Service Manual Rol-Lift
Contents
1. D 4 M AAA QU A Service Manual Rol Lift Series T and E Developed by Generic Parts Service This manual is intended for basic service and maintenance of the Rol Lift pallet jack The pallet jacks you are servicing are tools that make moving products easier Operating pallet jacks with rusty broken or worn parts makes usage and maintenance more difficult Pallet jack parts are inexpensive and easy to replace To ensure maximum life from the jack always replace the parts that are broken or worn Remember that all parts on a pallet jack depend on the adjoining parts to work properly and to perform to their full potential When used in conjunction with our catalog this service manual will explain how and when to replace a pallet jack part Remember when in doubt replace it If you have any questions just call us We make it easy 1 800 331 0839 Iss 968 Fax 1 800 366 5939 CAN 29 95 CALL 1 800 331 0839 2 GENERIC PARTS SERVICE GPS Inc Contents 2 Suggested Assemblies 2 Commonly Used Tools 2 Helpful Reminders 3 Axles 3 Bushings 4 Load Rollers and Load Roller Brackets 6 Steer Wheels and Axle T Traverse 8 Push Rods 10 Lifting Link 12 Handle Removal and Installation Hydraulic Unit 13 Inspection 14 Service Hints 15 Removal 15 Installation Copyright 1999 by GPS Inc All rights reserved Rol Lift pallet jacks all models are products of L amp L Fabrications2. Insert the shoulder bolts through the lifting link and into the traverse Secure the shoulder pins with their roll pins Position the traverse bearing onto the stem of the hydraulic unit and slide the hydraulic unit into the traverse Raise the frame and insert the top of the ram with the thrust bearing assembly still in place into the top of the A Frame Pump the jack up to its maximum height and insert the snap ring that secures the thrust bearing assembly in place Install the snap ring under the traverse onto the stem of the hydraulic unit Assemble the steer wheel axle and the steer wheels see Steer Wheels and Axle to the hydraulic unit 25 minutes Lifting Link Lower Thrust Bearing Traverse Bushing Grease Zerk Washer cy i Shoulder Pin Snap tin 6 GENERIC PARTS SERVICE ri CALL 1 800 331 0839 GPS Inc Push Rods Inspection When inspecting the push rods look for broken or cracked welds bends missing roll pins and worn bushings It is best to mark the position of the eyebolt and nut in relation to the push rod to ensure proper adjustment during installation Removal T Series Standard height Fully lower the jack and then turn the jack over so that the undercarriage is facing up Remove one of the snap rings on the pivot axle and drive the pivot axle out of the bracket and frame Remove one of the snap rings on the push rod axle and drive the axle out of the bracket Loosen the set screw holding
3. Locking Nut Handle Socket 12 GENERIC PARTS SERVICE GPS Inc Hydraulic Unit Inspection Inspect the outside of the pump for oil leaks Test the unit under a load to determine if there is a problem This can be done by lifting a heavy pallet and letting it stand for 15 20 minutes Below are symptoms and solutions to common hydraulic unit failures If the following solutions fail to correct the problem a complete rebuild of the malfunctioning unit may be necessary Please refer to our catalog for information about ordering the appropriate seal kit or take advantage of our hydraulic unit exchange program Jack fails to lift load e Air Lock in Pump Foot or Hand Control Place the control mechanism in the release position then pump handle rapidly 10 15 times 5 minutes e Low Fluid Level Foot or Hand Control With the jack in a lowered position remove filler plug slowly to avoid rapid depressurization Using RL HO oil fill the reservoir until the oil is level with the fill plug hole Replace filler plug rotating no more than 360 degrees Place the control mechanism in the lift position and pump the jack up to its maximum height Remove filler plug to allow air into the reservoir then replace the filler plug creating a snug fit Do not overtighten 10 minutes NOTE If lack of oil pressure is evident by short lifting strokes repeat procedure If failure is still evident see Air Lock in Pump e Hand Control Out of Adjustmen
