Total Source TRP0029 User manual

OPERATING MANUAL
MANUAL PALLET TRUCK
TRP0029 TRP0030
Original operating
manual
11/2020 – V00
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© 11-2020. TVH
®
and TotalSource
®
are registered trademarks. TVH Parts Holding NV, Brabantstraat 15, B-8790 Waregem. All rights reserved.
No part of this publication may be reproduced or communicated in any form or by any means, electronic or mechanical, including copying,
recording or use in an information storage or retrieval system, without prior and explicit permission of TVH Parts Holding NV. Printing errors
reserved.
Responsible editor: TVH Parts Holding NV, Brabantstraat 15, BE-8790 Waregem
TVH is a supplier of after-market spare parts and accessories that are suitable for the maintenance and repair of OEM equipment.
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Thank you for using our product. For your safety and to ensure a correct operation, we would
like to bring to your attention some aspects of this manual:
• This booklet supplies useful instructions for the correct operation and maintenance of the
product. It is therefore necessary to pay the utmost attention to all of the paragraphs that
illustrate the most simple and secure way to operate and use this product.
• This booklet must be considered an integral part of the machine and must be included
with the deed of sale.
• Neither this publication, nor part of it, can be reproduced without written authorisation on
the part of the manufacturer.
• All of the information reported herein is based on data available at the moment of printing;
the manufacturer reserves the right to carry out modifications to its own products at any
moment, without notice and without incurring in any sanction. It is therefore suggested to
always check for possible updates.
The person responsible for the use of the product must make sure that all of the safety rules
in force in the country of its use are applied, to guarantee that the equipment is used in
conformity with the use for which it is destined and to avoid any dangerous situation for the
user.
The following warning signs are used in this manual to warn you for dangers and risks:
Informative, be careful.
Warning, can lead to injury and damage if instructions aren’t followed.
Danger, can lead to serious or fatal injury and serious damage if instructions
aren’t followed.
The following conventions are used in this manual:
1
2
4
3
1 Right
2 Left
3Front
4 Back
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TABLE OF CONTENTS
1. INTRODUCTION..................................................................................... 5
2. DESCRIPTION AND OPERATION ................................................................ 6
2.1. Technical data .......................................................................................6
2.2. Main components of the product.................................................................7
2.3. Placement of the decals ...........................................................................7
2.4. Type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. SAFETY INSTRUCTIONS.......................................................................... 8
3.1. Explanation of the safety decals .................................................................8
3.2. General safety instructions .......................................................................9
4. TRANSPORT AND STORAGE ..................................................................... 9
4.1. Parking the pallet truck ...........................................................................9
4.2. Transporting the pallet truck ....................................................................10
5. ASSEMBLY AND INSTALLATION ...............................................................10
5.1. Packing list..........................................................................................10
5.2. Safety instructions.................................................................................10
5.3. Required material for assembly.................................................................10
5.4. Assembly of the tiller handle and commissioning the pallet truck .......................10
6. OPERATION.........................................................................................12
6.1. Safety instructions.................................................................................12
6.2. Operating instructions ............................................................................12
7. MAINTENANCE ....................................................................................13
7.1. Safety instructions for repairs of the pallet truck............................................13
7.2. Maintenance schedule............................................................................13
7.3. Maintenance instructions ........................................................................13
8. TROUBLESHOOTING .............................................................................16
9. FINAL DECOMMISSIONING AND DISPOSAL ................................................17
10. ANNEXES ...........................................................................................18
10.1. CE-certificate.......................................................................................18
10.2. Hydraulic circuit....................................................................................20
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1. INTRODUCTION
This pallet truck is a manually operated pallet truck designed to lift and transport pallets on
hard and even surfaces. It can lift open-bottom or diagonal board pallets. Suitable ambient
temperature is 5°C up to 40°C.
If the pallet truck is used for extended periods of time in ambient temperatures below 5°C,
cold storage, or in extreme conditions with temperature and humidity changes, you must
contact your dealer and obtain permission from the manufacturer. We guarantee a long
period of trouble free operation if the unit is operated and maintained correctly.
