........................................................................14
2.4 FUNCTION CHECK................................................................................... 18
Function Check Items .....................................................................19

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SECTION - 3 - MACHINE OPERATION............................................................ 20
3.1 GENERAL.................................................................................................. 20
3.2 MACHINE DESCRIPTION......................................................................... 20
3.3 MACHINE OPERATION............................................................................ 22
General ........................................................................................... 22
3.4 SET-UP AND USE ..................................................................................... 24
Set-Up and Prepare for Loading................................................... 24
Load the PowerTower.................................................................... 26
Check Complete Installation ......................................................... 28
Unload the PowerTower................................................................ 30
SECTION - 4 - SERVICE AND MAINTENANCE............................................... 32
4.1 MAINTENANCE SAFETY PRECAUTIONS .............................................. 32
General ........................................................................................... 32
Maintenance Safety....................................................................... 33
4.2 PREPARATION, INSPECTION AND MAINTENANCE ............................. 34
General ........................................................................................... 34
Preparation, Inspection and Maintenance................................... 34
Pre-Use Inspection......................................................................... 34
Frequent and Pre-Delivery Inspection.......................................... 35
Preventative Maintenance ............................................................ 35
4.3 PREVENTATIVE MAINTENANCE AND INSPECTION SCHEDULE......... 36
Inspection and Maintenance Codes ............................................. 36
4.4 SERVICING AND MAINTENANCE GUIDELINES.................................... 38
General ........................................................................................... 38
Safety and Workmanship ............................................................. 38
Cleanliness ..................................................................................... 38
Component Disassembly and Reassembly ................................. 38
4.5 REPLACEMENT KITS ............................................................................... 40
4.6 DECAL REPLACEMENT ........................................................................... 42
TABLE OF CONTENTS

PowerTower Hitch Hauler by IRONguard Safety Products
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This manual is your guide for establishing habitual precautions for safe operation
of the Hitch Hauler.This section is your guide in developing a daily routine that
focuses on safety and proper maintenance of the Hitch Hauler prior to each
use. A maintenance program must be established and conducted by a qualified
person to ensure the Hitch Hauler is in safe working condition before it is used.
Before using the Hitch Hauler, the user shall:
1. Read, understand and obey the operating instructions and safety rules.
2. Obey all labels, warnings and instructions located on the Hitch Hauler.
3. Be sure that all operators of the Hitch Hauler wear appropriate personal
protection equipment (PPE) for the conditions.
If there are any questions regarding safety, training, maintenance, inspection,
application or operation of the machine, please contact IRONguard Safety
Products.
FAILURETO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL
COULD RESULT IN HITCH HAULER DAMAGE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
1.1 General
DANGER
NOTICE
CAUTION
WARNING
SECTION 1: SAFETY PRECAUTIONS
User Preparedness
• Do not operate this Hitch Hauler until the operator has read and fully
comprehends the Operator’s Safety Manual of the Hitch Hauler.
• Only competent personnel may operate the Hitch Hauler.
• Read, fully comprehend and obey all DANGERS, WARNINGS, CAUTIONS
and operating instructions on the Hitch Hauler and in this manual.
• Only use this Hitch Hauler in a manner which is within the scope of the
intended application set by IRONguard Safety Products.
1.2 Pre-Use
Figure 1-1: Read your manual

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• All operators must read, comprehend and obey all applicable
employer, local and governmental regulations as they pertain to the
safe operation of the Hitch Hauler.
Transport Vehicle Inspection
• The user is to take measures to identify and avoid all hazards that will
affect the safe operation of the Hitch Hauler.
• Be sure the transport vehicle is capable of safely transporting the
PowerTower.
• Be sure to inspect the vehicle receiver hitch. Make sure it is a 2” class
3 minimum vehicle receiver hitch and is installed properly, in good
condition and capable of carrying the intended load.
Hitch Hauler Inspection
• Before installing the Hitch Hauler on the vehicle, perform an inspection
and function check. Refer to Section 2 of this manual for further
instructions.
• No one shall use the Hitch Hauler until it has been inspected, serviced
and maintained according to the requirements in this manual.
MODIFICATION OR ALTERATION OF THE HITCH HAULER SHALL BE MADE
ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER
• Do not use any Hitch Hauler on which the safety decals or instruction
placards are missing or illegible.
• Avoid any build up of debris on the components of the Hitch
Hauler. Keep mud, oil, grease and other slippery substances from
accumulating on the Hitch Hauler.
SECTION
1
SAFETY PRECAUTIONS
DANGER
NOTICE
CAUTION
WARNING

