LoadSurfer XTN 540-1150 User manual

Hand Pallet Truck 2.5 tons

Instructions

For your safety

Please read this instruction manual before you use the Hand

Pallet Truck!

Please keep these instructions for future reference.

Contents: Part List and Instruction

Model .: XTN 5 0-1150

Safety-Lifting Group

Unit 23 Atlantic Road

Avonbridge Trading Estate

Avonmouth

Bristol

BS16 1XB

Tel: +

(0)1179 381600

Fax: +

(0)1179 381602

www.safety-lifting.com

Table of Contents

Safety rules and Instruction .....................................................2

andle assembling .......................................................... 2 – 4

Setting of Realse Valve ...................................................... 4 – 5

ow to work with and Pallet Truck .................................. 6 – 7

Service and Guarantee ...................................................... 7 – 8

Fault diagnosis, Examination, Disposal ................................. 10

Assembling Break .................................................................. 11

Part list ................................................................................. 12

Part list drawing ..................................................................... 13

Introduction & Precautions

Safety warning and Instruction

1.1 Introduction

Thank you for using this pallet truck. This pallet truck is made of high quality steel

and is designed to give you a durable, reliable and easy to use product. For your

safety and correct operation, please carefully read this instruction manual before

using this pallet truck.

1.2 Introduction and precautions

All of the information reported herein is based on data available at the moment of

printing. We reserve the right to modify our own products at any moment without

notice and incurring in any sanction. So, it is suggested to always verify possible

updates.

1.3 Technical Specification

Model: XTN540-1150

Rated Capacity: 2500 kg

Fork length and width: 1150 mm x 540 mm

Minimum height 80 mm

Maximum lifting height 190 mm

Fork wheel Nylon

Steering wheel Nylon

Dead weight without load 70 kg

Assembling the Handle

1. Tools you need

ammer 180g , medium size screw driver. 3 mm Punch

1.5 Parts

andle(45), andle axis (46), 2x spring pin (23).

These parts are supplied in a plastic bag, which is attached to the handle

Note

The number of the handle and pump should be the same

2 Assembling the Handle

Pict 1.

2.1

Pull down the lever to the Lifting position. (lifting )

2.2 Pass the adjusting nut (Part No. 59), adjusting bolt (Part No.58) and chain

(Part No. 60) assembly through the hole of axle (Part No. 46) with your hand

Insert the handle onto the pump piston (Part No. 1), then use a hammer to insert

the axle with hole ( Part No. 46) into the hydraulic pump and handle from the right

to the left. (See Pict 1).

2.3 Use the hammer to tap another spring pin (Part No. 23) into the axle with the

hole (Part No. 46). Using a 3mm Punch to finish

2. Using screw driver to lift up the Cam (17) and put the adjusting nut into the

Cam slot, check the correct position of the chain. (see Pitc 2, 1).

2.5 Remove the Pump locker (Pict 1,Nr.3)

2.6 Now the andle is already assembled to the and Pallet Truck.

Pict 2

3 To adjust the release device

On the handle of this hand pallet truck, you can find the lever, which operates in

three positions

Lower ................................ = Lowering the fork .......................... LOWER-Position

Drive ................................. = Drive the truck ................................... Drive-Position

Raise ................................ = Lift the fork ........................................ Raise-Position

If however they have been changed, you can adjust according to the following

steps

3.1 If the forks elevate while pumping in the DRIVE position, turn the adjusting

nut (Part No. 59) on the adjusting bolt (Part No. 58) clockwise until pumping

action does not raise the forks and the DRIVE position properly.

3.2 If the forks descend while pumping in the DRIVE position, turn the nut (Part

No. 59) counter-clockwise until the forks do not lower.

3.3 If the forks do not descend when the Lever is in the LOWER position, turn

the nut (Part No. 59) clockwise until raising the Lever (Part No. 51

) lowers the

forks. Then check the DRIVE position according to item 3.1 and 3.2 to be

sure that the nut (Part No. 59) is in the proper position

3. If the forks do not elevate while pumping in RAISE position, turn the nut (Part

No. 59) counter-clockwise until the forks elevate while pumping in the RAISE

position. Then check the LOWER and DRIVE positions according to item 3.1,

3.2 and 3.3 .

.0 Handling

.1 Driving and Steering the truck with Handle

The handle is adjusted directly to the steering wheels. The steering wheels will

follow the position of the handle.

Pict 3

.2 How to take the load

Drive the truck slowly in front of the pallet. Then, drive the fork of the truck under

the pallet up to end of the fork length. (Pict 3.A).

Lift the load by pumping the handle at Raise position.The load must be on the

center of the hand pallet truck. Otherwise, the hand pallet truck can be overturned

.3 Drive with load

It is not necessary to pump the pallet truck to the highest position to drive. You

must pay attention to the space between the bottom of the pallet and always keep

the pallet clear of the floor. You should carefully drive the hand pallet truck at a

stable speed paying due care and attention to the environment around you.

. Lowering the Load

Lift the Lever to the Lower position, ensuring a free space behind. Then the truck

can be pulled out of the pallet.

