GT DFH Instruction Manual

Operating Instructions
& Safety Manual
DFH
BF
Note: Operator must read and fully
understand the operating instructions
before using this product.
Hand
Pallet Truck
Manual
www.gtlifting.co.uk
George Taylor & Company Lifting Gear (Midlands) Ltd.
Unit 4, Fryers Road, Walsall WS2 7LZ UK
T+44 (0)1922 490220 F+44 (0)1922 490229 E[email protected]

2
OPERATING PALLET TRUCK
To raise the forks, place handle lever in UP position
(bottom part of the handle slot).
To lower forks, pull lever to DOWN position (upper part of
the slot).
To freely move the handle, set the lever in NEUTRAL
(centre notch of the slot).
TO LIFT A LOAD
1. Lower forks to lowest position.
2. Insert forks under load or into pallet.
3. Place lever in UP position (bottom notch of the slot).
4. Move handles up and down until the forks reach
desired height.
TO MOVE A LOAD
1. Place lever in NEUTRAL position (centre notch of
the slot).
2. Pull or push to desired location.
TO LOWER A LOAD
1. Place lever in DOWN position (upper notch of the
slot).
2. Pull forks away from load.
CLEANING RELEIF VALVE
Over time, relief valve may become clogged with debris
and will not work properly. To clean relief valve, flush our
hyraulic system as follows:
Pump handle quickly, raising pallet truck to full extend.
Then, quickly release pumping action
Safety Information
DOWN
NEUTRAL
UP
Figure 2
• Read and understand the entire
operator’s manual before using
the pallet truck.
• Don’t load pallet truck beyond
rated capacity.
• Secure load before
transporting.
• Keep the load centred on the
pallet.
• Don’t operated loaded pallet
truck on ramps or inclines.
• Always wear appropriate
safety shoes.
• Never leave a loaded pallet
truck unattended in the raised
position; always lower load to
the floor.

3
Troubleshooting
Condition Probable
Causes
Corrective
Action
Hydraulic unit does not lift
Oil low in tank ensure there is no leakage from
valve, and add oil
Steel ball not seated in
hydraulic unit
See “CLEANING RELIEF VALVE” in
this manual
Worn O ring in ram cylinder Consult authorised service centre
Once lifted, truck lowers by itself
Steel ball not seated in
hydraulic unit See “CLEANING RELIEF VALVE” in
this manual
Worn O ring in ram cylinder
Relief valve not seated properly
Relief valve not adjusted properly
Reload truck within load capacity
and adjust valve by pressure
adjustment screw
Oil leakage from each valve Tighten plug of each valve
Fork does not lower Cam broken Replace cam chain
UP-DOWN cam nut out
of adjustment
Refer to “Adjusting UP-DOWN
Cam” in this manual
Broken fork rods and linkage Replace broken parts
Lever does not set at
NEUTRAL position
UP-DOWN cam nut out
of adjustment
Refer to “Adjusting UP-DOWN
Cam” in this manual
DO NOT adjust the up/down
lever control using the lock
nut at the end of the handle
chain. If nylon locking
threads are removed from
the screw threads, rolling
vibration will cause the
nut to unscrew and fall off,
leaving the up/down lever
unusable.
ADJUSTING UP-DOWN CAM
Use proper set screw and
lock nut adjustment located
on the side of the pump.
This feature was designed
to ease the pallet truck
adjustment. Tools required
are:
• Flat head screwdriver.
• 14mm wrench.