PowerTower Hitch Hauler by IRONguard Safety Products
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1.3 User Guidelines
General
• Do not use the Hitch Hauler for any purpose other than to carry and
transport a PowerTower.
• Never use a Hitch Hauler that is not working properly. If a malfunction
occurs, remove the Hitch Hauler and contact IRONguard Safety Products.
• Be sure that all locking pins are present and in good condition before
installing the Hitch Hauler.
• Do not transport tools, drills or other materials on the PowerTower
platform.
• Be sure to fully lower the PowerTower platform before loading the
PowerTower on the Hitch Hauler.
• Be sure the mast sections and outriggers of the PowerTower are in their
properly stowed position before loading on the Hitch Hauler.
• Be sure all pins and fasteners are in place and secure before leaving the
loaded PowerTower unattended.
Fall Hazards
• Do not enter the PowerTower platform while it is loaded on the Hitch
Hauler (Figure 1-2).
• Do not stand or sit on any part of the Hitch Hauler (Figure 1-3).
• Be sure to check that there are no rear obstructions that could cause the
user to trip while unloading (curb, pothole,uneven pavement, etc).
SECTION
1SAFETY PRECAUTIONS
Figure 1-2: Do not enter PowerTower
platform while loaded on Hitch Hauler
Figure 1-3: Do sit or stand on any part of Hitch Hauler

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SECTION
1
SAFETY PRECAUTIONS
Lifting Instructions
The number of people required to load and unload the PowerTower on to the
Hitch Hauler is dependent on a number of factors:
• The physical condition, strength, ability and prior injuries of the people
involved.
• The stance, posture and grip used by the people involved.
• The lifting techniques used.
• The site conditions and weather on which the activity is being
performed.
• The appropriate number of people, proper lifting techniques and must
be used to prevent injury.
Note: If it is determined that the user is unable to safely load or unload the
PowerTower from the Hitch Hauler in a safe manner and no additional help
is available, the user should remove the appropriate number of components
(mast sections, outriggers, platforms) to optimize the weight to better suit the
operators physical ability
• Before loading or unloading the PowerTower, be sure the transport
vehicle is parked on a surface that is level and free of slippery
substances such as ice, wet leaves, loose gravel or any other substance
that could cause the user to loose traction and fall (Figure 1-4).
Figure 1-4: Do not load or unload on uneven or slippery surfaces

PowerTower Hitch Hauler by IRONguard Safety Products
10
Tipping Hazards
• Do not attempt to load or unload the PowerTower from the Hitch
Hauler if the vehicle is on a slope or
if the ground or pavement surface is
uneven (Figure 1-5).
• Always maintain a firm, comfortable grip
on the PowerTower during loading
and unloading.
• Apply even lifting pressure when
loading and even resistance when
unloading the PowerTower.
• When unloading, be sure to
maintain control of the PowerTower at all times.
• Be sure there is adequate space for both the user and the PowerTower
when unloading.
Crushing and Collision Hazards
• Be sure to determine that there is an adequate escape path for the user
during the loading and unloading process (Figure 1-6).
• Check area clearances above, on sides and on bottom of platform
when loading and unloading the PowerTower.
• Always check to be sure the PowerTower
will clear any overhead obstacles
during transport (parking garages,
overhead doors, drive through
awnings, etc.).
• Be sure the bearing surfaces of
the Hitch Hauler are clear of any
foreign debris before loading.
SECTION
1SAFETY PRECAUTIONS
Figure 1-5: Tipping Hazard
Figure 1-6:Tripping on a Pothole or Curb

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SECTION
1
SAFETY PRECAUTIONS
Additional Safety Information
• Do not use Hitch Hauler as a ground for welding.
• Do not attempt to load the PowerTower on to the Hitch Hauler with a
forklift.
• Be sure there is adequate clearance between the castors and ground
surface. Refer to Section 3 for more details.
Notes:

