Southwire SUMNER PJ20 Manual

OPERATING and MAINTENANCE
INSTRUCTIONS
SUMNER PALLET TRUCKS
(PJ20/PJ27)
READ AND UNDERSTAND ALL
INSTRUCTIONS AND SAFETY INFORMATION IN
THIS MANUAL BEFORE OPERATING OR
SERVICING THIS TOOL
09/20 (PJ20/PJ27 )

1
TABLE OF CONTENTS
Important Safety Information ..................................................2-4
Introduction.................................................................................5
Dimensions………………….……………………..……………...5-6
Assembly....................................................................................6
Setup and Operation.............................................................6-12
Servicing...................................................................................13
Troubleshooting and Maintenance......................................13-14
Warranty..............................................................................15-16
2
SAFETY ALERT SYMBOLS
These symbols
are used to call attention to hazards or unsafe
practices related that could result in injury or property damage.
The three safety words defined below indicate the severity of the
hazard. The message after the signal word provides information for
preventing or avoiding the hazard.
DANGER - Immediate hazards that if not avoided WILL
result in severe injury or death
WARNING - Hazards that if not avoided COULD result in
severe injury or death
CAUTION - Hazards or unsafe practices that, if not
avoided MAY result in severe injury or death
SAFETY FIRST
Safety is essential in the use and maintenance of Southwire Con-
tractor Equipment. This instruction manual and any markings on the
tool provide information for avoiding hazards and unsafe practices
related to the use of this tool. Observe all the safety information
provided.

• Only qualified persons should use the Sumner Pallet Trucks.
• Wear eye protection, hard hat, cut resistant gloves and safety
toe shoes when using this tool.
• Do not use tool while tired or under the influence of drugs,
alcohol, or medication.
• Keep body parts and loose clothing away from moving parts.
• Always follow operating procedures.
• Do not use if any parts are damaged as this can cause an unsafe
condition and lead to tool malfunction or failure.
• If tool is in disrepair, DO NOT USE. Have tool serviced at an
Authorized Sumner Repair Center.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH
WARNING - Personal Safety Hazards
WARNING
• Read and understand all instructions and safety information in
this manual before operating or servicing this tool.
• Failure to observe these warnings could result in severe injury or
death.
3
IMPORTANT SAFETY INFORMATION
4
IMPORTANT SAFETY INFORMATION
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
WARNING:
Tool Use Hazards
CAUTION
Read and understand all the instructions and safety information in
this manual before operating or servicing this tool.
CAUTION
WARNING:
Cancer and Reproductive Harm
WARNING:
• Read and understand the entire owner’s manual before using
the pallet truck.
• Do not place hands or feet under the pallet truck at any time.
• Do not operate a loaded pallet truck on ramps or inclines.
• Do not tip load pallet truck forks. This may cause damage to the
forks and personal injury if the rear of the pallet truck suddenly
“pops up.”
• Never leave a loaded pallet truck unattended in the raised
position. Always lower load to the floor.
• Do not load pallet truck beyond its rated capacity.
• Secure load before transporting.
• To prevent accidental tipping, make sure load is centered on the
forks.
• Do not move a loaded pallet truck by other than manual force.
• Replace warning labels if they become obscured or removed.
• Only qualified personnel should use Sumner pallet trucks.
• Do not use the pallet truck for any means other than outlined in
this manual.
FAILURE TO OBSERVE THESE WARNINGS COULD
RESULT IN SEVERE INJURY OR DEATH.
Prop 65