4. closely see Bushing Inspection Snap nine Load Roller Load Roller Bracket Bearing Load Roller Axle Bushing Pivot Axle pol Pin Push Rod CALL 1 800 331 0839 4 GENERIC PARTS SERVICE GPS Inc Load Rollers and Load Roller Brackets Removal Tip We recommend servicing one load roller assembly at a time using the other assembly as a reference Load rollers Standard height Turn the jack over onto its side Remove one of the snap rings and punch the axle out of the wheel and bracket 10 minutes Lowered height Turn the jack over onto its side Remove the roll pin and punch the axle out of the wheel and bracket 10 minutes Load roller brackets Standard height Turn the jack over onto its side and remove the load roller Remove the snap ring on the pivot axle and punch it out of the frame and bracket Remove the snap ring and drive the push rod axle out of the bracket 15 minutes Lowered height Turn the jack over onto its side and remove the load roller Remove the roll pin securing the pivot axle in place and punch the axle out Remove the roll pin fastening the push rod axle to the bracket and drive the axle out 15 minutes Installation Load roller brackets Standard height With the jack on its side insert the axle through the bracket and the push rod Secure it in place with the snap rings Attach the bracket to the frame by inserting the pivot axle through the frame and bracket Secur
5. softer material and are expendable It is recommended that anytime the jack is torn down to a point where the bushings are accessible they be replaced This will ensure longer life of the jack and will reduce the amount downtime Bushings are very inexpensive and it is cost effective to change them regularly Inspection If the bushings are cracked broken egg shaped or worn more than 16 from the original size replace them Remember If the jack is already disassembled replace all accessible bushings Tip Coating axles and bushings with anti seize compound before installation makes future maintenance easier GENERIC PARTS SERVICE 3 CALL 1 800 331 0839 GPS Inc Load Rollers and Load Roller Brackets Inspection Load rollers Load rollers should not have flat spots or large pieces of metal imbedded in them i e tacks nails or metal shavings Any chips in the wheel that keep it from rolling smoothly indicate the need for replacement If the wheel has cracks loose tread or does not turn freely replace both wheels Always change the wheels in pairs to reduce uneven wear New load rollers have an outside diameter of 3 or 3 4 If the diameter is worn more than 4 from normal size replacement is necessary Load roller brackets Inspect the bracket for cracks or broken welds Ensure the axle holes are not out of round Replace the bracket if it has worn thin due to prolonged rubbing on the floor Also check the bushings
6. the roll pin that fastens the push rod axle to the load roller bracket out and remove the axle Unscrew the push rod from the eye bolt It is helpful to mark the adjustment of the eye bolt for proper installation 20 minutes Load Roller Push Rod Axle Load Roller Axle Pivot Axle Snap Ring GENERIC PARTS SERVICE GPS Inc Push Rods Installation T Series Standard height Insert the eccentric through the lifting link and push rod Secure it with its snap ring Insert the push rod axle through the bracket and push rod Secure with its snap rings Slide the pivot axle through the frame and bracket Secure the axle in place with its snap rings Turn the jack upright and fully lower it Adjust the push rod by turning the eccentric with a large screwdriver through the access hole on the side of the frame By turning the eccentric you effectively lengthen or shorten the push rod Test the adjustment by pumping the jack up and then lowering it If the forks hit bottom at the same time then it is adjusted correctly If one fork hits bottom before the other then further adjustment is necessary Turn the eccentric about 1 8 to 1 4 of a turn and test the adjustment again Once the push rods are adjusted correctly turn the jack over onto its side and tighten the set screw down to keep the eccentric from turning 30 minutes Lowered height Thread the push rod onto the eye bolt and try to match the other side if it is
7. GENERIC PARTS SERVICE CALL 1 800 331 0839 GPS Inc Suggested Assemblies to Save Repair Time RL T5BOK H Super d Super Seal Kit for Hand Control RL T5BOK F Super E Super Seal Kit for Foot Control Ne Z S RL 32 Ce Ultra Poly Steer Wheel Assembly ye lt e RL 31 A D Super x Super Ultra Poly Load Roller Kit RL 31 D Ultra Poly Load Roller e RL 31 3 Super Super Poly Load Roller Kit Commonly Used Tools e Hammer e Jack Stand e 45 Snap ring pliers large and small nen PIN PUNCH SNAP RING PLIERS e 9 16 Wrench e 1 4 Allen wrench e 1 4 Pin punch e 3 16 Pin punch e Soft hammer nylon mallet e Anti seize compound e Lubricant i e WD40 may be necessary to remove rusted parts Z LE SF Helpful Reminders e Never hammer directly on an axle always use a pin punch e Always replace old roll pins and snap rings e Replace accessible bushings whenever the jack is torn down CALL 1 800 331 0839 2 GENERIC PARTS SERVICE GPS Inc Axles Inspection If the axle is bent out of round or shows signs of wear replace it Check for worn snap ring grooves and roll pin holes If these are damaged or worn replace the axle The standard height jacks have a knurl on one end of the axle to prevent it from spinning Insert the end of the axle Without the knur first for easier installation Bushings Bushings are designed to wear out sooner than the mating parts They are made of