4
PALLET TRUCK ASSEMBLY
Individual trucks are assembled and ready to use. Pallets trucks purchased in crate quantities (6 units to a crate) require
some assembly.
Tools needed for assembly: Hammer, Flat Head Screwdriver, 14mm Wrench.
TO ATTACH HANDLE ASSEMBLY TO THE FRAME:
Safety Information
1.
IMPORTANT
Verify that spring safety pin is
in place. The pin should be well
rested in the holes situated on
each side of the pump housing.
If the safety pin is not rested
properly in one of the holes, put
pressure on the spring using
a “C” clamp pushing down on
the pump stem. Once pressure
is relieved on the pin, reinsert
properly and remove clamp
slowly.
2.
Insert handle pin into
corresponding holes and
using a hammer, drive in one
spring pin on one side only.
3.
Insert handle pin without the
handle and verify that the
centre hole is facing you.
4.
If handle pin’s centre hole is
facing away from you, insert
pin from other side
IMPORTANT
The up/down lever’s chain
passes through this centre
hole. If left this way, the
chain will have an “S” form
and be under too much
tension, maing the up/
down lever difficult to use
accurately.
5.
IMPORTANT
Before this step, make sure
to feed the chain on the
outside of the piston stem
roller (see arrow). If left in its
proper position, it will not be
possible to insert the handle
pin and chain, breakage may
occur. Align handle holes
with pump housing holes and
push through handle pin
(see arrow).
6.
Make sure that the handle
pin is completely through the
handle and resting on the
other side.

5
Safety Information
7.
Pull down on the handle
to release the tension on
the safety pin. CAREFULLY
remove the safety pin.
8.
Feed the chain and nut
first back inside the handle
THROUGH the handle pin’s
centre hole.
IMPORTANT
Release the up/down lever to
it’s lowest position to make
the process easier.
9.
Once the chain is in the
proper position, check to see
that it moves freely and that
it is not obstructed.
10.
Using both hands, push on
the valve cam to raise the
hook inside the housing and
feed the end of the chain in
the cam (see under).
11.
Pump the lever a few times
to raise the forks. Put the up/
down lever to it’s NEUTRAL
position.
Using a 14mm wrench and a
flat head screwdriver, adjust
the valve cam so that the
forks don’t lower or rise (if
handle is pumped) at this
position.
12.
Test all the features of the
pallet truck before this
step. The handle should be
pumped with full strokes to
prime and eliminate air in the
system. The up/down lever
should be checked at the
handle’s lowest position for
this puts the most tension on
the chain. Once the pallet
truck is adjusted properly
and is performing well, drive
in the second spring pin
using a hammer.

6
Spare Parts Diagram
Chassis

7
No. Part Description Qty
201D 20201 Chassis 1
202 10202 Circlip for hole ø26 2
203 10203 Spring gasket ø6 1
204D 20204 Bolt M6x12 1
205D 20205-1 Connecting pin ø15.8*48.5 (DFH Pump) 2
20205-2 Connecting pin ø15.8*41 (BF Pump) 2
207D 20207-1 Swing arm for 550mm 1
20207-2 Swing arm for 685mm 1
210 10210 Axle 15.8*52 2
211 10211 Push rod fork 2
212 10212 Circlip for shaft ø15.8 2
213 10213 Nut M22 2
214D 20214-1 Long axle ø24.5*496 for 550mm 1
20214-2 Long axle ø24.5*608 for 685mm 1
215D 20215 Push rod (only 1150mm) 2
217D 20217 Axle ø15.8*82 2
218 10218 Spring pin ø5x26 2
219D 20219 Lever block axle ø19.8*152 2
221D 20221 Axle sleeve 4
222 10222 Spring pin ø5x30 2
223 10223-1 Roller axle ø19.8*94.5 4
223B 20223-2 Roller axle ø19.8*120 2
224 10224 Tri-connect plate 4
225B 20225 Level block (For double loading wheel) 2
226 10226 Spring pin ø5x35 4
227 10227 Bearing 6204-2RS 8
228 10228-1 PU double loading wheel ø80*70 4
10228-2 PU double loading wheel ø80*70 4
228A 10228-3 PU single loading wheel ø80*93 2
10228-4 PA single loading wheel ø80*93 2
229 10229 Nut M10 2
230 10230 Enter roller 2
231 10231 Bolt M10x65 2
232 10232 Axle adjusting gasket 4
Spare Parts List
Chassis

