Roughneck 39602 User manual

Thank you very much for choosing a Roughneck™ Product! For future reference, please complete
the owner’s record below:
Model: _______________ Purchase Date: _______________
Save the receipt, warranty and these instructions. It is important that you read the entire manual
to become familiar with this product before you begin using it.
This pallet truck is designed for certain applications only. The distributor cannot be responsible
for issues arising from modification. We strongly recommend this pallet truck is not modified
and/or used for any application other than that for which it was designed. If you have any
questions relative to a particular application, DO NOT use the pallet truck until you have first
contacted distributor to determine if it can or should be performed on the product.
For technical questions, please call 1-800-222-5381.
WARNING: Read carefully and understand all INSTRUCTIONS before operating.
Failure to follow the safety rules and other basic safety precautions may result in
serious personal injury.
Save these instructions in a safe place and on hand so that they can be read when required.
Keep these instructions to assist in future servicing.
INTENDED USE
The pallet truck is designed for transportation of loads with a level, fixed base and may be used
only on a firm and even surface, such as concrete or asphalt. The load must be on evenly
distributed pallets, with the ideal loading mode such that the center of gravity of the load is at
the central position of the fork.
TECHNICAL SPECIFICATIONS
GENERAL SAFETY REGULATIONS
WARNING: Read and understand all instructions.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be
understood by the operator that common sense and caution are factors that cannot be built
into this product, but must be supplied by the operator.
1. Keep the work area clean and dry. Damp or wet work areas can result in injury.
2. Keep children away from work area. Do not allow children to handle this product.
3. Store idle equipment. When not in use, tools and equipment should be stored in a dry
location to inhibit rust. Always lock up tools and equipment, and keep out of reach of children.
4. Use the right tool for the job. Do not attempt to force small equipment to do the work of
larger industrial equipment. There are certain applications for which this equipment was
designed. It will do the job better and more safely at the capacity for which it was intended.
Do not modify this equipment, and do not use this equipment for a purpose for which it was
not intended.
4400-LB., 72IN. LONG PALLET TRUCK
OWNER’S MANUAL
4400-LB., 72IN. LONG PALLET TRUCK
OWNER’S MANUAL
WARNING: Read carefully and understand all
INSTRUCTIONS before operating. Failure to
follow the safety rules and other basic safety
precautions may result in serious personal injury.
Item# 39602
1 of 7
Item#
Capacity
Fork Length
Width
Min./Max. Fork Height
39602
4400 lbs.
72in.
26 15/16in.
3 3/8in. – 7 7/8in.
Front Wheel Size
Rear Wheel Size
Material of Wheels
Width between Forks
3.15in.
7in.
Poly
14 1/2in.

2. Using a screwdriver, pry the LEVER PLATE (Fig. 2) up and slip the bolt head
under the notch in the LEVER PLATE. Do not adjust the nut unless the pallet
truck doesn’t work properly.
WARNING: DO NOT LOOSEN OR OVER TIGHTEN THE LOCK
NUT (13). The nut is pre-locked on the bolt at
the factory. If this lock nut is damaged or needs to be
replaced, call customer service at 1-800-222-5381.
3. Secure the HANDLE to the pallet truck by the three
SPRING WASHERS and SCREWS (Fig. 1).
NOTE: It is a good idea to remove any air bubbles
that might have accumulated in the hydraulic
system during shipping. Refer to “BLEEDING
THE AIR” in “MAINTENANCE” section.
OPERATION INSTRUCTIONS
NOTE: Numbers in parentheses refer to part numbers in the breakdown.
This pallet truck is designed for use with open style pallets or skids only. Closed style pallets
must be placed on top of fork prior to use.
1. Insert the fork into the pallet.
2. To raise the fork, push control lever all the way down, and pump the handle until the desired
fork height is reached.
3. To move the handle without affecting the fork setting, set the control lever in the center
neutral position. The load can now be pushed or pulled using the handle.
4. To lower the fork, pull lever all the way up. Allow the load to descend slowly in a controlled
manner. The lever is spring-loaded and will return to the neutral position when released.
WARNING: When not in use, do not allow heavy loads to remain on the fork for an
extended period of time. Always lower fork completely when not in use.
ADJUSTING THE CONTROL HANDLE'S THREE POSITIONS
On the Handle Tube (1) of this pallet truck, you can find the Control Lever (5), which can be
regulated in three positions (See Fig. 3):
LOWER - Pull the Control Lever (5) up and the forks / load will lower to the desired height.
The Control Lever (5) will move back the NEUTRAL position when released.
NEUTRAL - When the Control Lever (5) is in the middle position the forks will not move when
the Handle Tube (1) is pumped. The Control Lever (5) must be in the neutral position
when the truck is driven.
LIFT - Push the Control Lever (5) down and pump the Handle Tube (1) to raise the forks /
load to the desired height.
