Clarke PT685BM, PT685CM, PT540BM, PT540M, PT540CM Operation & Maintenance Instructions Manual

HYDRAULIC PALLET TRUCK

MODEL NO: PT540M/BM/CM & PT685BM/CM

PART NO: 7631700, 7631705, 7631710, 7631715, 7631720

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0316

INTRODUCTION

Thank you for purchasing this CLARKE Hydraulic Pallet Truck.

Please note that the M, BM, and CM on the model number indicate the type
of rollers on the pallet truck.

M = Single Nylon, BM = Single Polyurethane and CM = Twin Polyurethane

Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.

INTENDED USE

This pallet truck is a manually operated hand pallet truck designed to lift and
transport the rated load on industrial pallets.

Do not lift or carry people and don’t use this pallet truck for any other purpose
than its intended use. incorrect usage can cause injuries or can damage
equipment.

The operator / operating company has to ensure the correct usage and that
this pallet truck is used only by staff who are trained and authorized to use this
pallet truck.

WARNING: THE TRUCK HAS TO BE USED ON SUBSTANTIALLY FIRM,
SMOOTH, LEVEL AND PREPARED SURFACES. THE LOAD MUST BE PLACED
CENTRALLY ON THE FORKS.

GUARANTEE

This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required 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 the purpose for which it was
intended.

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.

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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 oil 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.

SAFETY INSTRUCTIONS

1. The operator should read all warning signs and instructions here and on the
pallet truck before use.

2. Keep these instructions safe for future reference.

3. Examine the condition of the pallet truck before use, with particular
attention to the wheels, handle, forks and lift/lower controls. Do not use the
pallet truck if any defects are found.

4. Do not operate a hand pallet truck unless you are familiar with it and have
been trained or authorized to do so.

5. Do not make any changes or modifications to the pallet truck.

6. Do not use if the wheels or rollers are damaged. Have them replaced
immediately

7. Keep the work area tidy and well lit.

8. Keep children and bystanders away from the work area.

9. Do not exceed the capacity of the pallet truck. Refer to the labelling on
the pallet truck and the specifications section in this manual,

10. Do not use on rough terrain. The pallet truck is designed for use on smooth
flooring only.

11. Do not use the pallet truck on a gradient if the load is too heavy to be
easily handled by the operator. The pallet truck must not be used by
anyone not capable of handling the full weight of the pallet truck when
loaded.

12. Watch for differences in the floor levels when moving the truck. The load
may overbalance or the truck could become uncontrollable.

13. Do not let the pallet truck come into direct contact with food.

14. DO NOT Use the truck in explosive atmospheres.

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15. The operator must wear safety shoes and gloves.

16. Do not allow personnel other then the operator to stand in front of or
behind the truck when it is moving or lifting/lowering.

17. Do not put your foot in front of rolling wheels, Injury could result.

18. Do not use the pallet truck as a jack.

19. Load the pallet truck evenly with the centre of gravity of the load above
the centre of the forks. Do not move unstable or loosely stacked loads. Use
extra care when moving long, tall or wide loads which impair your view.

20. Keep watching the load. Stop if the load becomes unstable.

21. When not in use, always make sure that the truck is stored where it is not
danger to others. Do not leave the truck on a gradient without first securely
chocking the wheels.

22. Carry out maintenance work according to the “Maintenance” on page 9.

23. This truck is not designed to be water resistant, therefore use it in dry
environments.

MARKINGS AND DECALS

Before using the pallet truck,
ensure that all markings and decals
are on the right place and not
damaged. If necessary replace the
decals.

• A Operating instruction label

• B. Capacity label

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ASSEMBLY

After unpacking, it is necessary to attach the truck handle assembly as follows.

1. Remove the 3 socket-headed
screws from base bracket.

2. Take the handle assembly and
lower the end of the chain
through the hole in the pump
body, so that it emerges at the
bottom of the housing.

3. Secure the handle to the base
bracket with the three socket­headed screws, as shown.

• Tighten them with the hexagon

key provided.

4. Push and hold the screw adjuster
inwards to raise the end of the
forked lever.

5. Hook the nut attached to the end
of the chain, under the claws on
the underside of the forks. Release
the forked lever and use the
screw adjuster to remove any
slack from the mechanism.

6. Your pallet truck is now fully
assembled, however, before you
use it you must follow the
adjustment procedure on the
next page.

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ADJUSTMENT

• The control lever has three

positions shown 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.

1. Set the control lever to the 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 (B) 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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OPERATING INSTRUCTIONS

DAILY INSPECTION

Daily inspection is effective to find any malfunction or fault on the pallet truck.

