PUSH TROLLEY 3 TON

91492
ASSEMBLY AND OPERATING INSTRUCTIONS

3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our Web site at http://www.harborfreight.com

TO PREVENT SERIOUS INJURY, READ AND UNDERSTAND ALL WARNINGS AND INSTRUCTIONS BEFORE USE.
Copyright 2004 by Harbor Freight Tools. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. For technical questions and replacement parts, please call 1-800-444-3353

Specifications
Load Capacity Hangar Thickness Hanger Eyelet Size Frame Wheel Dimensions Gross Weight Overall Dimensions I-beam Size 3 Ton
1/ " 2

1-1/2" x 2-7/16"
29/ " Steel Plate 64

5-1/16" OD x 4" ID x 3/8" Wall 58.3 Lbs. 11-1/2" (L) x 11-7/8" (W) x 14-1/4" (H) 4" to 8"

Minimum Curve Radius 4' 4"

Basic Use
This Trolley is to be used along with a lifting device (such as a chain hoist) to support and move an item over a distance. It uses an I-beam along the ceiling to support itself. It is not intended to move or support people or hold weight for an extended period, however-see Push Trolley Specific Safety Warnings and Precautions on page 3 for details.

Save This Manual

You will need the manual for the safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list, and assembly diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future reference.

General Safety Warnings and Precautions

WARNING: When using tool, basic safety precautions should always be followed to reduce the risk of personal injury and damage to equipment. Read all instructions before using this tool! 1. 2. 3. 4. 5. Keep work area clean. Cluttered areas invite injuries. Observe work area conditions. Do not use machines or power tools in damp or wet locations. Dont expose to rain. Keep work area well lit. Keep children away. Children must never be allowed in the work area. Do not let them handle machines, tools, or extension cords. Do not force tool. It will do the job better and more safely at the rate for which it was intended. Do not use inappropriate attachments in an attempt to exceed the tool capacity. Use the right tool for the job. Do not attempt to force a small tool or attachment to do the work of a larger industrial tool. Do not use this product for a purpose for which it was not intended. Dress properly. Do not wear loose clothing or jewelry as they can be caught in moving parts. Protective, electrically non-conductive clothes and non-skid footwear are recommended when working. Wear restrictive hair covering to contain long hair.

6.

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7. 8. 9.

Use eye and ear protection. Always wear ANSI approved impact safety goggles and heavy work gloves during use. Also, wear a hard hat or other protective gear if necessary. Do not overreach. Keep proper footing and balance at all times. Do not reach over or across running machines. Maintain tools with care. Keep tools clean for better and safer performance. Follow instructions for lubricating and changing accessories. The handles must be kept clean, dry, and free from oil and grease at all times.

10. Stay alert. Watch what you are doing, use common sense. Do not operate any tool when you are tired. 11. Check for damaged parts. Before using any tool, any part that appears damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment and binding of moving parts; any broken parts or mounting fixtures; and any other condition that may affect proper operation. Any part that is damaged should be properly repaired or replaced by a qualified technician. 12. Replacement parts and accessories. When servicing, use only identical replacement parts. Use of any other parts will void the warranty. Only use accessories intended for use with this tool. Approved accessories are available from Harbor Freight Tools. 13. Do not operate tool if under the influence of alcohol or drugs. Read warning labels on prescriptions to determine if your judgment or reflexes are impaired while taking drugs. If there is any doubt, do not operate the tool. Warning: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator.

Push Trolley Specific Safety Warnings and Precautions

1. Never exceed the load capacity of 3 Tons total load* for this Trolley. Always be aware of Dynamic Loading. If you suddenly pull on or swing the load it may create, for a brief instant, an excess load; possibly causing property damage and/or SERIOUS PERSONAL INJURY.

*The total load includes the load lifted, the equipment used to lift the load, and all chains or straps used to hold and secure the load.

2. 3. 4. 5. 6.