5 6
Description of OperationINTRODUCTION
Description of Operation
DIMENSIONS
The Sumner Pallet Truck is a 6600 lb. rated pallet truck available in
two sizes Model# PJ27 (27” x 48”) and Model# PJ20 (20” x 48”).
The Sumner Pallet Truck is used to lift and transport loads to
desired locations with the use of a hydraulic lift. Placing material
on the pallet truck or inserting pallet truck through a pallet, user
can lift and move material with ease.
To better understand the proper use and safe operation of your
Sumner Pallet Truck, please take a few minutes to carefully read
and follow the instructions contained in this manual. When
finished reading and understanding the manual, please file in a
safe and convenient location for the life of the pallet truck. You will
notice several important features about your Sumner Pallet Truck.
It features a 2-1/2” lowered height, rounded fork tips and nylon
entry/exit rollers to provide easy entry and exit of pallets. A large,
easy-to-use ergonomic handle with a 180° turning radius allows
maximum maneuverability. The articulated steer wheel axle helps
maintain floor contact on uneven surfaces. The cast iron pump
design features top-of-the-stroke and overload by-pass systems
hardened and chromed ram and piston, and a single point valve
service for easy replacement. A special lowering valve allows you
to control the rate of descent and prevent “shock” loads. Your
Sumner Pallet Truck is designed and built to offer consistent,
long-term operation with minimal maintenance and service atten-
tion. For more information go to www.sumner.com
MODEL STOCK
No.
W1
(IN.)
W2
(IN.)
L1
(IN.)
L2
(IN.)
H1
(IN.)
H2
(IN.)
A (DxW)
(IN.)
B
(DxW)/in.
C
(IN.)
MAX.
LOAD
LBS.
NET WT.
LBS
SHIP
WT.
(LBS)
PJ20 779766 6 20.5 48 63 6.25 2.5 6.25x2.75 2.5x3.75 45.13 6600172192
PJ27 779765 6 27 48 63 6.25 2.5 6.25x2.75 2.5x3.75 45.13 6600196216
All Models
Number of Strokes to Reach Maximum Height: 8
Force Required to Pump @ Maximum Load (Lbs.): 89
Force Required to Move Maximum Load (Lbs.): 110
Handle Assembly & Test
Tools: Box Cutter, Crescent Wrench, Pliers, & Hammer
Step 1. - Remove Packing Material (using box cutter)
Pallet Jack

7 8
SETUP AND OPERATION SETUP AND OPERATION
Step 2. - Stage hard ware kit (out of bag) & Manual on work table
Step 3. – Ensure parts are present: 2 – Silver Pallet Jack Pin
2 – Pallet Jack Split Roll Pin (dowel)
Step 4. - With left hand hold pallet jack handle, also grasping
chain bolt in upright position (As shown)
- Align handle holes with base holes while in motion
(As shown)
Step 5. - Insert Silver pin on either side of handle and base holes
- Align silver pin holes with base receiver holes, with
hammer tap silver pin inward, till flush with receiver
base
Step 6. – Using Pliers, hold split pin dowel in place and tap into
position, through both handle and base
Note: Silver pin adjustment might be needed, if split pin dowel
does not set through base properly (Example)
787350-Pallet Jack Hardware Kit

109
SETUP AND OPERATION SETUP AND OPERATION
Step 7. – Pull down pallet jack handle to remove spacer tube
Step 8. – Position Chain Bolt
Step 9. - Lift chain bolt, torque nut, and slip in cylinder lever notch
Pic. 1- If dowel does not set
correctly, you will need to
adjust silver pin
Pic. 2- Using a crescent
wrench, claim and rotate
silver pin in any direction,
till base hole and silver pin
hole align
Pic. 3- Base dowel hole
and silver pin hole should
align as shown.Tap silver
pin in to positon with
base hole
Pic. 4- Using a hammer, tap in dowel
flush to base hole entrance
Spacer Tube Removal (Example)
Pic. 1- Insure handle is in
upright position, clamp down
on spacer tube with pliers
Pic. 2- Lower handle,
sagelyand slowly pull
out spacer tube
Pic. 3- Once spacer tube is
removed, set aside and discard
after full assembly
Chain Bolt Positioning
Pic. 1- Holding pallet jack
handle down, position
chain bolt down hole
Pic. 2- Insure the path
down is free and clear of
obstructions
Pic. 3- The chain bolt
should be in this position,
slowly lift handle to upright
position
Chain Bolt - Nut Torque and Placement
Pic. 1- While the pallet jack
handle is upright, lift chain
bolt in a workable position
as shown.
Pic. 2- Using a crescent
wrench, torque nut
clockwise to increase
cylinder prssure
(If need)