This pallet truck may be unsafe/hazardous if adequate maintenance is neglected.
Therefore, adequate maintenance facilities, trained personnel and procedures
should be provided.
Maintenance and inspection shall be performed conform with the following
practices:
1. A scheduled planned maintenance, lubrication and inspection system should be
followed. (See maintenance instructions in chapter7)
2. Only qualified and authorised personnel shall be permitted to maintain, repair,
adjust, and inspect the pallet truck.
3. Modifications and additions which affect capacity and safe operation shall not
be performed by the customer or user without the manufacturer’s, prior written
approval. Capacity, operation and maintenance plates or decals shall be changed
accordingly.
4. If modifications are made without the written approval of the manufacturer,
thewarranty will no longer apply.
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2. DESCRIPTION AND OPERATION
2.1. Technical data
Always check the data plate for the correct information.
Model TRP0029 TRP0030
Load capacity (kg) 2500 2500
Material of the pump Painted steel (casted) Quick lift– painted steel
(casted)
Total length (L2) (mm) 1550 1550
Length of the forks (L1) (mm) 1150 1150
Width across the forks (W1/W3) (mm) 525 525
Minimum height (H1) (mm) 85 85
Lifting height (H2) (mm) 200 200
Material of the steering wheels Rubber Nylon
Material and number of fork wheels Tandem/polyurethane Tandem/nylon
Material of the pallet truck Steel Steel
Weight (kg) 63 63
H3
100
WA
100
L3
L2
AST
T1
CG L4
H1
W2
W4
H2
W1/W3
Q
L1
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2.2. Main components of the product
4 5
2
1
3
N° Component
1Tiller with handle
2Pump unit
3Steering wheels
4 Frame
5Fork wheels
2.3. Placement of the decals
The safety and warning labels should be placed as described in the pictures below.
See chapter3 for the explanation of the safety warnings. If the decals are damaged or
missing, replace them.
5
2
3
1
4
N° Decal Explanation Reference
1Brand decal 166TA2311
2.4. Type plate
N° Type plate Explanation
2
Type of pallet truck
Manufactured outside the EU for:
TVH PARTS NV
Brabantstraat 15 - 8790 WAREGEM - Belgium
TRPxxxx Fork length xxxx mm
Serial No. xxxxxx Width over forks xxx mm
Capacity xxxx kg Wheels xxx
Net weight xx kg Year of manufacturing xxxx
1 6
7
8
9
10
2
3
4
5
1Type of pallet truck
2Serial number
3Capacity of the pallet truck
4Weight of the pallet truck
5Name and address of the
manufacturer
6Length of the forks
7Width across the forks
8Wheel combination
(fork wheels/steering wheels)
9Year of manufacture
10 CElogo
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3. SAFETY INSTRUCTIONS
3.1. Explanation of the safety decals
If the decals are damaged or missing, please replace them.
N° Decal Explanation Reference
3
1
2
3
1. Load capacity: 2500kg
2. Indication of load centre
3. Read the manual before use
166TA2315
4
1
3
5
7
9
11
2
4
6
8
10
1. Foot crushing hazard, wear safety shoes
2. Do not use on a slope
3. Do not use to lift or transport people
4. Keep other persons at a distance while
operating the pallet truck
5. Do not put feet in front of rolling wheels, wear
safety shoes
6. Keep other persons at a distance and be
aware of loading bridges and docks to prevent
the pallet truck or the load from falling down
7. Hand crushing hazard, wear safety gloves and
be careful where you put your hands
8. The load must cover the full length and width
of the forks
9. The load must be centred on the forks
10. The centre of gravity of the goods should be in
the centre of the two forks
11. Read the manual before using the pallet truck
166TA2313
5
1
2
3
4
5
6
7
Operating instructions handle:
1. Handle up: lower the forks
2. Neutral: driving position
3. Handle down: pump up
4. The load must be centred on the forks
5. The load must cover the full length and width
of the forks
6. The centre of gravity of the goods should be in
the centre of the two forks
7. Do not use on a slope
166TA2314
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3.2. General safety instructions
• The operator should read all warning signs and instructions in the manual and on
the pallet truck before using it.
• Do not operate a pallet truck unless you have been trained or authorised to do so.
• Do not exceed the maximum capacity.
• The operator should wear safety shoes and gloves when using or maintaining the
pallet truck.
• It is forbidden to carry or lift passengers.
• The pallet truck can’t be used if it’s damaged or when faults appear.
• Do not use the pallet truck on a slope. It is designed to be used on even and level
floors.
• The weight of the goods should be distributed over the two forks, do not use only
one fork. The centre of gravity of the goods should be in the centre of the two forks.
• Be aware of hazardous situations like ledges or potholes, bumps and floor
obstructions, debris, overhead obstructions and high-voltage conductors,
inadequate surface support to withstand all load forces imposed by the machine.
• When transporting goods, raise the forks as little as possible. Transport with
raised forks should be carried out slowly and for as short a distance as possible.
• Do not operate a pallet truck unless you are of age.
• The person responsible for the use of the product must make sure that all of the
safety rules in force in the country of its use are applied, to guarantee that the
equipment is used in conformity with the use for which it is destined and to avoid
any dangerous situation for the user.
• In case of emergency, use the emergency stop button.
The pallet truck is equipped with a pressure valve and an overflow valve:
• The pressure valve on the machine is factory-set for the maximum load capacity of
2500kg or according to the capacity mentioned on the pallet truck.
• The pressure relief valve is set to avoid the risk of overloading. When the machine
is overloaded, the overflow valve opens to prevent lifting, because that could result
in a dangerous situation.
4. TRANSPORT AND STORAGE
4.1. Parking the pallet truck
Park the pallet truck securely in a dry and frost-free environment. Do not park on
an inclined surface. Always completely lower the forks. If the pallet truck is parked
for longer than a month, lubricate the necessary parts, follow the instructions in
chapter7.
Safely park the pallet truck by following these steps:
1. Bring the forks to their lowest position by pulling the lever upwards.
2. Store the pallet truck on a firm, flat floor, without any load, and in a dry area.
3. When the pallet truck is stored in a trailer or vehicle, secure the pallet truck to the trailer
or vehicle.
4. The pallet truck is parked.
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4.2. Transporting the pallet truck
Make sure that the truck is in a secured and stable position, ensuring that it will not
suddenly move.
Safely transport the pallet truck by following the next steps:
1. Check the type plate to know the weight of the pallet
truck. Select the appropriate material according to the
weight. (lift truck, chains and slings)
2. Attach the slings to the pallet truck as indicated in the
picture on the right.
3. Lift the pallet truck with a crane or lift truck. Only use a
crane or lift truck with sufficient capacity.
4. Put the pallet truck onto a pallet with sufficient capacity.
5. Secure the pallet truck onto the pallet.
5. ASSEMBLY AND INSTALLATION
5.1. Packing list
Description Amount Reference
Handle with chain 1 166TA5176
Axle 1 166TA5147
Elastic pin/split pin 1 129TA7876
Frame 1 Contact
your dealer
Operating manual 1
Spare parts list 1 166TA5615
5.2. Safety instructions
Wear safety gloves and safety shoes when assembling the pallet truck. Position the
pallet truck on a level surface.
5.3. Required material for assembly
• Plier
• Utility knife
• Hammer
5.4. Assembly of the tiller handle and commissioning the pallet truck
1. Remove the packaging from the lever.
Attention: the axle and split pin are
supplied in a little bag attached to the
pallet truck.
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2. Take the lever and position it above the
pump. Make sure the handle is in the
correct position, the lever on the handle
should be on the right. Insert the axle in
the pump through the holes in the pump
and the holes of the lever, from right to
left.
3. Take the chain in the lever and run it
through the hole in the axle. Attach the
chain to the lever of the lowering valve.