8. VICE GPS Inc Installation E Series Standard height Thread the push rod onto the eye bolt Try to match the other side if it is still assembled If it isn t adjust the length after you have assembled the load roller bracket onto the push rod Insert the push rod axle through the bracket and push rod Secure the axle with the snap rings Insert the pivot axle through the frame and bracket Secure the axle in the frame with the snap rings If you have not adjusted the push rod yet place the lifting link in a position that matches a fully lowered position Spin the push rod and bracket one way or the other until the pivot axle hole on the bracket lines up with the frame Then insert and secure the pivot axle Test the adjustment by pumping the jack up and then lowering it If the forks hit bottom at the same time then it is adjusted correctly Turn the jack over onto its side and tighten the nut on the eye bolt up to the push rod to secure the adjustment during any other repairs If one fork hits bottom before the other then further adjustment is necessary You can either shorten the push rod on the fork that hits first or lengthen the push rod on the fork that hits second Keep adjusting until both forks hit bottom at the same time 25 minutes Lowered height Thread the push rod onto the eye bolt Try to match the other side if it is still assembled If it isn t adjust the length after you have assembled the load roller bracket o
9. e in place with the snap rings Install the load roller Insert the end of the axle without the knurl first for easier installation 15 minutes Lowered height With the jack on its side insert the push rod axle into the bracket and push rod Secure it in place with the roll pin Fasten the bracket to the frame by inserting the pivot axle through the frame and bracket and securing the axle in place with the roll pin Install the load roller 15 minutes Load rollers Standard height With the jack on its side insert the axle through the bracket and wheel Secure it in place with the snap ring Insert the end of the axle without the knurl first for easier installation 10 minutes Lowered height With the jack on its side insert the axle through the bracket and wheel Secure the axle in place by replacing the roll pin 10 minutes GENERIC PARTS SERVICE 5 CALL 1 800 331 0839 GPS Inc Steer Wheels and Axle Inspection Steer wheels should not have flat spots or large pieces of metal imbedded in them i e tacks nails or metal shavings Chips in the wheel which keep it from rolling smoothly indicate the need for replacement Steer wheels should turn freely They should not rub the bottom of the traverse If they do check for the correct installation of the snap ring under the traverse Rol Lifts older style steer wheel has an 8 diameter and their newer style has a 7 1 2 diameter If the wheel is worn more than 4 from the nor
10. eight and turn the jack onto its side Remove the steer wheels and axle see Steer Wheels and Axle Removal and the snap ring under the traverse on the stem of the hydraulic unit Turn the jack upright be careful no to damage the stem of the hydraulic unit while lowering Remove the snap ring securing the upper thrust bearing assembly on the ram to the A Frame Lift the frame off the ram tip the handle and hydraulic unit away from the frame and rest both pieces on the ground Pull the hydraulic unit out of the traverse and remove the handle if necessary see Handle Removal 45 minutes Installation Slide the stem of the hydraulic unit into the traverse with the lower thrust bearing already in place on the stem Insert the top of the ram and the upper thrust bearing assembly into the A Frame and secure in place with the snap ring Carefully turn the jack onto its side keeping the hydraulic unit in the traverse and frame Attach the snap ring to the stem of the hydraulic unit under the traverse Install the steer wheel assembly see Steer Wheel and Axle Installation and the handle if necessary see Handle Installation Bleed the hydraulic unit see Air Lock and Pump 45 minutes a Bearing Cap Handle Upper Thrust Bearing Snap Ring Thrust Collar Snap Ring e Snap Ring Axle Pin Snap Ring GENERIC PARTS SERVICE 15 CALL 1 800 331 0839 GPS Inc
11. he push rod still attached by removing the snap ring that fastens it onto the lifting link Remove the snap ring on the lifting link shaft Use a hammer and punch to drive the shaft out far enough to grip it on the other side and pull it out 45 minutes CALL 1 800 331 0839 10 GENERIC PARTS SERVICE GPS Inc Lifting Link Installation Turn the jack over so that the undercarriage of the jack facing up position the lifting link in the frame Insert the lifting link shaft and secure it with its snap ring Attach the push rod see Push Rods and the load roller bracket see Load Roller Brackets Turn the jack upright and install the traverse with the hydraulic unit and steer wheel assembly still attached see Traverse Position the ram and upper thrust bearing assembly into the A Frame Secure it with the snap ring 45 minutes Snap Ring Lifting Link Lifting Link Bracket ES g Rot sr DAS Ring Traverse Z ee yy Push Rod Axle L 2 On Ze T Pivot Axle 6 Se SERIES SPR Eccentric Pin Steer Bearing Wheel GENERIC PARTS SERVICE 11 CALL 1 800 331 0839 GPS Inc Handle Removal Inspection Inspect the handle for cracks and structural integrity There should be minimal side play in the handle socket Check for worn bushings If bushings are not replaced regularly the handle socket holes can become worn This may require complete handle socket replacement to prevent unnecessary wear on mating parts Al
12. height Remove the snap ring under the A Frame that secures the upper thrust bearing assembly on the ram to the jack Lift the jack off of the ram and pivot the hydraulic unit away from the frame Remove the shoulder bolts fastening the traverse to the lifting link by driving out their roll pins Remove the hydraulic unit and traverse assembly as one piece Turn the jack over so that the undercarriage is facing up Loosen the set screw that holds the eccentric in adjustment Remove the snap ring on the eccentric and pull the eccentric out through the access hole in the side of the frame Remove the snap ring on the lifting link shaft Use a hammer and punch to drive the shaft out far enough to grip it on the other side and pull it out 45 minutes Lowered height see E Series Lifting Link Removal below Removal E Series Standard and Lowered height Pump the jack up to its maximum height Remove the snap ring under the A Frame that secures the upper thrust bearing assembly on the ram to the jack Lift the jack off of the ram and pivot the hydraulic unit away from the frame Remove the shoulder bolts fastening the traverse to the lifting link by driving out their roll pins Remove the hydraulic unit and traverse assembly as one piece Turn the jack over so that the undercarriage is facing up Remove the pivot axle Remove the snap ring on the axle for standard height jacks or the roll pin on lowered height jacks Then remove the eye bolt with t
13. mal diameter replacement is necessary Removal Steer wheels Standard height With the jack on its side remove the roll pin and the wheel will be free to slide off 10 minutes Lowered height Turn the jack onto its side remove the snap ring and the wheel will be free to slide off 10 minutes Steer wheel axle PIE Standard height Turn the jack onto its side and remove the steer wheels Remove the snap ring on the pin that fastens the axle to the stem of the hydraulic unit Punch the pin out of the stem and the steer wheel axle will be free to remove 15 minutes Lowered height Turn the jack onto its side and remove the steer wheels Remove the snap ring on the pin that fastens the axle to the stem of the hydraulic unit Punch the pin out of the stem and the steer wheel axle will be free to remove 15 minutes Roll Pin Installation Steer Wheel Steer wheel axle Standard height With the jack on its side line up the pivot hole on the steer wheel axle with the hole in the stem of the hydraulic unit and insert the pin that attaches the axle to the hydraulic unit Secure the pin in place with its snap rings Slide the steer wheels onto the axle and secure them in place with the roll pins 15 minutes Lowered height With the jack on its side line up the pivot hole on the steer wheel axle with the hole in the stem of the hydraulic unit and insert the pin that attaches the axle to the hydraulic unit Secure the pin i
14. n place with its snap rings Slide the steer wheels onto the axle and secure them in place with the snap rings 15 minutes Steer wheels Standard height Slide the steer wheels onto the axle and secure them in place with the roll pins 10 minutes Lowered height Slide the steer wheels onto the axle and secure them in place with the snap rings 10 minutes CALL 1 800 331 0839 6 GENERIC PARTS SERVICE GPS Inc Traverse Inspection There are few things that can be wrong with the traverse Wear can occur on the bearing shoulder or where the shoulder pins attach to the lifting link If these areas are egg shaped or out of round replace the traverse Removal Pump up the jack to gain access to the snap ring that secures the thrust bearing assembly on top of the ram to the A Frame Turn the jack onto its side and remove the steer wheels steer wheel axle see Steer Wheels and Axle and the snap ring that holds the traverse in place on the stem of the hydraulic unit Turn the jack back over and carefully lower the stem of the hydraulic unit onto the ground Remove the snap ring securing the upper thrust bearing assembly in place and lift the frame off of the ram Pull the hydraulic unit out of the traverse with the traverse bearing Punch out the roll pins that fasten the shoulder pins to the traverse Remove the shoulder pins and the traverse 25 minutes Installation Position the traverse between the ears of the lifting link
15. nto the push rod Insert the push rod axle through the bracket and push rod Secure the axle in the bracket with the roll pin Insert the pivot axle through the frame and bracket Secure the axle in the bracket with the roll pin If you have not adjusted the push rod yet place the lifting link in a position that matches a fully lowered position Spin the push rod and bracket one way or the other until the pivot axle hole on the bracket lines up with the frame Then insert and secure the pivot axle Test the adjustment by pumping the jack up and then lowering it If the forks hit bottom at the same time then it is adjusted correctly If one fork hits bottom before the other then further adjustment is necessary You can either shorten the push rod on the fork that hits first or lengthen the push rod on the fork that hits second Keep adjusting until both forks hit bottom at the same time 25 minutes CALL 1 800 331 0839 Lifting Link Inspection Check lifting link for out of round holes cracks in welds or bent ears If any of these conditions exist replace the lifting link We suggest that you work on one side of the jack at a time so you can use the other side as a reference The T Series standard height uses an eccentric for adjustment and the lowered height uses an eye bolt for adjustment Both standard and lowered height of the E Series uses an eye bolt as well Removal T Series Standard height Pump the jack up to its maximum
16. rvoir filler plug leaking Replace the washer and restore air pressure see Low Fluid Level One fork lifts the other does not Check for damage in the following areas and their attached parts e Lifting link lifting link pin and traverse shoulder pin e Pushrod e Load roller bracket pivot axle GENERIC PARTS SERVICE 13 CALL 1 800 331 0839 GPS Inc Hydraulic Unit Service Hints e Tampering and abuse are two of the most common problems In most cases minor repairs become major when inexperienced people attempt to rebuild a hydraulic unit If you come across a unit that looks like it has been tampered with or modified inspect the unit carefully to be sure it can be rebuilt or call Generic Parts Service for technical assistance e The ram is chromed and the pump piston polished to a fine finish for maximum seal life and minimum oil leakage If you see these surfaces nicked or pitted this will cause the unit to fail in a short time Replace any rusty or damaged parts that will cause premature wear on their mating parts or the body of the hydraulic unit e The high pressure relief valve is pre adjusted by the factory and usually needs no attention e Use RL HO hydraulic oil Rol Lift jacks use oil which is less dense than most pallet jack hydraulic oil Do not use automotive oil or hydraulic brake fluid CALL 1 800 331 0839 14 GENERIC PARTS SERVICE GPS Inc Hydraulic Unit Removal Pump the jack to its maximum h
17. so inspect the pivot shaft and the piston pusher for wear If any of the above parts are worn more than 1 16 replace them Foot Control Removal Remove the roll pin Pull up on the handle while twisting from side to side 5 minutes Foot Control Installation Insert the handle into the handle socket so the hole on the handle aligns with the hole in the handle socket Drive the roll pin in place to secure the handle 5 minutes Hand Control Removal Remove the locking nut and the adjustment screw in the fulcrum bar This will allow the glide pin and the ball to slide out of the way and allow room for the actuator to come out of the handle pivot shaft Remove the handle bolt and carefully pull up on the handle to pull the actuator out of the handle pivot shaft Do not twist the handle until the actuator is out of the handle pivot shaft 5 minutes Hand Control Installation Insert handle into handle socket so holes will align when completely inserted While pushing the handle into the socket the actuator must slide completely in the handle pivot shaft Slide the ball and then the glide pin into the pivot shaft Replace handle bolt Install the adjusting screw and locking nut back into the fulcrum bar 10 minutes CALL 1 800 331 0839 and Installation Handle Socket Roll Pin 4 ihe Handle NN Pivot Ball Shaft Ste Q Fulcrum Bar Handle Bolt io PET v Glide re Adjustment Screw