1211
To lift a load:
1. Lower forks to lowest position.
2. Insert forks under load or into pallet.
3. Push the lever down.
4. Move handle up and down until forks reach desired height.
To move a load:
1. Place lever in center neutral position.
2. Pull or push to desired location.
To lower a load:
1. Pull lever up and allow load to settle.
2. Pull forks away from load.
SETUP AND OPERATION SETUP AND OPERATION
Step 10. – Test Upright Position
Step 11. – Test Lowered Position
Pic. 3- Using pliers, raise
the cylinder lever, slip
chain bolt into cylinder
lever notch.
Pic. 4- Insure chain bolt is
firmly set and nut is
suppporting cylinder lever
bottom.
Pallet Jack Test - Upright position
Pic. 1- Setting the handle
lever in the position shown,
crank pallet handle down
and up to test proper
cylinder function.
Pic. 2- As you crank handle up
and down you will see the
pallet jack raising and the
chrome position.
Pic. 3- This picture shows the
pallet jack in its fully elevated
position.
Pic. 1- Squeezing the lever
handle up will release
cylinder pressure and pallet
jack will start to lower.
Pic. 2- Continued squeezing
of the pallet jack handle lever,
will completely lower pallet
jack to floor.
Pic. 3- This picture shows the
pallet jack in its fully lowered
position.
Pallet Jack Test - Down position

LUBRICATION
Check the oil level annually by unscrewing oil fill plug (FIG 10).
When changing or adding oil, fill the reservoir through the top plug
hole in the reservoir to 80% capacity with hydraulic jack oil. Do not
overfill.
A- Filler Plug
B- Drain Plug
C- Bleeder Plug
D- Grease Fitting
After filling and re-installing filler plug, bleed the pump.
• Pump handle to build up pressure in the reservoir.
• Loosen bleeder plug until fluid flows from bleeder plug.
• Tighten bleeder plug.
• Repeat process until no air remains in the system.
There is one grease fitting located on the black cross bar just
under front of reservoir. This fitting should be greased on a
semi-annual basis (FIG 11 “D”).
1413
FIG 10
FIG 11
A
B
C
D
SERVICING TROUBLESHOOTING
SPECIFICATIONS
• Model # PJ20
• Stock # 779766
• Height- 45.13”
• Width- 20.5”
• Depth- 63”
• Weight- 172lbs
• Capacity- 6,600lbs
• Model # PJ27
• Stock # 779765
• Height- 45.13”
• Width- 27”
• Depth- 63”
• Weight- 196lbs
• Capacity- 6,600lbs
TROUBLE PROBABLE CAUSE REMEDY
Low oil level in reservoir.
Make sure there is no oil leakage from valve,
and add oil.
Steel ball not seated in hydraulic unit.
Place the lever in the down posion and
pump the handle repeatedly.
Worn U-packing in ram cylinder Consult authorized service facility.
Steel ball not seated in hydraulic unit. Bleed the pump.
Worn seal in ram cylinder. Have seal(s) replaced.
Release valve not seated properly. Bleed the pump.
Release valve not adjusted properly.
Reload truck within load capacity and adjust
valve by pressure adjustment screw.
Oil leakage from each valve. Tighten plug of each valve.
Relief cam or chain element broken. Replace affected element.
Relief cam nut out of adjustment. Refer to "Adjusng Relief Cam."
Broken fork rods and linkage.
Inspect linkages for breaks or cracks. Replace
elements as needed
Lever does not set at Up-Load. Relief cam nut out of adjustment. Refer to "Adjusng Relief Cam."
Truck doesn't roll smoothly or
evenly.
Wheels have debris embedded, or
out of round due to wear.
Inspect and remove debris. If worn, replace
wheels. Note: Always replace wheels in
pairs.
Hydraulic unit does not li.
Once lied, truck lowers by itself.
Fork does not lower.
MAINTENANCE
IMPORTANT: Repairs and seal ring replacements should only be
performed by qualified personnel at authorized Sumner Repair
Facilities.
Any disassembly of the Sumner Pallet Truck should be done by
authorized and qualified service personnel. Contact Sumner
customer service for a list of authorized repair facilities.
TROUBLESHOOTING