4. Remove the strap around the safety pin
and pump so that the safety pin falls out.
5. Make sure the hole in the axle fits the
hole in the pump. You can use a hammer
to do this.
6. Insert the split pin in the hole to secure
the lever to the pump.
7. If the pump functions unsatisfactorily:
loosen the nut and adjust by tightening
or loosening the screw. After
performing the adjustment, retighten
the nut.
8. The pallet truck is now ready to use!
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6. OPERATION
6.1. Safety instructions
• A damaged or malfunctioning machine must never be used. If damage or
malfunctions are discovered during daily inspection or function tests, the machine
must be tagged and removed from service.
• The operator may not wear any loose objects, such as necklaces, rings, scarves…
as they may become entangled in the machine and thus cause harm to the
operator.
• Do not operate a pallet truck unless you have been trained or authorised to do so.
• Do not exceed the maximum load capacity.
• Wear safety shoes and safety gloves.
• When goods are being transported or lifted, bystanders should keep a minimum
distance of 1metre.
• Make sure that the flooring can support the combined weight of the pallet truck
and its load.
• Be aware of hazardous situations like ledges or potholes, bumps and floor
obstructions, debris, overhead obstructions and high-voltage conductors.
• When loading and unloading the pallet truck, always do this with the forks in the
lowest position.
• In normal conditions the pallet truck moves without a lot of effort or noises.
6.2. Operating instructions
Please see chapter 7 for the daily maintenance schedule.
1. Positions of the operating lever:
On the drawbar of the pallet truck, you can find the control handle which can be regulated in
three positions:
1
2
3
1. UP = to lower the forks
2. NEUTRAL = to move the load
3. LOWER = to pump up the forks
If the pallet truck doesn’t lower or lift, see troubleshooting chapter 8.
2. Adjustments of the operating lever
Adjustment of neutral position:
1. Place the operating lever in the normal position.
2. Push the tiller handle to the lowest position.
3. Regulate the adjusting nut and screw on the linkage so that, when the tiller handle is
pumped, the forks neither raise nor lower.
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Adjustment of lifting position:
1. Place the operating lever in the lifting position.
2. Pump the tiller handle; the linkage is not operated, the forks raise and tilt while the
discharge valve remains completely closed.
3. If the forks do not lift or tilt, regulate the adjusting nut and screw until a normal lifting
and tilting action is attained.
Adjustment of lowering position:
1. Pull the operating lever in the lowering position.
2. The linkage is operated, causing the discharge and pressure valve to open completely,
and the forks to lower.
3. If the forks don’t lower, regulate the adjusting nut and screw until a normal lowering
action is attained.
7. MAINTENANCE
7.1. Safety instructions for repairs of the pallet truck
• No modifications or alterations which could affect capacity, stability or safety
requirements of the pallet truck, but not limited to these examples, shall be made
without the prior written approval of the original manufacturer, its authorised
representative, or a successor thereof.
• Make sure that the truck is in a secured and stable position, ensuring that it will not
suddenly move.
• Wear safety gloves and safety shoes.
7.2. Maintenance schedule
Task D W M 6M
1. Cleaning 
2. Daily maintenance check 
3. Lubrication 
4. Check oil level 
5. Check chain 
D: daily, W: weekly, M: monthly, 6M: every 6months
7.3. Maintenance instructions
1. Cleaning
When cleaning the machine, do not direct the jet onto bearings and seals, otherwise the
grease will be washed out and the lifespan of the product will be shortened.
The environment in which the truck is used, determines the cleaning frequency. It is
recommended to assess the need for cleaning based on the applicable rules in the company.
The pallet truck can be cleaned with warm water and maintenance cleaner (165TA7474).
After cleaning, wipe down the truck and lubricate the moving parts (see point 3 in this
chapter).
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2. Daily maintenance check
A daily maintenance check of the pallet truck can limit wear to a minimum:
• Check the wheels and axles for blockages.
• Check if there are any damaged or loose bolts, nuts or cotter pins.
• