Clarke PT685BM Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0316
HYDRAULIC PALLET TRUCK
MODEL NO: PT540M/BM/CM & PT685BM/CM
PART NO: 7631700, 7631705, 7631710, 7631715, 7631720

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

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

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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
Do not attempt to repair the pallet truck unless you are trained or authorized to
do so.
PROBLEM CAUSE ACTION
The forks
cannot be
raised to
the max
height
Hydraulic oil is low Top up with oil.
The oil has impurities Change the oil.
The adjusting screw is not in the
correct position.
See Page 6.
Air in the hydraulic system. Bleed the hydraulic
system.
The forks
cannot be
lowered
The piston rod or pump body is
deformed resulting from partial
loading slanting to one side or
over loading.
Replace the piston rod or
the pump body.
The fork was kept in the high
position for long time with piston
rod exposed which caused
rusting and jamming of the rod.
Keep the fork in the lowest
position when not in use,
and lubricate the piston
rod.
The adjusting screw is not in the
correct position.
See Page 6.
Leaks oil seals worn or damaged. Replace with the new one.
The forks
lower
on their
own.
Impurities in the oil cause the
release valve to remain open.
Replace with the new oil.
Leaks in the hydraulic system. Inspect and replace the
broken parts.
Air in the hydraulic system. Bleed the hydraulic
system. see Page 9.
The adjusting screw is not in the
correct position.
See Page 6.

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SPECIFICATION
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.
PT685BM PT685CM PT540BM PT540M PT540CM
Width to outside of
the forks 685 mm 685 mm 540 mm 540 mm 540 mm
Fork Length 1150 mm 1150 mm 1150 mm 1150 mm 1150 mm
Gap between the
forks. 360 mm 360 mm 220 mm 220 mm 220 mm
Maximum Capacity 2500 kg 2500 kg 2500 kg 2000 kg 2500 kg
Dims (L x W x H) mm 1555 x 540 x
1230
1555 x 540 x
1230
1555 x 520 x
1230
1555 x 520 x
1230
1555 x 520 x
1230
Weight 65 kg 67 kg 64 kg 61 kg 64 kg

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PARTS DIAGRAM - HANDLE
Please quote ZNEPT + Model Number + Part number above when ordering
parts.
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

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PARTS LIST + DIAGRAM - FORKS (M)
Please quote ZNEPT + Model Number + Part number above when ordering
parts.
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

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PARTS DIAGRAM - PUMP (M)

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PARTS LIST - PUMP (M)
Please quote ZNEPT + Model Number + Part number above when ordering
parts.
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

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PARTS DIAGRAM - PUMP (BM + CM)

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PARTS LIST - PUMP (BM + CM)
Please quote ZNEPT + Model Number + Part number above when ordering
parts.
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

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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