4400-LB., 72IN. LONG PALLET TRUCK
OWNER’S MANUAL
4400-LB., 72IN. LONG PALLET TRUCK
OWNER’S MANUAL
5. Check for damaged parts. Before using this product, carefully check that it will operate
properly and perform its intended function. Check for damaged parts and any other conditions
that may affect the operation of this product. Replace damaged or worn parts immediately.
6. Do not overreach. Keep proper footing and balance at all times to prevent tripping, falling,
back injury, etc.
7. DO NOT use the equipment when tired or under the influence of drugs, alcohol, or
medication. A moment of inattention while operating this equipment may result in serious
personal injury.
8. Industrial applications must follow OSHA requirements.
SPECIFIC OPERATION WARNINGS
WARNING:
To prevent personal injury, perform the Pressure Relief Procedure before
and after
operating the pump and before performing any disassembly or assembly.
WARNING: Failure to comply with these warnings may result in severe injury or
even death.
• Read and understand the entire owners manual before using the pallet truck.
• Do not place hands or feet under the pallet truck at any time.
• Never allow anyone to ride on the pallet truck.
• Operate on smooth, level, finished floors only; do not use on ramps or sloping floors.
• To prevent accidental tipping, make sure load is centered on the fork.
• Do not lift a load with fork tips only. This may cause damage to the forks and personal injury if
the rear of the pallet truck suddenly tips upward.
• Do not load pallet truck beyond its rated capacity.
• Never leave a loaded pallet truck unattended in the raised position. Always lower the load to
the floor.
• Pull pump release lever slowly to allow load to descend in a controlled manner.
• Secure load before transporting.
• Do not move a loaded pallet truck by other than manual force.
• The handle is designed to pull and steer the pallet truck only. Do not use the handle as a
leverage tool.
• Failure to comply with these warnings may result in personal injury and/or property damage.
WARNING: Moving parts can crush and cut. Always keep your hands away from the
front wheels.
• When lifting a pallet jack the hydraulics may retract the wheels into the frame
of the forks
• DO NOT place your hands on the side of a pallet jack while lifting –
ALWAYS LIFT THE END OF THE FORKS
• While team lifting, the person on the fork end should grab the end
of the forks and ensure their hands are not in the area of the
retracting wheels.
INSTALLATION
Tools required for assembly:
• Allen Key (8mm)
• Flat Head Screwdriver
1. Put the base of the HANDLE TUBE (Fig. 1) on the
PRESSURE PLATE (Fig. 1). Align the holes (Fig. 1)
at the base of the HANDLE with the holes in the
PRESSURE PLATE. The chain should drop
through the middle hole of SHAFT (Fig. 2).
2 of 7 3 of 7
PRESSURE FRAME(b)
HANDLE TUBE(a) SCREW
SPRING WASHER
Fig.1
Fig.3
SHAFT
LEVER PLATE(c)
Fig.2

Fig.6
4400-LB., 72IN. LONG PALLET TRUCK
OWNER’S MANUAL
4400-LB., 72IN. LONG PALLET TRUCK
OWNER’S MANUAL
NOTE: These three positions have been set at the factory
to work appropriately as soon as the handle tube is
attached. Check to see if the truck works well in the 3
control positions. If the forks do not raise or lower as
expected, proceed to the following steps (see Fig. 4):
1. Pull the Control Lever (5) upward to the "LOWER"
position. If the fork frame does not lower, turn the
Nut (13) CLOCKWISE until the fork frame lowers.
2. Push the Control Lever (5) down to the "LIFT" position.
If the fork frame does not elevate, turn the Nut (13)
COUNTERCLOCKWISE until the fork frame elevates.
3. Keep the control handle in "NEUTRAL" position. If the fork frame lowers, turn the Nut (13)
COUNTERCLOCKWISE until the fork frame does not lower.
4. Check again to see if the truck works well in the 3 control positions. If not, repeat the steps
above until the pallet truck works well.
WARNING: Only use this pallet truck for loads weighing less than the rated loading
capacity (5500 lbs.) To avoid serious bodily injury or death, and/or property damage,
there is overload protection in this pallet truck. It will stop working automatically when the
load is over loading capacity.
MAINTENANCE
1. OIL
Check the oil level annually by removing the oil plug (46) on
top of the pump housing. When changing or adding oil, fill
the tank through the oil plug hole with 8.8ounces (0.26L) of
new hydraulic jack oil. See Figure 5. Do not use any other
type of oil. When finished, replace oil plug (46).
2. LUBRICATION
Wheel bearings are sealed and require no lubrication. The crankshaft features “oil lite” bushings
that also require no lubrication.
Lightly oil all other moving parts.
3. BLEEDING THE AIR
There may be times when the forks do not rise while pumping when in the "LIFT" position. Most
likely this is because air has been introduced in to the hydraulic system. The air can be
removed by moving the control handle to the "LOWER" position, then pumping the handle up
and down several times. Repeat this process until the forks lift as intended.
4 SEAL AND O-RING REPLACEMENT FOR RAM AND PLUNGER PISTON
①. Raise the pallet truck by pumping handle.