.5 How to use the hand pallet truck on the truck

Only move the pallet truck slowly, at all times be careful that the hand pallet truck

can not fall down from the truck or the user will not be in the middle between the

hand pallet truck and other loads. If the pallet truck is not used, it must be firmly

fixed on the truck when the truck is moving.

5.0

Service and warranty

5.1 Oil

The ydraulic oil in the pallet truck is used for work condition of 6°C to 45°C only.

If the pallet truck is used in a temperature under 6°C , it must be used with other

ydraulic oil with vicostity under 10.

Please check the oil lever every six months. The hydraulic oil volume in the pump

is 300 ml.

Used oil must be disposed off according to the latest regulations.

5.2 To remove the air

The air may come into the hydraulic oil because of transportation or pump in upset

position. It can cause that the forks do not elevate while pumping the RAISE

position. The air can be removed in the following way: Let the Lever (Part No. 51)

on the LOWER position, then move the andle up and down several times.

5.3 Daily check and Maintenance

Daily check of the pallet truck can limit wear as much as possible. Special attention

should be paid to the wheels, the axles, as thread, rags, etc. It may block the

wheels. The forks should be unloaded and lowered in the lowest position when the

job is over.

5. Lubrication

All bearings and shafts are provided with long-life grease at the factory. You only

need provide long-life grease at monthly intervals or after each time the truck is

cleaned thoroughly to the lubrication points.

6.0

Guide to safety operation

6.1

Operator should read all warning signs and instruction here and on the pallet

truck before using this truck

6.2 Do not operate a hand pallet truck unless you are familiar with it and have

been trained or authorized to do so.

6.3 Do not operate a hand pallet truck unless you have checked its condition. Give

special attention to the wheels (part No. 26, Part No. 71), the andle unit, the

fork unit, the cam (Part No. 17), etc.

6. Do not use the pallet truck on a uneven or slopping ground. Do not use the

pallet truck on gradients.

6.5 The pallet truck is not allowed to be used in insufficiently illuminated areas.

Minimum illimination must be at least 50 lux.

6.6 If the pallet truck is moving, it is not allowed to turn the handle into the right

angle to stop the pallet truck.

6.7 It is forbidden to use hand pallet truck for people transportation.

6.8 It is not allowed to use the pallet truck as a jack.

6.9 It is not allowed to use the fork of the pallet truck as a lever to lift loads.

6.10 Do not load like the picture 3.B.

6.11 Do not load over maximum capacity.

6.12 It is not allowed to use the pallet truck in risky conditions.

6.13 It is not allowed to use the pallet truck in direct contact with food.

6.1 It is not allowed to use the pallet truck in explosive atmosphere.

6.15 Operator must wear safety boots and gloves.

6.16 Whilst the goods are being transported all none operational staff should be at

a minimum

distance of 600mm.

6.17 At service work, it is not allowed to scatter parts.

6.18 Under any special conditions or environments, the operator should carry out

all relevant risk assessments and method statements before commencing work

with the pallet truck

6.19 It is forbidden to use the pallet truck if there is a risk that the pallet truck and

load may fall down, for example, from unsecured ramps.

7.0

Guarantee

This hand pallet truck is guaranteed within 12 months from the date of

purchase. The guarantee is only given if the hand pallet truck is used and serviced

as instructed in this Manual. There is no guarantee for consumable parts or

damage caused by misuse.

8.0

TROUBLE SHOOTING

No.

Trouble Clause Fixing Methods

1 The forks cannot be up at

the max height

The hydraulic oil is not enough Pour in the oil

The fork cannot be lifted

- Without hydraulic oil

- The oil has impurities

- The nut (Part No. 59) is too high, keep the

pumping valve open.

- The air comes into the hydraulic oil.

- Fill in the oil

- Change the oil

- Adjust the nut (Part No.59) (see

item 3.4)

- Bannish the air (see item 5.2)

The forks cannot be

descended

-The piston rod (Part No. 9) or pump body

(Part No. 15) is deformed resulting from

partial loading slanting to one side or over

- The fork was kept in the high position for

long time with piston rod bared to arise in

rusting and jamming of the rod.

- Adjusting the nut (Part No. 59) is not the

correct position.

- Replace the piston rod (Part No. 9)

or the pump body (Part No. 15)

- Keep the fork in the lowest position

if not using, and pay more attention

to lubricate the rod.

- Adjust the nut (Part No.59) (see the

item 3.3)

Leaks

- Sealing parts worn or damaged.

- Some parts creaks or worn into small

- Replace with the new one.

The fork descends

without the release valve

worked.

- The impurities in the oil cause the release

valve to be unable to close tight.

- Some parts of the hydraulic system is

cracked or bored.

- The air comes into the hydraulic oil.

- Sealing parts worn or damaged.

- The adjusting nut (Part No.59) is not the

the correct position.

- Replace with the new oil.

- Inspect and replace the waste

parts.

- Bannish the air (See item 5.2)

- Replace with the new one.

- Adjust the nut (Part No.59) (see the

item 3.3)

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

8.1 Inspection

The hand pallet truck must be inspected by authorized person minimum one time per year.

The result of checking must be filled in the report.

VBG 36, § 37

8.2 Disposal

After using, the pallet truck should be disposed corresponding to the law regulations.

All parts should be brought for recycling.

Table of contents

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