18. still assembled If it isn t adjust the length after you have assembled the load roller bracket onto the push rod Insert the push rod axle through the bracket and push rod Secure the axle in the bracket with the roll pin Insert the pivot axle through the frame and bracket Secure the axle in the bracket with the roll pin If you have not adjusted the push rod yet place the lifting link in a position that matches a fully lowered position Spin the push rod and bracket one way or the other until the pivot axle hole on the bracket lines up with the frame Then insert and secure the pivot axle Test the adjustment by pumping the jack up and then lowering it If the forks hit bottom at the same time then it is adjusted correctly If one fork hits bottom before the other then further adjustment is necessary You can either shorten the push rod on the fork that hits first or lengthen the push rod on the fork that hits second It is easier if you do the adjustment on the eye bolt end once the load wheel bracket is attached to the frame Remove one of the snap rings on the pin that fastens the eye bolt to the lifting link and punch the pin out Pull the eye bolt away from the lifting link and turn it one way or the other to adjust as needed Assemble the eye bolt and the lifting link with the pin and its snap rings Turn the jack over and test the adjustment Keep adjusting until both forks hit bottom at the same time 25 minutes GENERIC PARTS SER
19. t Place hand control in neutral Loosen the lock nut on the adjustment screw Back the set screw out 3 4 turns being careful not to completely remove it Pump the handle slowly to raise the jack then turn the adjusting screw in until the jack Stops raising Now turn the adjusting screw an additional 4 of a turn and tighten the lock nut Test the jack by placing the handle control in the neutral position then pump the handle The jack should not raise Place the handle control in the lower position and the jack should lower see Diagram on page 12 10 minutes e Foot Control Malfunctioning If the foot control shoulder bolt is bent replace it If the foot control pedal is worn to the point that it is not properly engaging the actuator pin replace the foot control pedal If the foot control pedal appears to be properly engaging the actuator pin the problem is probably within the hydraulic unit Jack fails to lower e The foot control pedal shoulder bolt is loose or bent Replace if necessary e The hand control may be out of adjustment see Hand Control Out of Adjustment e Oil is too dense Empty unit and refill with RL HO oil e Look for any bent or damaged frame parts lifting link push rod etc Bent or damaged frame parts should be replaced e Debris blocking an oil channel in the hydraulic unit Contact us for our hydraulic core exchange program Jack lifts in short increments e Loss of oil pressure see Low Fluid Level e Rese
20. the eccentric in the proper adjustment remove the snap ring securing the eccentric to the lifting link and drive the eccentric out of the lifting link through the access hole in the frame It is helpful to mark the adjustment of the eccentric for easier adjustment of the push rods during assembly 25 minutes Lowered height Fully lower the jack and then turn the jack over so that the undercarriage is facing up Drive out the roll pin fastening the pivot axle to the load roller bracket and remove the pivot axle Drive the roll pin out that fastens the push rod axle to the load roller bracket and remove the axle Unscrew the push rod from the eye bolt it is helpful to mark the adjustment of the eye bolt for proper installation 20 minutes CALL 1 800 331 0839 Removal E Series Standard height Fully lower the jack and then turn the jack over so that the undercarriage is facing up Remove one of the snap rings on the pivot axle and drive the pivot axle out of the bracket and frame Remove one of the snap rings on the push rod axle and drive the axle out of the bracket Loosen the nut and unscrew the push rod from the eye bolt It is helpful to mark the adjustment of the eye bolt for proper installation 20 minutes Lowered height Fully lower the jack and then turn the jack over so that the undercarriage is facing up Drive the roll pin fastening the pivot axle to the load roller bracket out and remove the pivot axle Drive
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