PowerTower Hitch Hauler by IRONguard Safety Products
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2.1 Personnel Requirements
This Hitch Hauler is intended to be used as a PowerTower transport device only
and must be used and maintained by competent personnel only.
Anyone under the influence of drugs, alcohol or are subjected to dizziness,
seizures or loss of physical control must not operate this Hitch Hauler.
User Requirements
Before operating this Hitch Hauler, the owner must read and comprehend
this manual.
The operator must be familiar with:
1. Use and limitations of the components of the Hitch Hauler.
2. The Hitch Hauler and in this manual.
3. Employer and government regulations.
4. Enough mechanical aptitude and knowledge of the Hitch Hauler to
recognize a component malfunction or a potential malfunction.
5. The safest means to operate the Hitch Hauler where overhead
and ground hazards are present.These hazards include: overhead
obstructions, obstacles, depressions, drop-offs, etc.
SECTION 2: PREPARATION & INSPECTION
User Responsibilities
The exercise of good judgment, safety control, and caution in evaluating each
situation is the responsibility of the User.The User must discontinue use of the
Hitch Hauler in the event of a malfunction or other unsafe condition of the Hitch
Hauler.

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2.2 Preparation, Inspection & Maintenance
SECTION
2
PREPARATION & INSPECTION
The following table (Table 2-1) outlines the periodic Hitch Hauler inspection
and maintenance recommended by IRONguard Safety Products. Consult local
regulations for further requirements.
The frequency of inspections and required maintenance must be increased if the
Hitch Hauler is exposed to harsh conditions, increased use or if the machine is
used in a severe manner.
Table 2-1: Inspection and Maintenance
TYPE FREQUENCY
PRIMARY
RESPONSIBILITY
SERVICE
QUALIFICATION REFERENCE
Pre-Use
Inspection
Before starting
each day or at
shift change.
Owner, User Owner, User Operator’s
Safety Manual
Frequent
Inspection
In service or out
of service for 3
mo. or purchased
used.
Owner, Dealer or
User
Qualied
Mechanic*
Operator’s
Safety Manual
Replacement
When components
are worn or
damaged.
Owner, Dealer or
User
Qualied
Mechanic*
Operator’s
Safety Manual
NOTE: Use this manual to perform inspections.
NOTE: *A person who has acquired training, qualifications or a combination
of these, the knowledge and skill enabling the person to inspect and repair the
Hitch Hauler to the level required by the complexity of the task.

PowerTower Hitch Hauler by IRONguard Safety Products
14
SECTION
2PREPARATION & INSPECTION
The Pre-Use Inspection should include each of the following:
1. Cleanliness - Check all surfaces for build-up of debris or foreign
objects.
2. Decals and Placards - Check for cleanliness and legibility. Make
sure none of the decals or placards are missing. Make sure all
illegible decals are cleaned or replaced. (Reference Section 4.6 Decal
Installation).
3. Safety, Service - Make sure a copy of the Operator’s Safety manual is
available for reference.
4. Assembly - Make sure the Hitch Hauler is assembled in accordance with
Section 3.
5. Pre-Use Inspection - Refer to (Table 2-2) and (Figure 2-1).
6. Function Check - Once the Pre-Use Inspection is complete, perform a
function check to be sure the Hitch Hauler moves freely.
2.3 Pre-Use Inspection
Pre-Use Inspection
Begin the Pre-Use Inspection starting at item one (1) as noted on the diagram
(Figure 2-1). Continue around the Hitch Hauler checking each item in sequence
for the conditions listed in the following check list (Table 2-2).
TO AVOID POSSIBLE INJURY DO NOT USE THE HITCH HAULER UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED.
NOTE: Do not overlook the underside of the Base Frame and Receiver Mount.
Check these areas for corrosion, debris and cracks.
NOTE: Make sure there are no loose or missing parts and that all components
are present and securely fastened. Make sure that there is no visible damage or
excessive wear.
DANGER
NOTICE
CAUTION
WARNING

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SECTION
2
PREPARATION & INSPECTION
Notes:

PowerTower Hitch Hauler by IRONguard Safety Products
16
SECTION
2PREPARATION & INSPECTION
6
1
7
3
5
9
8
12
13
4
210
11
Figure 2-1: Pre-Use Inspection Points