8
Spare Parts Diagram
Handle & Pump

9
No. Part Description Qty
100C 10100C Handle Assembly (Triangle without rubber) 1
100D 10100D Handle Assy (Square with rubber special for DFH Pump) 1
200 10200 Steel ball ø19 1
222 10222 Spring pin ø5x30 2
226 10226 Spring pin ø5x35 2
227 10227 Bearing 6204-2RS 4
300D 20300A DFH pump assembly 1
300E 20300B BF pump assembly 1
301 10301 Wheel axle 1
302 10302 Dust ring 1
303 10303 Circlip for shaft ø20 1
304 10304 Axle adjusting gasket 1
305D 20305 Circlip for shaft ø50 (DFH Pump) 1
10305 Circlip for shaft ø55 (BF Pump) 1
306D
20306-1 PU steering wheel ø180*50 2
20306-2 PA steering wheel ø180*50 2
20306-3 Rubber steering wheel ø180*50 2
307 10307 Spring pin ø8x45 1
309D 20309 Pushing ball bearing 51110 (DFH Pump) 1
10309 Pushing ball bearing 51111 (BF Pump) 1
310D 20310 Handle axle ø19.8*85.5 (For DFH Pump) 1
10310-1 Handle axle ø19.8*98 (For BF Pump) 1
311D 20311 Thrust strip (For DFH Pump) 1
10311 Thrust strip (For BF Pump) 1
Spare Parts List
Handle & Pump

10
Spare Parts Diagram & List
Handle-C (Triangle without rubber)
No. Part Description Qty
101C 10101C Handle body 1
102 10102 Spring pin 6x30 1
103 10103 Pinch roller 1
104 10104 Pinch roller pin 1
105 10105 Spring pin 4x30 1
106 10106 Torsional spring 1
107 10107 Hinge 1
108D
10108D
Rod & chain
assy.
Connecting rod 1
Chain 1
Swing bolt M5 1
Nut M5 1
Connecting plate 1
Rivet ø3x6 1
109 10109 Finger lever 1
110 10110 Spring pin 4x13 1
111 10111 Spring pin 4x17 1
112 10112 Roller 1
113 10113 Axle sleeve 2

11
Spare Parts Diagram & List
Handle-D (Square with rubber special
for DFH Pump)
No. Part Description Qty
101D 10101D Handle body 1
102 10102 Spring pin 6x30 1
103 10103 Pinch roller 1
104 10104 Pinch roller pin 1
105 10105 Spring pin 4x30 1
106 10106 Torsional spring 1
107 10107 Hinge 1
108D
10108D
Rod & chain
assy.
Connecting rod 1
Chain 1
Swing bolt M5 1
Nut M5 1
Connecting plate 1
Rivet ø3x6 1
109 10109 Finger lever 1
110 10110 Spring pin 4x13 1
111 10111 Spring pin 4x17 1
112 10112 Roller 1
113 10113 Axle sleeve 2

Spare Parts List & Drawing
No. Part Description Qty
701 30701 Small pump core 1
702 30702 Cover of spring 1
703 30703 Big spring cap 1
704 30704 Dust ring ø18*26*4.5/6 1
705 30705 Seal washer ø18*26*5 1
706 30706 Small cylinder 1
707 30707 Copper gasket 1
708 30708 Steel ball ø19 1
709 30709 Piston rod 1
710 30710 Dust ring ø31.5 1
711 30711 O-ring ø31.5 1
712 30712 Seal washer ø31.5 1
713 30713 Bolt 1
714 30714 Seal 1
715 30715 Relief valve 1
716 30716 Safety valve 1
717 30717 Check valve 1
718 30718 Lever plate 1
719 30719 Spring pin 1
720 30720 Nut 1
721 30721 Bolt 1
722 30722 Pump body 1
No. Part Description Qty
401 30401 Small pump core 1
402 30402 Cover of spring 1
403 30403 Big spring cap 1
404 30404 Dust ring ø18*26*4.5/6 1
405 30405 Seal washer ø18*26*5 1
406 30406 Small cylinder 1
407 30407 Copper gasket 1
408B 30408B Dust ring ø31.5 1
409B 30409B O-ring ø31.5 1
410B 30410B Seal washer ø31.5 1
411B 30411B Slide bushing 1
412B 30412B O-ring 1
413 30413 Steel ball ø19 1
414 30414 Piston rod 1
415 30415 Pump body 1
416 30416 Bolt 1
417 30417 Seal 1
418 30418 Relief valve 1
419 30419 Safety valve 1
420 30420 Check valve 1
421 30421 Lever plate 1
422 30422 Spring pin 1
423 30423 Bolt 1
424 30424 Nut 1
DFH Pump BF Pump