WARNING: DO NOT USE THE PALLET TRUCK IF ANY MALFUNCTION OR
DEFECT IS FOUND.

1. Check the following points before operation.

• Visually check for structural deformation or cracks and listen for any

unusual noise or binding of the lifting mechanism.

• Check if there is any oil leakage.

• Raise/Lower the forks to check for vertical creep of the lifting

mechanism.

• Check for any damage to the wheels and make sure they rotate

smoothly.

• Check that all the bolts and nuts are tight.

• Verify that all labels are in place.

PARKING

When parking the pallet truck, lower the forks to the lowest position and park
on smooth, even level ground where it is not an obstruction.

LIFTING

1. Check that the load does not exceed the rated capacity of the pallet
truck.

2. Roll the pallet truck with its forks slowly under the pallet/load until the back
end of the fork rests against the load.

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3. Move the operating lever down to
the ‘Lifting’ position. Lift the load
by moving the handle assembly
up and down.

• The load must be evenly

distributed across both forks.

• DO NOT OVERLOAD THE PALLET

TRUCK!

MOVING

• Do not operate the truck on a slope.

• Watch for differences in the floor level when moving the pallet truck.

• Make sure that the load is stable.

Move the truck by pushing or pulling the handle assembly.

• If the pallet truck is moving, do not turn the handle at a right angle to

stop the pallet truck.

LOWERING

Do not put your foot or hand under
the lifting mechanism.

Lower the load by moving the
operating lever up to the lowering
position carefully.

• By releasing the lever, the

lowering movement will stop.

Ensure there is adequate clearance behind you, then withdraw the pallet
truck from the load.

MALFUNCTIONS

If there are any malfunctions, stop using it until it is repaired.

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MAINTENANCE

Whilst the pallet truck requires very little maintenance, the following care can
be expected.

PURGING AIR FROM THE HYDRAULIC SYSTEM

If the pallet truck has been
transported over any distance or has
been overturned at any time, air may
have entered the hydraulic system.
This will make it impossible to raise the
forks under load.

1. Hold the control handle in the
‘lower’ position.

2. Move the handle up and down
several times.

CHECKING THE OIL

1. Check the oil level every six
months by topping up if necessary
at the filler plug.

• 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.

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
will restore smooth movement.

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TROUBLESHOOTING

PROBLEM CAUSE ACTION

The forks
cannot be
raised to
the max
height

The forks
cannot be
lowered

Leaks oil seals worn or damaged. Replace with the new one.

The forks
lower
on their
own.

Hydraulic oil is low Top up with oil.

The oil has impurities Change the oil.

The adjusting screw is not in the
correct position.

Air in the hydraulic system. Bleed the hydraulic

The piston rod or pump body is
deformed resulting from partial
loading slanting to one side or
over loading.

The fork was kept in the high
position for long time with piston
rod exposed which caused
rusting and jamming of the rod.

The adjusting screw is not in the
correct position.

Impurities in the oil cause the
release valve to remain open.

Leaks in the hydraulic system. Inspect and replace the

Air in the hydraulic system. Bleed the hydraulic

The adjusting screw is not in the
correct position.

See Page 6.

system.

Replace the piston rod or
the pump body.

Keep the fork in the lowest
position when not in use,
and lubricate the piston
rod.

See Page 6.

Replace with the new oil.

broken parts.

system. see Page 9.

See Page 6.

Do not attempt to repair the pallet truck unless you are trained or authorized to
do so.

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SPECIFICATION

PT685BM PT685CM PT540BM PT540M PT540CM

Width to outside of
the forks

Fork Length 1150 mm 1150 mm 1150 mm 1150 mm 1150 mm

Gap between the
forks.

Maximum Capacity 2500 kg 2500 kg 2500 kg 2000 kg 2500 kg

Dims (L x W x H) mm 1555 x 540 x

Weight 65 kg 67 kg 64 kg 61 kg 64 kg

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.

685 mm 685 mm 540 mm 540 mm 540 mm

360 mm 360 mm 220 mm 220 mm 220 mm

1230

1555 x 540 x

1230

1555 x 520 x

1230

1555 x 520 x

1230

1555 x 520 x

1230

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PARTS DIAGRAM - HANDLE

No Description No Description

D601 Spring D609 Pull Board

D602 Blade Spring D610B Handle

D603 Roller D611 Screw

D604 Roll Pin D612 Chain

D605 Roll Pin D613 Pin

D606 Roll Pin D614 Adjusting Bolt

D607 Roll Pin D615 Adjusting nut

D608 Control lever D616 Spring Washer

Please quote ZNEPT + Model Number + Part number above when ordering
parts.