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SECTION
2
PREPARATION & INSPECTION
Figure 2-1: Pre-Use Inspection Points
NO. PART BE SURE TO CHECK THE FOLLOWING:
1 Receiver Mount The main component is not bent or misshapen in any way. The intersecting welds are not
cracked and any visible rust or corrosion is conned to the surface discoloration only.
2 Base Frame Check for cracks or corrosion especially at intersecting weld joints. Check the underside of the
Base Frame for any excessive skid wear, rust or corrosion.
3 Rubber Bumpers All six (6) rubber bumpers are present, properly installed and free of excessive wear. 4 Retaining Washers All six (6) retaining washers are present, properly installed free of excessive rust or
corrosion.
5 Retaining Pin It is present and is in good working condition. 6 Master Pin It is present, not bent or misshapen in any way and is free of excessive rust or corrosion. 7 Receiver Hitch Pin It is in good condition free of excessive rust or corrosion. 8 Adjustment Pins They are is present and complete with hairpin cotter pin and are in good condition free of
excessive rust or corrosion.
9Rear Rocker Arm It is present, securely attached, not bent or misshapen in any way and that it rotates freely.
10 Front Rocker Arm It is present, securely attached, not bent or misshapen in any way and that it rotates freely.
11 Rocker Plate It is present, securely attached, not bent or misshapen in any way and that it rotates and
tilts freely and completely.
12 Rocker Plate Latch It is present, securely attached, not bent or misshapen in any way and that it rotates and
tilts freely and completely.
13 Latch Spring It is present, securely attached, not bent or misshapen in any way and that it rotates freely.
Table 2-2: Pre-Use Inspection

PowerTower Hitch Hauler by IRONguard Safety Products
18
SECTION
2PREPARATION & INSPECTION
Once the Pre-Use Inspection check is complete, perform a function check making
sure the Hitch Hauler components fit properly and operate smoothly. Refer to
Table 2-3 and Figure 2-2.
IF THE HITCH HAULER DOES NOT OPERATE PROPERLY, REMOVE FROMTHE
TRANSPORT VEHICLE IMMEDIATELY! REPORTTHE PROBLEM TOTHE PROPER
MAINTENANCE PERSONNEL AND DO NOT INSTALL OR USE THE HITCH
HAULER UNTIL IT HAS BEEN DEEMED SAFE FOR USE.
2.4 Function Check
DANGER
NOTICE
CAUTION
WARNING
1
4
2
3
Figure 2-2: Pre-Use Inspection Points

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SECTION
2
PREPARATION & INSPECTION
Table 2-3: Function Check Items
NO. PART BE SURE TO CHECK THE FOLLOWING:
1Receiver
Mount
Check to be sure one of the two (2) clearance holes in the tube of the
receiver mount properly align with the clearance hole in the receiver.
2 Base Frame
Check to be sure the adjustment bracket of the Base Frame aligns with
the adjustment bracket of the receiver mount and that the vehicle mounted
receiver is at a height that can provide adequate ground clearance for
safe PowerTower transport.
3Rocker
Plate
Check to be sure the Rocker Plate is functioning freely and properly by
tilting the Rocker Plate forward and back checking to be sure it rotates
smoothly and seats properly. Check to be sure when the Rocker Plate is
tilted in the forward position the front rocker arm comes in to even contact
with the Base Frame.
4Rocker
Plate Latch
Check to be sure the Rocker Plate Latch is functioning freely and properly
by tilting the Rocker Plate Latch forward and back. Check to be sure it
rotates smoothly and locks properly.
Notes:

PowerTower Hitch Hauler by IRONguard Safety Products
20
3.1 General
NOTE: The manufacturer has no direct control over the machine application and
operation.The operator is responsible for following good safety practices.
3.2 Machine Description
The IRONguard Safety Products Hitch Hauler (Figure 3-1) is a vehicle mounted
system designed to transport the IRONguard Safety Products PowerTower
from site to site.The Hitch Hauler is rated only to carry the IRONguard Safety
Products PowerTower (Figure 3-2) and is compatible with most Class III
minimum 2” receiver hitches.
SECTION 3: MACHINE OPERATION
Figure 3-1: Hitch Hauler Unloaded
1. Receiver Mount
2. Base Frame
3. Rubber Bumpers
4. Retaining Washers
5. Retaining Pin
6. Master Pin
7. Receiver Hitch Pin
8. Adjustment Pins
9. Rear Rocker Arm
Legend
6
1
7
3
5
9
8
12
13
4
210
11
10. Front Rocker Arm
11. Rocker Plate
12. Rocker Plate Latch
13. Latch Spring