1615
Warranty Claim Information/How Do You Get Service?
Sumner Manufacturing Co., LLC
7514 Alabonson Road
Houston, Texas 77088
Phone Number: 1.281.999.6900
Sumner – Canada
75 Saltman Drive, Unit 5
Cambridge, Ontario N3H 4R7
Phone Number: 1.519.651.5300
Sumner – U.K.
Unit 3 Kepton Road
Keytec 7 Business Park
Pershore Worcestershire
WR10 2TA, UK
Phone Number: [phone]
Sumner – Netherlands
Handelsweg 26
3881LS Putten
The Netherlands
Repair Your Product When it is Out of Warranty
Sumner is happy to provide information about where a purchaser can send a product for repair
at consumers’ own expense, please contact 1.281.999.6900 or visit www.sumner.com for
more information about servicing for Sumner Products.
WARRANTY ON
SUMNER EQUIPMENT
What Does This Warranty Cover?
Limited Lifetime Warranty on Sumner Equipment
Under Sumner’s Equipment Limited Lifetime Warranty, Sumner Manufacturing Co., LLC
warrants that all Sumner Equipment will be free from manufacturer defects for a Limited
Lifetime except for moving parts deemed consumables from the date of the original end
user’s purchase. Products deemed as consumable products, components and parts such as
steel cables, rollers, bearings, wheels, lift mast sections components are excluded from this
Limited Lifetime Warranty and are subject to One -Year Limited Warranty terms. Sumner
electrical components are excluded from this Limited Lifetime Warranty and are subject to
One -Year Limited Warranty terms. Under this Limited Lifetime Warranty, the following are
also excluded, and Sumner will have no liability for any of the following: normal wear and tear
resulting from product use and damage arising out of misuse, abuse, modification, and
improper product maintenance. This warranty also does not cover Sumner’s Equipment
products that have been modified by any party other than Sumner or its authorized
third-party designee. This Limited Lifetime Warranty is not transferrable to or enforceable by
any person other than the product’s original end user.
Three-Year Limited Warranty on Pallet Jacks and Hydraulic Tools
Under Sumner’s 3-Year Limited Warranty, Sumner Manufacturing Co., LLC warrants that all
Sumner Pallet Jacks and Hydraulic Tools will be free from manufacturer defects for a period
of three (3) years from the date of the original end user’s purchase. Under this Three-Year
Limited Warranty for Pallet Jacks and Hydraulic Tools, the following are excluded and
Sumner Manufacturing Co., LLC will have no liability for any of the following: normal wear
and tear resulting from product use and damage arising out of misuse, abuse, modification,
and improper product maintenance. This warranty also does not cover Pallet Jacks and
Hydraulic Tools that have been modified by any party other than Sumner Manufacturing Co.,
LLC or its authorized third-party designee. This 3-Year Limited Warranty is not transferrable
to or enforceable by any person other than the product’s original end user.
One-Year Limited Warranty on All Products
Under Sumner’s 1-Year Limited Warranty, Sumner Manufacturing Co., LLC warrants that all
products will be free from manufacturer defects for a period of one-year from the date of the
original end user’s purchase. Under this 1-Year Limited Warranty, Sumner Manufacturing
Co., LLC will have no liability for any of the following: normal wear and tear resulting from
product use and damage arising out of misuse, abuse, modification, and improper product
maintenance. This warranty also does not cover Sumner Equipment that has been modified
by any party other than Sumner Manufacturing Co., LLC or its authorized third-party
designee. This 1-Year Limited Warranty is not transferable to or enforceable by any person
other than the product’s original end user.
1. All warranty claims must be approved by Sumner’s Warranty Department prior to return of
product. If Sumner determines that a product is defective, Sumner will, at its option, repair or
replace defective products or defective product components, free of charge.
2. Upon approval, Sumner will issue a Product Return Authorization Form which will include
instructions on how and where to return the product. The product serial number and the
original date of delivery must be set forth on the Product Return Authorization Form.
3. Sumner will cover standard freight charges (Courier Ground rate) incurred in connection
with products that Sumner ultimately determines to be defective.
4. All defective components and defective products that Sumner replaces under these
Warranties will become Sumner’s property and will be retained by Sumner.
Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
Exclusion of Incidental, Consequential, Indirect, Special and Punitive Damages
SUMNER MANUFACTURING CO. LLC MAKES NO WARRANTY THAT SUMNER MANUFAC-
TURING CO. LLC PRODUCTS WILL BE MERCHANTABLE OR FIT FOR ANY PARTICULAR
PURPOSE. SUMNER MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED, OTHER
THAN THE RELEVANT WARRANTY SPECIFICALLY SET FORTH IN THIS WARRANTY
SECTION. SOUTHWIRE WILL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL,
INDIRECT, SPECIAL, OR PUNITIVE DAMAGES FOR ANY BREACH OF THIS LIMITED
LIFETIME WARRANTY.
Phone Number: [phone]
For all warranty, customer service, and product return authorizations and inquiries, please
contact Sumner at: