Mau TER MOUBMENS Value delivered, Always ited iden ae es Bile <) babes TET ieee 9 TRUCKS patel gO TRUCK 3 ELECTRIC Bay vel <3 ELECTRIC TNT Pte (a3 ELECTRIC PV 25 L | INSTRUCTION MANUAL | SERVICE & SPARE PARTSSI No. Table of Contents Content Safety and Operating instructions Assembly instructions Assembly and Maintenance instructions Maintenance instructions ‘Spare part list for Pump and Frame unit Spare part list for Pump unit and Packing kit Page number JAN-2012Important 1. All designated operators of the equipment must read and understand the contents ofthis manual before operating the ‘equpment. 2. Nopart of the equipment may be modified or altered in any way, ether temporariy or permanently, under any circumstances without written permission of the manufacturer, MAINI MATERIALS MOVEMENT. Violation ofthis requirement voids waranty, 1. The equipment should always be used with care, good judgement and in a responsible manner. 2. The equipment must not be used with oily hands or oily shoes due to risk of slipping 3. Incorrect operation or maintenance may esult in damage. Therefore do not operate or repair the equipment unless you hhave received sufficient instruction. Please read the operating and maintenance manual carefully. 4. Checkall the equipment functions before starting ajo. 5. Donot use the equipmentif itis defective, Report the defect to the supervisor. 6. Read and understand the equipments authorised capacity as indicated on the equipment 7. Donotoverioad the equipment. 41. The operator should ensure that the floor where the equipment isto be used has sufficient load bearing capacity forthe total weight ofthe equipment, including the equipment’s maximum load. 2, Take special care i there are protrusions from racks, shelves or walls that can cause injury or damage the equipment 3, tis forbidden for others to be present in the area around the equipment when there isa isk of personal injury, e.g. areas that can be reached by falling goods, lowering or liting devices or in the equipment’s maneuvering area. 1. Always wear safety shoes when working with the equipment 2. The equipment must only be used for towing function. In general, its forbidden to use the equipment for personal transport Controls = Handleverasilustrates. HAND CONTROL. Raising Load When thelever(@)isatthe alsing postion thefts are ready for iting. Move the handle, and ve fork wil raise, Lowering Load © - When the lever(8)is at lowering poston, tetris will lower. Neutral Position - When thelever(8)isat he neutral gearpostionthe trucks ready for moving. Move the handle and the forks will not raise or lower. (Remember : A safe operator is @ smart operator! Page21. Seetig spring dowel (1) is disassembled from axe pin (2) before pulling out axe pin (2). 2, Insert handle (3)in postion Aand connect handle (3) wth pump body () by tre ale pa (2. 2. Ensure he halein the ade perencicuarto the cross member. Pass the chain (6) trough theasleas shown nf 2. 4. Assemble the end of chain (5) which is wih srew andnyloc nut andftintothe sof ever pad (8) se ig 2 and. 5. Lockthe ate pn (2) wth spring dowel (1). 6, See'ig.3movehandleto horizontal poston. Pulloutpin rom he handle (7) and preserve for future replaementofhehandle tube 7. Movathehandle and operate over (8) diferent postions o see weather thetruck works at isin neta gea an lowering £8. Inthe ig She sxow (6) used forthe modieaton of the ruck Inthe eventthat te truck body lowers sherk aerating, tum serew {G)alitie ant-clockwise direction. nme event that the tuck body s unable to lower, turn screw (9) alten a clockwise direction and then try the ruck again until normal Towering is functioning. Hexnut (10) at screw (8) functions asalock, soit shal be loosened before modification and tightened ater ‘medication. “Applicable only pallet tuck s dlspached from works ae in two sub assembles. |e) Frame and Pump assembly and b) Handle assembly. For prompt service, please mention the correct part numbers in all your enquiries. Pages‘Ac tock may occurin hydraulc system when trucks not used fora long time, ‘Te airlock can be removed inthe following ways. PPutthe lever (8)atthe lowering positon. Move the handle for4-6 tmes and then release the lever. needed, the above operaton can bbedone for several imesuntl normal working. (atenane atritn) Every day routine examination fs necessary fo solving the abnormal operations at sight, Donot use the troubled truck forthe sake of ‘rolonging its wok Ife. Every turing join must be lubricated by SAE 10 motor ol every ree months, and seethathewheels and aes ‘renal entangled by caten waste or other materia. Daily Check Annual Check CCheckthat all wheels are complete andcan bemaved freely. 1. Athrough overhaulof the pallet truck should bemase ‘once a year. Weekly Check ‘Check for any bends inthe forks, frame or push rods these 1. Lubricate as perinstruction ‘should be straightened to prevent breakdowns. 2. Change theoilin the hydraulic system to ensure smoat 2. Clean the machine completely. Special attention should be paid fo wheels and axes as threads, rags and tho ike ‘and effciont functioning. DTT TS 3. Checkfor the proper functioning of the pump uwitanathe hydraulic seals. These should be replaced if hey are weak ordamaged. 4. Check thatall the bearings are functoning smooth 5, Lubricate the machine as at assembly Lubrication Instructions Location Description Lubdcant Frequency A Pivot bushings SAE 10motor it Monthly 8 Wheel bearings ‘Standard - Sealed -No lube required Monthly Optional - Grease fiting ce Thrust bearing ‘Automotive Chassis Grease Annual Remove-Clean and repack ° Hydrauliepump ‘Above 0° F (18° C) Change Esso Polar 41, Exxon Esstic 42 or equal ‘Annual Below 0"F (-18"O) EssoUnivis N32, Boon Univis 40 or equal Pump capacity 12flud oz Do not use brake fluid. Do not overfill Be sure that al contaminated greaseis evacuated as new grease is pumped Recommended frequencies are for normal operating conditions. In corrosive conditions increase lubrication accordingly. : Pages For prompt service, please mention the correct part numbers in all your enquiries.Trotible Shooting No. Failure Insufficient lifting 2 Improper lowering ‘The forks do not lower after raising, Leakage of | hydraulic ol, 5 The forks do not lift. ie sie || bees tg ten ern a | bekonte ann | © | Pima set rete | | edited | | ee, serie, Causes The hydraulic oil is not adequate. 1. Too much hydraulic, oil 2. The pust rod assembly parts are stuck due to deformation 3. Seizing-up between piston and guide screw. ‘See Parts Fig. B152 and 8143. Unloading device is not functioning 2. Deform and damage in parts. 1. Failure of oll seal 2. Light crack on the surfaces of one or ‘two pars. 3. Loosening of joints. 1. Viscosity of working oil is too high or the working oil is not added, 2. Impurity in ol, 3. Unloading device is not funetioning, The valve is caught up by impurities. Solution ‘Add appropriate fitered working oil. 1. Extract excess amount of hydraulic il to bring quantity to 250m 2. Replace the parts, 3. Replace 8152 and 8153. 1. Re-adjusting the unloading device. See 3.8 clause. 2. Repalce the deformed ‘and damaged parts. 1. Replace the seal 2. Replace the damaged parts 3, Tighten the joints. 1. Replace the working oi 2. Remove the impurities, in the oil circuit and replace the oil. 3, Re-adjust the unloading device. See 3.8 clause. Loosen the part B119, take out and clean part B121, 8122, 123, and B124, Reassemble and tighten B119 after cleaning the oil holes.B40 839 /~. a Fe bis do ooh 8 PartNo, Qty Description Pano. Qty Description B11 Hande 225 2 Shat B2 1 Big Wheel Shaft B26 2 Shaft B31 Batt e272 Spring pin Sianiatescs e284 Rang B5 1 Supportingbase B29 2 Shaft e682 SprngPh 590 2 SpingFin Sree eas nee 8312 Fram@OrFork Whee! 2 2 Big Wheel (Nylon)* 552 8 Spring Pin B82 Big Wheel (Polyurethane)* eS Bano nicc wen cateie BM 4 NogOf Fork Whee! be 8 Bowing 8352 ForkWheet BIO 4 Half Cirque 535-2 Balt Bi 2 BowtWasher aa Bi2 2 Retaining ing ForAe one ae B13 2 ~~ Dustcover ee B42) Pn B40 1 Fork Frame (1150Lx510W) * Ba 2 Be B40 1 ForkFreme (150160500 * ce eo B40 1 Fork Frame (1220196100) * a B40 1—Fork Frame (122013685!) or 2 ee BA1 1 Spring Lock Washer B19 2 Straight Tappet (1150L)* eee * B19 2 Straight TapPet (12201) * B43 1 Rocker Arm (S100) B20 1 —_Long Shaft (510W) * td) B20. 1 __Long Shaft (685w) * eee * cee B4S 4 Fork Wheel (Nylon) iain B45 4 Fork Whee! (Polyurethane) 523 2 Roll Sheath B45 4 Fork Wheel (Cast!ron) e223 Rs B15? 1 Pumpoomplete * Please Specify the Indicated Dimensions Page 6 For prompt service, please mention the correct part numbers in all your enquiries. eeow ts Part No. Gly Description BIO! 1 —_BladeSpring Bt02 2 Spring Pin 8103.1 Roller B10! 1 Spring Pin 81051 Spring Pin 8106 1 Spring Pin BIO? 1 Handle 81081 Handle Tube 81091 Shaft B10 1 Springpin Bit 1 Pressure Roller B12 1 Bush B13 1 PullPole Bi4 2 Bush BIS 1 Chan BiG 1 Nut BIT 2 Spring Pin B18 2 Shaft Bio 1 Pug 8120 2 Copper Washer i211 Spring B12 1 Spindle Of Damping Valve B123 1 Seat Of Damping Valve Bi24 1 Steel Ball B12 1 Base 8126 2 Copper Washer Bia? 2 Balt Packing kit B155 8120 2 Copper Washor 8125 2 Copper Washer B10 1 ORng Bia 1 ORng Bit 1 ¥Ring Sin Waa Ls Bra 8150 Bist Description Song Stike Pin Ong ‘Ale Sleeve Ong Balt Na Levert Batt Sexing Ball Base Steel Ball Pin Ring Rng vine cap Ong Dust ng Steet Ball Pump Plunger Washer omg Dust Rng Ying Piston Rod Retaining Ring For Axle Drain screw Ong Dusting Dust Ring ‘Ring For prompt service, please mention the correct part numbers in all your enquir Page7