②. Remove shaft (18). This will free the pump and handle assembly from the pallet truck.
③. Remove the oil plug (46), turn pump over and empty the oil into a suitable container. Pump
handle until all oil has drained. Dispose of used hydraulic oil according to local disposal
regulations.
④. Pull out plunger piston (40) and/or ram piston (42).
⑤. Remove all O-rings and seals. See Fig. 6.
⑥. Insert new O-ring or seal one at a time making sure to
replace with the same size that was removed.
⑦. Reassemble and fill the oil tank through the oil plug hole
with 0.26L (8.8 oz.) of new hydraulic jack oil. See Fig. 5.
4 of 7
Fig.4
0.26L
Fig.5
5 DAILY INSPECTION AND MAINTENANCE
Daily inspection and maintenance of the pallet truck is required, especially for the wheels and
the axles. Remove thread or rags on the wheel or axle if any is detected. Unload and lower the
forks to the lowest position after every job is finished.
TROUBLE SHOOTING
Numbers in parentheses refer to item numbers in the breakdown.
5 of 7
Trouble
The forks cannot raise completely
Hydraulic unit does not lift
The forks do not descend
Once lifted, truck lowers by itself
Fluid leak
Probable Cause
Insufficient oil
Low oil level
Air in pump
Worn O-ring in ram cylinder
Deformed piston rod
Piston rod rusted
Handle tube, nut or chain broken or missing
Air comes into the oil
Worn O-ring in ram cylinder
Pallet truck loaded beyond capacity
Damaged push rods and/or linkages
Component, likely seal, worn or damaged
Remedy
Refill oil (See instructions above).
Refill oil (See instructions above).
See "BLEEDING THE AIR".
Replace O-ring (refer to "Seal and O-Ring
Replacement").
Replace piston rod and cylinder.
Lubricate/ replace rod. Keep jack in lowered
position when not in use.
Replace the handle tube.
See "BLEEDING THE AIR".
Replace O-ring (refer to "Seal and O-Ring
Replacement").
Reduce load to within capacity.
Replace damaged parts. (It is recommended
that an authorized service center perform
this work.)
Inspect and replace worn or damaged parts.

4400-LB., 72IN. LONG PALLET TRUCK
OWNER’S MANUAL
4400-LB., 72IN. LONG PALLET TRUCK
OWNER’S MANUAL
DIAGRAM
6 of 7
Part No.
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
Description
Handle Tube
Blade Spring
Spring
Elastic Pin
Handle
Roller
Elastic Pin
Elastic Pin
Pull Rod
Pin
Chain
Adjusting Screw
Nut
Screw
Spting Washer
Pressure Frame
Shaft
Shaft
Oil Lite Bushing
Pressure Roller
Elastic Pin
Release Plug
O-ring
Release Screw
Spring
Valve
Steel Ball
Oil Baffe Washer
O-ring
Valve Base
Tapered Column
Description
Ball Bearing
Snap Ring
Dust Seal Cap
Steering Wheel
Lifting Yoke
Oil Lite Bushing
Oil Lite Bushing
Spring Pin
Oil Lite Bushing
Crank Pin
Push Rod
Crank Shaft
Spring Pin
Socket Head Cap Screw
Fork Frame
V Nut
Guide Roller
Hex Cap Screw
Spring Pin
Rod Pin
Load Wheel Axle
Flat Washer
Ball Bearing
Load Wheel
Spring Pin
Load Wheel Frame
Arm Pin
Spring Pin
Bracket
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Qty.
1
1
1
1
1
1
2
2
1
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
Description
Spring
Washer
Release Plug
U-packing
Dust Seal Ring
Spring
Spring Cap
E-ring
Plunger Piston
Steel Ball
Ram Piston
Dust Seal Ring
O-ring
U-packing
Oil Plug
O-ring
Pump Housing Assy
Oil Lite Bushing
Cam
Release Nozzle
O-ring
Release Nozzle Spring
Spring Pin
Spring Pin
Spring Pin
Bearing Base
Ball Bearing
Table Pin
Oiler
Snap Ring
Table
Part No.
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
2
1
1
2
1
1
1
Qty.
4
2
2
2
1
2
2
2
2
2
2
1
1
1
1
2
2
2
2
2
4
8
8
4
8
2
2
2
4
PARTS LIST
For replacement parts and technical questions, please call 1-800-222-5381.
WARRANTY
One-year limited warranty
7 of 7
Distributed by
Northern Tool + Equipment Co., Inc.
Burnsville, MN 55306
NorthernTool.com
Made in China
34 33
13 40
37
38
39
14
15
11
12
10
9
4
7
8
765
1
2
3
1
24 25
26 27
27
35
36
41
42
43
44
45 46
47
48
49
50
51
52
53
54
55
56
56
57
58
59
59
60
61 62
63 64
66
76
21
19
20
32 31 30
8
65
70
71
72
73
77
16
18 17
28
29
22 23
75
74
67
68
69
69
68
78
79
80
81
89
90
88
82
83
84
85
86
91
87