Always use proper couplings when connecting the Push Trolley to the load. Never lift people or hoist loads over people. After moving an item with the Push Trolley, secure the item. Do not rely on the Push Trolley to hold it for an extended period. Examine the Push Trolley before using. Components may be affected by exposure to chemicals, salts, and rust. Take care that, during pushing, the load doesnt swing back or come loose, causing SERIOUS INJURY or property damage. Page 3

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Install this trolley only on a metal I-beam between 4 and 8 Wide. If installing this trolley on a curved I-Beam, take extra care that the curve in the beam is not more severe than the Minimum Curve Radius, mentioned under Specifications on page 2. Failure to use the proper type of I-Beam may cause the trolley to fall, causing SERIOUS INJURY or DEATH. Not to be used for aircraft purposes.

8.

Installation
Warning: Because of the Push Trolleys weight, do not attempt to install it from a ladder. Use a stable platform. During installation, refer to the illustration below.
M = Width of I-beam Wheel (1b)

Left Plate (2a) Wheel (2b) Cotter Pin (3h) Castle Nut (3g) Adjusting Washers (3d)

Right Plate (1a)

Hanger Shaft (3a) Hanger Plate (4)

1. 2. 3.

Measure the width of the I-beam that will have to fit in space M, above. Measure the current distance of M on the preassembled Push Trolley. Calculate the number of Adjusting Washers (3d) that need to be added or removed to accommodate placement of the Push Trolley on the I-beam. Be sure to add 1/8 inch space (F) for each side of the I-beam. Remove Cotter Pin (3h), the Castle Nut (3g), and all Adjusting Washers (3d). Slide off the Left Plate (2a) from Hanger Shaft (3a). Now, with the two halves of the Push Trolley separated, hold the Right Plate (1a) and place on the lower section of the I-beam. Slide the Left Plate (2a) over the Hanger Shaft (3a) so that the Wheel (2b) rests on the Ibeam. Place the estimated number of Adjusting Washers (3d) on the Hanger Shaft (3a). Replace one of the Castle Nuts (3g) and tighten. There should be 1/4 inch play between the Wheels (1b, 2b) and the I-beam. If not, add or remove Adjusting Washers until there is 1/4 inch play.

4. 5. 6. 7. 8. 9.

10. Replace the other Castle Nut (3g) on the Hanger Shaft (3a) and tighten. Push the Trolley and see if it moves easily. If not, add more Adjusting Washers. 11. Replace the Cotter Pin (3h), bending its prongs to each side of the Castle Nut. SKU 91492 Page 4

Operation
Warning: 1. 2. 3. Never exceed the load capacity of 3 Tons total load* for this Trolley. *Read Push Trolley Specific Safety Warning # 1 on page 3 for details.

Place the load directly under the Push Trolley. Attach appropriate couplings from Hanger Plate (4) to load and hoist up to desired height. Push load to move Trolley. Caution: If the load does not move when pushed hard, stop operation and check for obstacles on the I-beam that may be obstructing movement.

Unpacking
When unpacking, check to make sure all parts are included. Refer to the Parts List and Assembly Diagram at the end of this manual. If any parts are missing or broken, please call Harbor Freight Tools at the number on the cover of this manual as soon as possible.

Maintenance
1. 2. Periodically grease the Bearings (1c, 2c) and I-beam surface. Check the Trolley for loose connections, bent or broken hardware, and any other damage periodically and before every use-see General Precaution 11 on page 3 for details.

PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

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Parts List
Assembly Name No. Part Name Right Plate Wheel Ball Bearing Right Plate Assembly 1 Snap Ring Bearing Cover Snap Ring Left Plate Wheel Ball Bearing Snap Ring Left Plate Assembly 2 Bearing Cover Snap Ring Name Plate Rivet Shaft Shor t Bushing Bushing Hanger Shaft Assembly Adjusting Washer 3 Thin Adjusting Washer Step Washer Castle Nut Cotter Pin Hanger Plate 4 3e 3f 3g 3h 2 2 2 2 1 2e 2f 2g 2h 3a 3b 3c 3d 2 2 1 4 1 2 3 12 1d 1e 1f 2a 2b 2c 2d 2 2 2 1 2 2 2 No. Qty. 1a 1b 1c 1 2 2

NOTE: NOTE:

Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts. Some parts may only be available as a complete assembly, not individually.

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Assembly Diagram

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