HYDRAULIC PALLET TRUCK Models; PT550C & PT685C Part Nos 7630172 & 7630177 OPERATING & MAINTENANCE INSTRUCTIONS GC05/12
INTRODUCTION Thank you for purchasing this CLARKE Pallet Truck. Before attempting to use the product, it is essential that you read this manual thoroughly and carefully follow all instructions given. In doing so you will ensure the safety of yourself and that of others around you, and you can also look forward to the product giving you long and satisfactory service. CONTENTS 1 x Pallet Truck Assembly 1 x Detachable Handle 1 x Allen Key 1 x Owners Manual (this document) GUARANTEE This CLARKE product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase. Please keep your receipt as proof of purchase. This guarantee is invalid if the product is found to have been abused or tampered with in any way, or not used for its intended purpose. Faulty goods should be returned to their place of purchase, no product can be returned to us without prior permission. This guarantee does not effect your statutory rights. ENVIRONMENTAL PROTECTION Do not dispose of this product or its packaging with general household waste. All tools, accessories and packaging should be sorted, taken to a recycling centre and disposed of appropriately. To avoid pollution due to leakage, the user should provide some absorbent materials to capture any escape of oil during refilling of the hydraulic mechanism. Such materials should then be disposed of appropriately. 2
TECHNICAL SPECIFICATION Feature PT550C PT685C Maximum capacity 2000 kg 2000 kg Dimensions (l x w x h) mm (exc handle) 1500 x 550 x 445 1500 x 685 x 445 Weight Width to outside of Fork Fork Fork length width thickness Gap between forks forks 67.5 kg 71 kg 550 mm 685 mm 1150 mm 1100 mm 160 mm 160 mm 60 mm 60 mm 205 mm 365 mm Entry options 4 2 Min fork Max height from ground fork height from ground Load roller size 75 mm 75 mm 190 mm 190 mm 70 x 70 mm 70 x 70 mm Number of actions to raise fully forks 12 13 Please note that the details and specifications contained herein, are correct at the time of going to print. However, CLARKE International reserve the right to change specifications at any time without prior notice. 3
SAFETY PRECAUTIONS 1. Keep the work area tidy & well lit and keep children and bystanders away from the work area. 2. Never carry out any alterations or modifications to the pallet truck. 3. Do not exceed the stated capacity of the truck. Refer to the technical specifications above and the labelling on the truck. Overloading may cause the truck to fail. 4. Load the truck evenly with the centre of gravity of the load over the centre of the forks. Never stand on the forks. 5. Do not use on rough terrain. The pallet truck is designed for use on smooth flooring only. Do not bounce the truck over rough ground, or down curbs etc. Use ramps wherever possible. 6. Do not move unstable or loosely stacked loads. Use special care when moving long, tall or wide loads or transporting a load which may impair your view. 7. Never position any part of your body under the lifting mechanism or under the forks. Do not transport passengers on the truck. 8. Do not operate a pallet truck until you have checked its condition, giving special attention to the wheels, handle, forks and lift/lower controls. 9. Never use the pallet truck on a gradient if the load is too heavy to be easily handled by the operator. The truck should not be used by operators who are not physically capable of handling the loaded pallet truck. 10. Do not use if wheels or castors are damaged. Have them replaced immediately. 11. When not in use, always ensure the truck is left where it is not hazard to others. Never leave the truck on a gradient without first securely chocking the wheels. Please keep these instructions in a safe place for future reference. 4
