1. business and industrial
2. energy
3. oil

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.
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
TECHNICAL SPECIFICATION
Feature
PT550C
PT685C
2000 kg
2000 kg
1500 x 550 x 445
1500 x 685 x 445
67.5 kg
71 kg
Width to outside of forks
550 mm
685 mm
Fork length
1150 mm
1100 mm
Fork width
160 mm
160 mm
Fork thickness
60 mm
60 mm
Gap between forks
205 mm
365 mm
4
2
Min fork height from ground
75 mm
75 mm
Max fork height from ground
190 mm
190 mm
70 x 70 mm
70 x 70 mm
12
13
Maximum capacity
Dimensions (l x w x h) mm (exc handle)
Weight
Entry options
Load roller size
Number of actions to raise fully forks
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.
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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.
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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.
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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.
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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.
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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: [email protected]
SERVICE: [email protected]
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
TROUBLESHOOTING
Problem
Cause
Action
Forks cannot raise to
the maximum height.
Insufficient hydraulic oil.
Top up with oil.
Forks will not raise.
Lack of hydraulic oil
Top up the oil.
Oil is contaminated
Change the oil.
Pumping valve is open due
to the nut (315) being too
high or the screw (154) is
too tight.
Adjust the nut (315) or the
screw (154).
Air present in the oil.
Bleed the oil to dispell the air.
Forks cannot be
lowered.
Piston rod (101) or pump
Replace pistion rod (101) or
body is damaged due to
the pump body.
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.
Always keep the forks in the
lowest position when the truck
is not in use. Lubricate the
piston rod with oil.
Adjusting nut (315) or the
screw (154) is not in the
correct position.
Adjust the nut (315) or the
screw (154).
Mechanism is leaking. Warn or damaged seals
Overhaul & replace with new
parts.
The forks raise but the Contamination of the oil is
release valve will not preventing the valve from
locking closed.
work.
Renew the oil.
Cracking or wear of the
components.
Inspect parts for wear &
replace as necessary.
Air present in the oil.
Bleed system to expel the air.
Oil seals worn or damaged.
Replace worn or damaged
seals.
Adjust the position of nut
(315) or screw (154).
Adjusting nut (315) or the
screw (154) is not in the
correct position.
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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
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
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
Roll Pin
040
112 Steel Ball
012
141
Steel Ball
041
113 Pump Base Casting
013
142
Piston Rod
042
114 Roll Pin
014
143
Dust Ring
043
106B Retaining Cap
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 Roller
047
119 Circlip
019
148
Shaft
048
120 Bearing Cover
020
149
Roll Pin
049
121 Bearing
021
150
Roll Pin
050
122 Roll Pin
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 Pin
028
157B Grub Screw
057
129 O-rings (pair)
029
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
PARTS LIST & DIAGRAM - PUMP
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
PARTS LIST & DIAGRAM - FORK FRAME
No
Description
Part Ref
No
Description
201
Screw
054
214
Pivot Shaft
067
202
Grease Nipple
055
215
Roller Arm
068
203
Pump Arm
056
216
Roll Pin
069
204
Roll Pin
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
060
220
Washer
073
208D Push Rod
061
221
Washer
074
209D Nut
062
222
Roller Shaft
075
210
063
223
Roll Pin
076
077
Joint Pin
Hinge Pin
Part Ref
211
Pivot Shaft
064
224
Washer
212
Spindle
065
225
Bearing
078
213
Roll Pin
066
226
Roller
079
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
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
Roller
082
311
Screw (x 3)
090
304
Roll Pin
083
312
Chain
091
305
Roll Pin
084
313
Pin
092
306
Roll Pin
085
314
Adjusting Bolt
093
307
Roll Pin
086
315
Adjusting Nut
094
308
Control Handle
087
316
Spring Washer (x3)
095
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
DECLARATION OF CONFORMITY
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]
NOTES
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Parts & Service: 020 8988 7400/E-mail:[email protected] or [email protected]