Clarke STRONG-ARM HLPT550 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC01/23 Rev 5
HIGH LIFT PALLET TRUCKS
MODEL NO: HLPT550 & HLPT685
PART NO: 7630180 & 7630185

2
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
INTRODUCTION
Thank you for purchasing this CLARKE High Lift Pallet Truck. This truck is
designed to raise and lower awkward or heavy loads to an operating height
where they may be handled with relative ease, avoiding the risk of injury
which might otherwise occur if manhandling the load to the same height.
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.
The operator / operating company has to ensure the correct use and that this
pallet truck is used only by staff who are trained and authorized to use it.
CONTENTS
• 1 x Pallet Truck Assembly
• 1 x Handle Assembly
• 1 x Fixings Kit (3 x Screws & 3 x Spring Washers)
• 1 x Owners Manual (this document)
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.

3
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
SAFETY INSTRUCTIONS
The operator should read all warning signs and instructions here and on the
pallet truck before use.
1. 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.
2. DO NOT operate a hand pallet truck unless you are familiar with it and
have been trained or authorized to do so.
3. DO NOT make any changes or modifications to the pallet truck.
4. DO NOT use if the wheels or rollers are damaged. Have them replaced
immediately.
5. Keep the work area tidy and well lit.
6. Keep children and bystanders away from the work area.
7. DO NOT exceed the capacity of the pallet truck. Refer to the labelling on
the pallet truck and the Product Specification section in this manual.
8. DO NOT use on rough terrain. The pallet truck is designed for use on smooth
flooring only.
9. 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 truck when loaded.
10. Watch for differences in the floor levels when moving the truck. The load
may overbalance or the truck could become uncontrollable.
11. DO NOT let the pallet truck come into direct contact with food.
WARNING: THE TRUCK HAS TO BE USED ON SUBSTANTIALLY FIRM,
SMOOTH, LEVEL AND PREPARED SURFACES. THE LOAD MUST BE PLACED
CENTRALLY ON THE FORKS.

4
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
12. DO NOT use the truck in explosive atmospheres.
13. The operator must wear safety shoes and gloves.
14. DO NOT allow personnel other than the operator to stand in front of or
behind the truck when it is moving or lifting/lowering.
15. DO NOT put your foot in front of rolling wheels. Injury could result.
16. DO NOT use the pallet truck as a jack.
17. Ensure nothing is beneath the pallet truck forks prior to lowering, especially
anyone’s feet.
18. 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.
19. Keep watching the load and stop if the load becomes unstable.
20. When not in use, always make sure that the truck is stored where it is not a
danger to others. DO NOT leave the truck on a gradient without first
securely chocking the wheels.
21. Carry out maintenance work according to the “Troubleshooting” on
page 10.
22. This pallet truck is not designed to be water resistant, therefore use it in a
dry environment.
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.
If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

5
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
ASSEMBLY
After unpacking it is necessary to attach the handle assembly as follows:
1. Lower the chain through the hole
in the handle bracket, so that it
emerges at the bottom of the
housing as shown in Fig 1.
2. Secure the handle to the base
bracket with the three socket
headed screws and spring
washers provided.
3. Raise the end of the forked lever
shown at A (Fig 2), against the
spring pressure using a screwdriver
or similar, and slide the threaded
rod attached to the end of the
chain, between the forks, so that
the locknut, screwed onto the
threaded rod, locates behind the
claws on the underside of the
forks. Release the forked lever.
4. Remove the travel plug from the
oil filler orifice and replace it with
the plug arrowed in Fig 3, which is
found in the loose polythene bag.
• Your pallet truck is now fully
assembled. However, before
use, it is IMPORTANT to check
the following adjustments.

6
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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 its lowest
position (i.e. Lever in its LIFT
position).
2. Check to ensure there is no
tension on the chain. If necessary,
adjust the locknut on the
threaded rod attached to the
end of the chain, until the free
movement on the end of the
control lever, when in its lowest
position is approx 1/4”.
3. Pump the handle and then lower to test its operation.
4. If the forks rise but lower immediately you stop pumping or only lift slowly,
slacken the locknut ‘A’ and screw the adjuster ‘B’ anticlockwise half a turn
as shown in Fig 5 and try again.
5. If the forks do not lower when the control handle is in the LOWER position,
turn the adjusting screw (A) in clockwise until the handle lowers the forks.
Tighten locknut ‘B’. Check it’s operation in the TRANSPORT position.

7
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
OPERATION
BEFORE USE
Before using the pallet truck always read the safety instructions in this manual.
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.
Daily inspection is advisable to find any defect of the pallet truck. Check the
following points before operation.
• Visually check for structural damage 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 ensure they rotate smoothly.
• Check that all the bolts and nuts are tight.
• Verify that all warning labels are in place.
LIFTING
1. Check that the load does not exceed the rated capacity of the 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.
3. Move the operating lever down to the ‘Lifting’ position. Lift the load by
moving the handle assembly up and down.
WARNING: DO NOT USE THE PALLET TRUCK IF ANY DEFECT IS FOUND.

8
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
• The load must be evenly distributed across both forks.
• DO NOT OVERLOAD.
MOVING
1. Ensure the control lever is in its middle (transport) position.
2. Move the truck using the handle assembly.
3. DO NOT operate the truck on a slope.
4. Watch for differences in the floor level when moving the pallet truck.
5. Make sure that the load is stable.
6. If the pallet truck is moving, DO NOT turn the handle at a right angle to stop
the pallet truck.
LOWERING
1. Lower the load by moving the operating lever up to the lowering position
carefully.
• By releasing the lever, the lowering movement will stop.
2. Ensure there is adequate clearance behind you when withdrawing the
forks from the pallet.
3. DO NOT put your foot or hand under the lifting components.
PARKING
When parking the pallet truck, lower the forks to the lowest position and park
on smooth, level ground where it is not an obstruction. If the ground is not flat,
chock the wheels to stop it moving.
MALFUNCTIONS
If there is any malfunction stop using the truck until it is repaired by your local
CLARKE dealer.

9
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
CARE & 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 for any oil leaks and top up if necessary at the filler plug.
• The capacity is approximately 0.22 litre.
• The recommended type is L-Hydraulic 32 oil, provided the truck is not to
be used outside the temperature range of -20°C to +40°C.
PRODUCT 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.
HLPT550 HLPT685
Width to outside of the forks 550 mm 685
Fork Length 1150 mm
Gap between the forks. 230 mm 365 mm
Fork width 160 mm
Maximum Capacity 1500kg
Weight 100 kg 110 kg
Entry options 4 2
Min/max lifting height (mm) 85-820 mm

10
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
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 oil.
The oil is contaminated with
moisture.
Change the oil.
The chain adjustment for the
operating lever is incorrect
Adjust the chain nut or
screw
Air in the hydraulic system. Purge air from the
hydraulic system.
The forks
cannot be
lowered
The piston rod is deformed
resulting from load slanting to
one side or over loading.
Replace the piston rod or
return to CLARKE dealer
for overhaul.
The fork was kept in the raised
position for long time with the
piston rod exposed to dampness
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 chain adjustment for the
operating lever is incorrect
Adjust the chain nut or
screw
Oil leaks
from the
ram
Oil seals are worn or damaged. Replace or return to
CLARKE dealer for
overhaul.
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. Return to CLARKE dealer
for overhaul.
Air in the hydraulic system. Purge air from the
hydraulic system.
The chain adjustment for the
operating lever is incorrect
Adjust the chain nut or
screw

11
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS - PUMP
No Description No Description
1 Dust ring 31 Valve spindle
2 O-ring 32 Spring
3 Cylinder 33 Washer
4O-ring 34 Screw
5 Screw 35 Steel ball
6 Washer 36 Spring
7 Plunger 37 Spring
8O-ring 38 Pin
9 Mandrell 39 Bearing
10 Spring 40 Supporting base
11 Plunger 41 Wheel housing
12 O-ring 42 Bolt
13 Shaft 43 Nut
14 Pressure frame 44 Wheel
15 Pin 45 Bearing
16 Bush 46 Half spacer
17 Roller 47 Washer
18 Pin 48 Circlip
19 Bush 49 Dust cover
20 Shaft 50 O-ring
21 Pin 51 Valve sleeve
22 Screw 52 O-ring
23 Washer 53 Striker pin
24 Screw 54 Spring
25 Spring 55 Adjusting screw
26 Spring seat 56 Nut
27 Steel Ball 57 Lever plate
28 Steel Ball 58 Base
29 Valve seat 59 Oil filler cap
30 Valve seat 60 Circlip

12
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS - PUMP

13
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS - HANDLE ASSEMBLY
No Description No Description
61 Washer 71 Bush
62 Bush 72 Cylinder
63 Piston rod 73 O-ring
64 Steel ball 74 Bush
65 O-ring 75 Seal
66 O-ring 76 Dust ring
67 Cylinder liner 77 Plug
68 Sealing ring 78 Cylinder tube
69 Dust ring 79 End cap
70 Dust ring 80 Insert
No Description
100 Spring
101 Spring blade
102 Roller
103 Roll pin
104 Roll pin
105 Roll pin
106 Roll pin
107 Control handle
108 Pull rod
109 Handle column
110 Screw
111 Lock washer
112 Chain
113 Securing pin
114 Adjusting screw
115 Nut

14
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
COMPONENT PARTS - FORKS & FRAME
No Description No Description
1 Screw 10 Bush
2 Bolt 11 Washer
3 Washer 12 Support Arm
4 Nut 13 Bearing
5 Bush 14 Wheel
6 Foot 15 Spindle
7 Circlip 16 Roller
8 Pin 17 Bush
9 Prop Arm 18 Fork Frame

15
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY - UK (HLPT550)

16
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY - CE (HLPT550)

17
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY - (UK) HLPT685

18
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
DECLARATION OF CONFORMITY - (CE) HLPT685

19
Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]
NOTES
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________