ASSEMBLY After unpacking, it is necessary to attach the truck handle assembly as follows. (Part numbers refer to the list/diagrams on pages 10-13). 1. Take the handle assembly and lower the end of the chain A, through the hole in the pump body, so that it emerges at the bottom of the housing. 2. Secure the truck handle to the base bracket with the three socket-headed screws, B, as in Fig 1, tightening them with the hexagon key provided. 3. Release the screw adjuster (154) in Fig 4, in order to raise the end of the forked lever, shown at C, Fig. 2, and slide the threaded rod/locknut attached to the end of the chain, A between the forks, so that the locknut, screwed on to the threaded rod, locates behind the claws on the underside of the forks. Release the forked lever and screw the adjuster (154) back in to remove any slack from the mechanism. Your pallet truck is now fully assembled, however, before use it is IMPORTANT to check the following adjustments. 5
ADJUSTMENT The control lever has three positions shown in Fig 3 and indicated by the label on the handle. With the lever pulled to the upper position, the forks will lower. The middle position allows the load to be transported. The lower position will cause the forks to lift when the handle is pumped. Fig. 3 1. Set the control lever to its lowest position (i.e. Lever in its LIFT position). 2. If the forks rise while pumping in the TRANSPORT position, release the locking nut (A) and turn the adjusting screw (B) clockwise until the pumping action does not raise the forks and they remain in position in the TRANSPORT position. 3. If the forks descend while pumping in the TRANSPORT position, turn the adjusting screw (154) anti-clockwise until the forks do not lower. 4. If the forks do not descend when the control handle is in the LOWER position, turn the adjusting screw (B) clockwise until raising the control handle lowers the forks. Check it s operation in the TRANSPORT position. 5. If the forks do not elevate while pumping in the LIFT position,turn the adjusting screw (B) anti-clockwise until the forks raise while pumping in the LIFT position. Finally check the operation in the LOWER and TRANSPORT positions. 6
OPERATION Before using the pallet truck always read the safety instructions in this manual and the labelling on the product. The rated capacity of the truck assumes an evenly distributed load with it s centre being at the halfway point along the length of the forks. With the forks in the lowest position, manoeuvre the truck so that it is adjacent to the pallet. Ensure the length of the forks match the length of the pallet. Always position the pallet truck carefully, ensuring the load is centred about the forks and is completely stable. Ensure there is no obstruction before raising the load, or that the load cannot foul the truck mechanism when raised. Lower the forks to the lowest height when the truck is not being used. When lowering the truck with the forks loaded, pull the control lever up carefully and gradually so that the load descends under complete control. 7
MAINTENANCE Whilst the pallet truck requires very little maintenance, the following care can be expected. DAILY CHECK Before use, check that there are no foreign bodies such as threads or rag to jam the wheels. Always leave the forks in the lowered position when work is over for the day. CHECKING THE OIL Check the oil level every six months by topping up if necessary at the filler plug (144). The capacity is approximately 0.3 litres. The recommended type is L-HV46 Hydraulic oil, provided the truck is not to be used outside the temperature range of -20 C to +40 C. BLEEDING AIR FROM THE PUMP UNIT If the pallet truck has to be transported over any distance or been overturned at any time, air may have permeated the hydraulic oil. This will make it impossible to raise the forks under any load when pumping. To bleed off the air, move the control handle (308) to the lower position, then move the handle (310) up and down several times. GREASING Moving parts can be lubricated with motor oil or grease. After prolonged use, the pivoting action of the steering wheel assembly may become stiff. In this case, a shot of grease via the grease nipples (118 and 202) will restore smooth movement. For parts & servicing, please contact your nearest dealer, or CLARKE International, on one of the following numbers. PARTS & SERVICE TEL: 020 8988 7400 PARTS & SERVICE FAX: 020 8558 3622 or e-mail as follows: PARTS: Parts@clarkeinternational.com SERVICE: Service@clarkeinternational.com 8