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PARTS LIST + DIAGRAM - FORKS (M)

No Description No Description

201 Fork Frame 216 Shaft

202G Bolt 217 Intermediate Roller

203 Arm assembly 219 Roll Pin

204 Bushing, 25x29x25 220 Roll Pin

205 Spindle 221 Shaft

206 Bushing, 16*18*15 222 Roller Bracket

208 Circlip 225 Washer

B209 Joint 226 Bearing

210 Pin 230 Roll Pin

B211 Nut 234 Loading Roller

B212 Push Rod 235 Shaft for Roller

213 Roll Pin 236 Washer

214 Shaft 237 Grease Nipple

215 Bushing

Please quote ZNEPT + Model Number + Part number above when ordering
parts.

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PARTS DIAGRAM - PUMP (M)

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PARTS LIST - PUMP (M)

No Description No Description

D101 Pump Piston Rod D132 Lever

D102 Washer D133 Adjusting Screw

D103 Spring D134 Nut

D104 Dust Ring D135 O – Ring

D105 Y – Seal D136 Axle Sleeve

D106 Screw D137 Adjusting Bolt

D107 O – Ring D139 Safety Valve Spindle

D108 Spring D140 Spring

D109 Pumping Valve Spindle D141 O – Ring

D110B Pumping Valve Seat D142 Screw

D111B O – Ring D143 O – Ring

D112 Steel Ball D144 Y – Seal

D113 Pump Base D145 Roll Pin

D115 Roll Pin D146 Steel Ball

D116 Steering Wheel D147 Piston Rod

D117 Axle D148 Dust Ring

D118 Thrust Plate D149 Filler Plug

D119 Grease Nipple D150 Shaft

D120 Circlip D151 Bracket

D121 Bearing Cover D152 Pressure Roller

D122 Bearing D153 Shaft

D123 Roll Pin D154 Roll Pin

D124 Dust Cover D155 Roll Pin

D125 Circlip D156 Bush

D126 Tab Washer D157 Seal Washer

D127 Bearing D158 Bush

D129 Spring D159B Sleeve

D130 Strike Pin D160B Screw

D131 O – Ring D161 Washer

Please quote ZNEPT + Model Number + Part number above when ordering
parts.

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PARTS DIAGRAM - PUMP (BM + CM)

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PARTS LIST - PUMP (BM + CM)

No Description No Description

D101 Pump Piston Rod D132 Lever

D102 Washer D133 Adjusting Screw

D103 Spring D134 Nut

D104 Dust Ring D135 O – Ring

D105 Y – Seal D136 Bolt

D106B Bolt D137 Adjusting Bolt

D107B O – Ring D139 Safety Valve Spindle

D108 Spring D140 Spring

D109 Pumping Valve Spindle D141 O – Ring

D110B Pumping Valve Seat D142 Screw

D111B O – Ring D143 O – Ring

D112 Steel Ball D144 Y – Seal

D113 Pump Base D145 Roll Pin

D115 Roll Pin D146 Steel Ball

D116 Steering Wheel D147 Piston Rod

D117 Axle D148 Dust Ring

D118 Thrust Plate D149 Filler Plug

D119 Grease Nipple D150 Shaft

D120 Circlip D151 Bracket

D121 Bearing Cover D152 Pressure Roller

D122 Bearing D153 Shaft

D123 Roll Pin D154 Roll Pin

D124 Dust Cover D155 Roll Pin

D125D Circlip D156 Bush

D126D Tab Washer D157 Seal Washer

D127 Bearing D158 Bush

D129 Spring D159B Sleeve

D130 Strike Pin D160B Sleeve

D131 O – Ring D161 Washer

Please quote ZNEPT + Model Number + Part number above when ordering
parts.

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PARTS LIST + DIAGRAM - FORKS (BM + CM)

No Description No Description

201 Fork Frame 220 Roll Pin

202G Bolt 221 Shaft

203 Lever Arm 222 Roller Bracket

204 Bush 25 x 29 x 25 223D Roller Spindle

205 Shaft 224D Linking Plate

206 Bushing, 16*18*15 225 Washer

208 Circlip 226 Bearing

B209 Clevis 227 Loading Roller

210 Clevis Pin 230D Roll Pin

B211 Nut 230 Roll Pin

B212 Push Rod 231 Bolt

213 Roll Pin 232 Roller

214 Shaft 233 Locking Nut

215 Bush 234 Loading Roller

216 Shaft 235 Shaft for Roller

217 Intermediate Roller 236 Washer

218 Extending Roller 237 Grease Nipple

219 Roll Pin

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DECLARATION OF CONFORMITY

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