Lift-rite Ergo 3000 nomic User manual

OPERATOR’S MANUAL/INSTRUCTIONS/PARTS & SERVICE

FOR MANUAL & ELECTRIC

This publication, 1130682/001G, applies to the Lift-Rite ERGONOMIC 3000 Series Hand Pallet Trucks and to all subsequent

releases of this product until otherwise indicated in new editions. Changes occur periodically to the information in this

publication.

To order additional copies of this manual, part number 1130682/001G, contact your local authorized Lift-Rite Sales and

Service Center.

If you need assistance with your lift truck, contact your local authorized Lift-Rite Sales and Service Center.

For more information please visit www.liftrite.com

TABLE OF CONTENTS

BEFORE YOU BEGIN 4

DELIVERY INSPECTION 4

SAFETY 5

Electric ERGONOMIC 3000 5

ERGONOMIC 3000 with Remote Control 5

OPERATION 6

DAILY CHECKLIST 7

MAINTENANCE 7

TROUBLESHOOTING 8

FRAME • SCISSOR ASSEMBLY 10

THRUST PLATE • WHEEL ASSEMBLY 12

PUMP & HANDLE ASSEMBLY MANUAL 14

PUMP & HANDLE ASSEMBLY ELECTRIC 16

ELECTRICAL COMPONENTS 18

ERGONOMIC 3000 WARRANTY 20

SELECTED OSHA REGULATIONS FOR LIFT TRUCKS 21

BEFORE YOU BEGIN

Always follow your facility’s rules regarding wearing Personal Protective Equipment such as safety

shoes and protective glasses whenever operating, working with, or assembling or dismantling

hand pallet trucks.

DELIVERY INSPECTION

Visually inspect the ERGONOMIC 3000 frame components and hydraulic unit for damage during

shipment by carrier. If damage is evident, notify delivering carrier immediately and file necessary

claims. Test the manual pump of the ERGONOMIC 3000 for proper operation.

If the hydraulic pump does not respond to movement of the handle, an air lock may have

developed during shipping. To remedy this, go to the user friendly TROUBLESHOOTING

guide in this manual.

CAUTION

•Alwaysstay within the rated capacity to make sure of a safe lift.

• Always make sure that the load is stable before moving to eliminate

opportunity for load shift.

•Keep hands on inner handle during travel to protect hands from

striking other objects.

•The ERGONOMIC 3000 is designed to ergonomically lift and position

loads. Horseplay is not recommended.

•When not in use, fully lower the forks to avoid injury.

•The operator must be familiar with the operator’s instructions and

warnings in this manual prior to operating this equipment.

•The operator must be trained in the safe operation and function of all

controls prior to operating this equipment.

SAFETY

(Read and understand prior to using this product)

• Do not operate this ERGONOMIC 3000 truck unless you are authorized and trained to do so.

• Never overload your ERGONOMIC 3000 truck. Stay within its rated capacity.

• Do not operate this truck if damaged or not in proper working order.

•Distribute the load evenly on the forks. Do not concentrate loads at one point or load one fork

more than the other.

• When the load impairs visibility, the ERGONOMIC 3000 truck should be pulled and not pushed.

• Always look where you are operating. Keep a clear view.

• Only handle loads on flat level surfaces. Do not use a loaded truck on inclines or declines.

• Never carry passengers.

•Do not place the center of your load beyond the load center of the ERGONOMIC 3000.

• Never put your feet, hands, or any other body part under the scissors or frame assembly.

• Always yield the right of way to pedestrians.

•Do not allow the ERGONOMIC 3000 to drop from one level to another. Even a drop of 1 in. (25

mm) more than doubles the effective load momentarily and results in a loading that can bend

or break components.

•Move loads only with the ERGONOMIC 3000 in its lowest position.

• Always make sure that the load is stable before moving to eliminate the opportunity for load

shift.

• Use extreme care when rounding corners. Too fast a speed could cause an ERGONOMIC 3000

truck to tip. If loaded, the load could shift and fall.

• When not in use, fully lower the forks.

•Electric ERGONOMIC 3000 must be charged in a well ventilated area. Always use the charger

provided. Never use jumper cables as these can cause sparks that could ignite the explosive

gases normally released by the battery during charging.

• The stabilizer engages to limit movement in the raised position and should not be tampered

with.