TROUBLESHOOTING Problem Cause Action Forks cannot raise to the maximum height. Forks will not raise. I nsufficient hydraulic oil. Top up with oil. Lack of hydraulic oil Top up the oil. Forks cannot lowered. be Mechanism is leaking. The forks raise but the release valve will not work. Oil is contaminated Pumping valve is open due to the nut (315) being too high or the screw (154) is too tight. Air present in the oil. Piston rod (101) or pump body is damaged due to uneven loading, overloading or leaning to one side. Fork has been in high position for long enough for corrosion of the exposed piston to occur. Adjusting nut (315) or the screw (154) is not in the correct position. Warn or damaged seals Contamination of the oil is preventing the valve from locking closed. Cracking or wear components. Air present in the oil. of the Oil seals worn or damaged. Adjusting nut (315) or the screw (154) is not in the correct position. Change the oil. Adjust the nut screw (154). (315) or the Bleed the oil to dispell the air. Replace pistion rod (101) or the pump body. Always keep the forks in the lowest position when the truck is not in use. Lubricate the piston rod with oil. Adjust the nut screw (154). (315) or the Overhaul & replace with new parts. Renew the oil. Inspect parts for wear & replace as necessary. Bleed system to expel the air. Replace worn or damaged seals. Adjust the position of nut (315) or screw (154). 9
PARTS LIST & DIAGRAM - PUMP When requesting spare parts, quote ref: ZNEPT 550C or 685C according to the model, followed by the suffix 001-onwards, and listed in the table. No Description Part Ref 10 Ref Description Part Ref 101 Pump Piston Rod 001 130 Sealing Washer 030 102 Washer 002 131 Retaining Cap 031 103 Spring 003 132 Bracket 032 104 Dust Ring 004 133 Adjusting Bolt 033 105 Seal 005 134 Safety Valve Spindle 034 106B Retaining Cap 006 135 Spring 035 107B O-ring 007 136 O-ring 036 108 Spring 008 137 Screw 037 109 Pump Valve Spindle 009 138 O-ring 038 110B Valve Seat 010 139 Y-Seal 039 111B O-ring 011 140 040 112 Steel Ball 012 141 Steel Ball 041 113 Pump Base Casting 013 142 Piston Rod 042 114 014 143 Dust Ring 043 115 Steering Wheel (pair) 015 144 Filler Screw 044 116D Steering Wheel Shaft 016 145 Shaft 045 117 Thrust Plate 017 146 Bracket 046 118 Grease Nipple 018 147 Pressure er 047 119 Circlip 019 148 Shaft 048 120 Bearing Cover 020 149 049 121 Bearing 021 150 050 122 022 151 Bushing 051 123 Dust Cover (pair) 023 152 Seal Washer 052 124 Bearing (pair) 024 153 Bushing 053 125 Washer (pair) 025 154 Adjusting Screw 054 126 Circlip (pair) 026 155 Nut 055 127 Spring 027 156B Sleeve 056 128 Strike 028 157B Grub Screw 057 129 O-rings (pair) 029
PARTS LIST & DIAGRAM - PUMP 11
PARTS LIST & DIAGRAM - FORK FRAME No Description Part Ref 12 No Description Part Ref 201 Screw 054 214 Pivot Shaft 067 202 Grease Nipple 055 215 er Arm 068 203 Pump Arm 056 216 069 204 057 217 Lifting Fork Frame 070 205 Retaining Ring 058 218 Front Hinge Bush 071 206D Fork End 059 219 Rear Hinge Bush 072 207 Joint 060 220 Washer 073 208D Push Rod 061 221 Washer 074 209D Nut 062 222 er Shaft 075 210 Hinge 063 223 076 211 Pivot Shaft 064 224 Washer 077 212 Spindle 065 225 Bearing 078 213 066 226 er 079
PARTS LIST & DIAGRAM - HANDLE No Description Part Ref No Description Part Ref 301 Spring 080 309 Draw Rod 088 302 Blade Spring 081 310 Handle Arm 089 303 er 082 311 Screw (x 3) 090 304 083 312 Chain 091 305 084 313 092 306 085 314 Adjusting Bolt 093 307 086 315 Adjusting Nut 094 308 Control Handle 087 316 Spring Washer (x3) 095 13
DECLARATION OF CONFORMITY 14
NOTES 15