Electric ERGONOMIC 3000

Connect the lift plug into the battery connection on the side of the battery box and test the electric

power pack by operating the raise button near the top of the handle. If the pump fails to respond,

see the “TROUBLESHOOTING” section.

ERGONOMIC 3000 with Remote Control

The hand or foot operated remote control must be plugged into the receptacle on the top of the

battery box for it to operate. Operate both the raise and lower push buttons or foot pedals tomake

sure the remote control functions correctly.

NOTE: If you purchased an electric ERGONOMIC 3000 without the remote control option, it can be

purchased separately from your Lift-Rite dealer.

OPERATION

Your ERGONOMIC 3000 is designed to ergonomically lift and position loads, but not pallets. Pallets

have bottom boards nailed to the stringers. These can damage your ERGONOMIC 3000 because

they restrict the lifting action of the scissor legs.

The pump piston and lifting ram have a polished hard chrome finish to provide maximum seal life

and minimum leakage. Do not allow these surfaces to be nicked or pitted by abuse. A slight oil

wetting of the external parts of the pistons is normal to provide lubrication for the highly polished

surfaces and the seals through which they pass. Do not be alarmed at a trace of oil even on new

units.

Load Center and Load Placement (Reference Layout): All loads must be placed on the back of

the fork nearest the operator to avoid tipping of loads (see diagram). In any case, do not exceed

load. Load center is indicated on the following chart.

Neutral Position: A gentle pull on the handle engages the neutral position and the handle can be

moved without lifting of the forks. This enables you to move the ERGONOMIC 3000 from one place

to another without activating the pump.

Manual Lifting: To raise the ERGONOMIC 3000 manually, pump the handle. Your ERGONOMIC

3000 has an automatic neutral sensor that activates the pump cylinder when pumping action is

detected.

Lowering: To lower the ERGONOMIC 3000, pull on the fingertip control lever. By varying the

position of the lever, you can control the lowering speed.

Electric Lifting: Raise the ERGONOMIC 3000 by pressing and holding the raise button on the

handle. To lower the ERGONOMIC 3000, pull on the fingertip control lever. By varying the position

of the lever, you can control the lowering speed. If your battery becomes discharged before you

finish your work, you can operate an electric ERGONOMIC 3000 manually as described above.

Max. Load Center

(Max L.C.) Max. Capacity

60 in. 30 in. 2200 lbs.

48 in. 24 in. 3000 lbs.

42 in. 21 in. 3000 lbs.

36 in. 18 in. 3000 lbs.

Remote Control: The remote control hand or foot operator must be plugged into the receptacle

on the top of the battery box. The raise and lower buttons or pedal now operate the ERGONOMIC

3000 as indicated.

Charging the 12 Volt Battery: Move your ERGONOMIC 3000 to a well ventilated area. Raise the

ERGONOMIC 3000 manually and unwind the AC plug from the tie-down inside the bulkhead. Lower

the ERGONOMIC 3000 completely and disconnect the lift plug from the battery connector (on the

side of the battery box). Insert the charge plug into the battery connector. The lights on the battery

charger indicate the current battery condition. Plug the AC plug into a 110 volt, 60 Hz receptacle.

When your battery is fully charged, unplug the AC plug from its receptacle, then disconnect the

charger plug from the battery plug and reinsert the lift plug. Carefully raise the ERGONOMIC 3000

and secure the AC cord and the charger plug to the respective tie-downs inside the bulkhead.

Store the charger power cord in the bracket at all times when not in use.

Electric hazard can occur if the plug comes in contact with the battery.

DAILY CHECKLIST

MAINTENANCE

Lubrication: All pivot points in the ERGONOMIC 3000 are equipped with permanently lubricated

bushings and bearings. To increase bearing life, it is recommended that a few drops of light

machine oil be applied at each pivot point every 6 months. The main bearing in the thrust plate is

equipped with a grease zerk. This should be greased every 6 months.

Hydraulic System: Your hydraulic system is maintenance free. Do not add hydraulic oil unless

there is, or has been, a leak. Use Sunoco Sunvis 832 oil or equal. Other oils, fluids, or solvents may

damage your hydraulic system. With the ERGONOMIC 3000 in its lowered position, fill the reservoir

through the oil plug hole until the oil is even with the plug hole.

CHECK

POINTS Steering

Hydraulic

System Wheels

Chassis/

Handle

Lifting/

Lowering Labels

Batteries (if

equipped)

ACTION Checkfull

rotation.

Check for

excessive

oil on

exterior.

Check for

wear,

damage,

and remove

debris.

Check for

damage

and

remove

debris.

Check for

manual

function

and electric

lift (if

equipped).

Check for

readability.

Check for

correct

voltage and

weight, no

leakage, and

battery

disconnect

function.

Maintenance-Free Batteries: The truck is equipped with a maintenance-free battery. Please obey

manufacturer’s recommendations for service of these batteries.

A maintenance-free battery still requires some care. The battery must be kept clean and dry and

may be washed to remove any accumulated foreign matter.

TROUBLESHOOTING

Manual Pump Fails to Raise ERGONOMIC 3000

Please make sure to pump the handle at a speed quick enough to overcome the manual pump

neutral position. There may be an air lock in the hydraulic system. Pull the control lever and operate

the pump several times. Operate the pump normally to raise ERGONOMIC 3000. Check to see if the

release lever on the pump base moves freely. Loosen the high pressure adjusting screw [item #21

on page 12]. Operate the pump several times, then tighten the high pressure screw. A small amount

may leak from the screw while it is loose.

ERGONOMIC 3000 Fails to Raise Completely

Check scissor legs and floor for obstructions. Check for proper hydraulic fluid level and look for

signs of an oil leak.

Electric ERGONOMIC 3000 Does Not Respond to Raise Button

Check the battery connection to make sure that it is plugged in. If the ERGONOMIC 3000 has been

idle for a long period of time, the battery may have become discharged. Connect the charger as

described under OPERATION on page 4, and make sure that the battery is fully charged. Check all

electrical connections.

Optional Remote Control Does Not Lower

Check to make sure that the remote control is plugged in. Check for damage to the hydraulic power

pack. The solenoid may be damaged and may need to be replaced.

Neutral Position

If the pump has no neutral position, turn the neutral valve [Item #23 on page 12 or 14] clockwise

until the desired neutral action is achieved. If the pump does not engage quick enough, turn the

neutral valve [Item #23 on page 12 or 14] counterclockwise until the pump action is satisfactory.

FOR THESE AND ALL OTHER TROUBLESHOOTING QUESTIONS, PLEASE CONTACT YOUR

LOCAL AUTHORIZED LIFT-RITE DEALER.

THIS PAGE LEFT BLANK INTENTIONALLY

FRAME • SCISSOR ASSEMBLY

Item No. Description Part Number Quantity

1 27 x 48 CHASSIS PR-8021A48 1

20.5 X 48 CHASSIS PR-8021B48 1

2 SNAP RING PL-20232 1

3SPLIT PIN PL-10269 4

4 BUSHING PL-10203A 4

5INNER LEG CLEVIS PIN PR-8012/8013 2

6 OUTER LEG CLEVIS PIN PR-8012/8013 2

7FORK ROLLER W/BUSHING PR-8007 4

8 BUSHING PR-8007A 4

948 IN. LEG ASSEMBLY RIGHT 1125955/003 1

10 48 IN. LEG ASSEMBLY LEFT 1125956/003 1

11 AXLE ASSEMBLY PL-20215-l 2

12 BEARING PL-20214 4

13 NYLON ROLLER COMPLETE PL-20210BN-B 2

POLY ROLLER COMPLETE 167609 2

STEEL ROLLER COMPLETE PL-20210S-BRG 2

14 WASHER PL-10239 4

15 SPLIT PIN PL-10242 2

16 BUSHING PR-8516 4

17 WASHER PL-10241 2

18 STABILIZER ASSEMBLY PR-8010 2

THRUST PLATE • WHEEL ASSEMBLY

Item No. Description Part Number Quantity

1 27 IN. THRUST PLATE - MANUAL MODEL PR-8024A 1

27 IN. THRUST PLATE - ELECTRIC MODEL 1130181/001 1

20.5 IN. THRUST PLATE - MANUAL MODEL PR-8024B 1

20.5 IN. THRUST PLATE - ELECTRIC MODEL 1130181/002 1

2 PUMP COLLAR AR-8030 1

3THRUST PLATE BEARING PR-8512 2

4 WHEEL MOUNT PR-8031A 1

5BUSHING PL-10203 2

6 HUB CAP PL-10236C 2

7STEER WHEEL

NYLON PL-20236BN-B 2

POLY PL-20236B-B 2

STEEL PL-10236BS-BRG 2

8SNAP RING PL-10237 2

9 BEARING PL-10238D 4

10 SOCKET HEAD CAP SCREW PR-8518 2

PUMP & HANDLE ASSEMBLY MANUAL

Item No. Description Part Number Quantity

1 BALL PL-10244 1

2PISTON PR-8530A 1

3 BUSHING PR-8538 1

4SEAL PR-8539 1

5 RING PR-8540 1

6LOCK RING PR-8541 1

7 TOP NUT COMPLETE PR-8529 1

8WIPER SEAL PR-8529A 1

9 O-RING PR-8529B 1

10 O-RING PR-8529C 1

11 SEALON PR-8582A 1

12 BREATHER PR-8582 1

13 SEALON PR-8528 1

14 FILLER SCREW PR-8527 1

15 SPLIT PIN PL-20274S 2

16 ADJUSTING SCREW PR-8542 1

17 WASHER PR-8543 2

18 SPRING PR-8544 1

19 8 mm BALL PR-8545 1

20 9 mm BALL PR-8546 1

21 ADJUSTING SCREW PR-8547 1

22 VALVE SEAT PR-8549 1

23 NEUTRAL VALVE PR-8548 1

24 O-RING PR-8548B 2

25 O-RING PR-8548A 2

26 O-RING PR-8551 1

27 PIN PR-8554 1

28 U-RING PR-8552 1

29 VALVE SCREW PR-8553 1

30 WASHER PR-8555 1

31 BUSHING PR-8556 1

32 WASHER PR-8537 1

33 SPRING PR-8533 1

34 PUMP CYLINDER PR-8536 1

35 U-CUP PR-8534B 1

36 RING PR-8534A 1

37 COMPLETE QUICK LIFT PISTON PR-8534 1

38 COMPLETE UNION NUT PR-8535 1

39 UNION NUT O-RING (THREAD) PR-8535C 1

40 UNION NUT O-RING PR-8535B 1

41 UNION NUT SEAL PR-8535A 1

42 WASHER PR-8532 1

43 TOP SCREW PR-8531A 1

44 CONTROL ROD COMPLETE PR-20274ACM 1

45 LOCK NUT 21094 1

46 LEVER CLIP 42631 1

47 SPLIT PIN PR-8559 1

48 LOWERING ARM PR-8558 1

49 PIN PL-20275 2

50 BUSHING PL-20306 2

51 SPLIT PIN PL-10269 1

52 CONTROL LEVER PL-20274BD 1

53 BALL PL-10254 2

54 SPRING PL-20274C 1

55 CAP PL-20274E 1

56 COMPLETE HANDLE PR-20276TDM 1

57 ERGO-PUMP VALVE KIT PR-8575 1

58 ERGO-PUMP SEAL KIT PR-8577 1

PUMP & HANDLE ASSEMBLY ELECTRIC

Item

No. Description Part No. Qty.

Item

No. Description Part No. Qty.

1 BALL PL-10244 1 35 U-CUP PR-8534B 1

2PISTON PR-8530A 136 RING PR-8534A 1

3 BUSHING PR-8538 1 37 COMPLETE QUICK

LIFT PISTON PR-8534 1

4SEAL PR-8539 138 COMPLETE UNION

NUT PR-8535 1

5 RING PR-8540 1 39 UNION NUT

O-RING (THREAD) PR-8535C 1

6LOCK RING PR-8541 140 UNION NUT

O-RING PR-8535B 1

7TOP NUT

COMPLETE PR-8529 1 41 UNION NUT

SEAL PR-8535A 1

8WIPER SEAL PR-8529A 142 WASHER PR-8532 1

9 O-RING PR-8529B 1 43 TOP SCREW PR-8531A 1

10 O-RING PR-8529C 144 CONTROL ROD

COMPLETE PR-20274ACM 1

11 SEALON PR-8582A 1 45 LOCK NUT 21094 1

12 BREATHER PR-8582 146 LEVER CUP 42631 1

13 SEALON PR-8528 1 47 SPLIT PIN PR-8559 1

14 FILLER SCREW PR-8527 148 LOWERING ARM PR-8558 1

15 SPLIT PIN PL-20274S 2 49 PIN PL-20275 2

16 ADJUSTING

SCREW PR-8542 150 BUSHING PL-20306 2

17 WASHER PR-8543 2 51 SPLIT PIN PL-90569E 1

18 SPRING PR-8544 152 CONTROL LEVER PL-20274BD 1

19 8 mm BALL PR-8545 1 55 CAP PL-20274E 1

20 9 mm BALL PR-8546 156 * COMPLETE HANDLE PR-20276TDE 1

21 ADJUSTING

SCREW PR-8547 1 57 RELIEF VALVE PR-8557 1

22 VALVE SEAT PR-8549 158 O-RING PR-8557B 1

23 NEUTRAL VALVE PR-8548 1 59 O-RING PR-8557A 1

24 O-RING PR-8548B 2

25 O-RING PR-8548A 2 61 SUCTION LINE 1143999 1

26 O-RING PR-8551 162 FITTING PR-8563 1

27 PIN PR-8554 1 63 ELBOW FITTING 1144002/001 1

28 U-RING PR-8552 1

29 VALVE SCREW PR-8553 1 65 RETURN LINE PR-8048 1

30 WASHER PR-8555 166 GROMMET 11813-04 1

31 BUSHING PR-8556 1 67 BUTTON HOUSING PR-20275 1

32 WASHER PR-8537 168 MACHINE SCREWS 5-011-003 2

33 SPRING PR-8533 1 69 ERGO-PUMP

VALVE KIT (NOT SHOWN) PR-8575 1

34 PUMP

CYLINDER PR-8536 170 ERGO-PUMP

SEAL KIT (NOT SHOWN) PR-8577 1

ELECTRICAL COMPONENTS

Item No. Description Part Number Quantity

1 BATTERY CHARGER 1337874 1

2CABLE CLAMP 1-074-087/005 1

3 BATTERY CONNECTOR 49854-09 3

4LIFT BUTTON PC-3017 1

5 HYDRAULIC POWER PACK 1160927/001 1

6HARNESS (MAIN) 1130733 1

7 14 IN. BATTERY CABLE 1099187/018 1

820.5 IN. BATTERY CABLE 1099187/019 1

9 TERMINAL COVER 301253-000 2

10 REMOTE CONNECTOR/HARNESS 1130732 1

11 SOLENOID 22226-02 1

12 GROMMET 11813-23 2

13 CABLE CLAMP 15677-11 1

14 FUSE 590-587/105 1

15 STANDOFF 307371-000 1

17 DESCENT VALVE (NOT SHOWN) PR-8574 1

18 LUG SET, BATTERY CONNECTOR (NOT SHOWN) 49852-08 3

ERGONOMIC 3000 WARRANTY

The Lift-Rite Ergonomic 3000 is warranted against defects in materials and workmanship for a period of one (1)

year from date of installation for non-wearable components and for three (3) months for wearable components

from date of installation.

Wearable Components include but are not limited to:

• Wheels, Rollers, and Bearings

• Non-Stationary Hoses and Cables

• Oilite Bearings and Bushings

Components found to be defective by an authorized Lift-Rite Sales and Service Center during the warranty

period will be replaced or repaired as indicated above. Replacement components installed during the defined

period set forth above, are warranted for the balance of the applicable truck warranty period, or 90 days,

whichever is longer. Additionally, freight charges for parts involved in the replacement or repair of a defective

component will be paid by Lift-Rite, provided that the replacement or repair is made by an authorized Lift-Rite

Sales and Service Center. Local taxes, if any, are excluded.

This warranty is void in the event of defects or damage caused by misuse, abuse, or accident.

This warranty does not cover oil leaks, adjustments, or loose hardware.

Lift-Rite reserves the right to make changes and improvements in design without making changes to

previously manufactured vehicles.

Notwithstanding any other language contained herein, this warranty is expressly voided without any further

notice if any modification is made to the Lift-Rite equipment, or if additional components or devices are added

to the Lift-Rite equipment, without prior approval having been granted in writing by Lift-Rite.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY.

THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

In no event shall Lift-Rite be liable for incidental, special, or consequential damages.

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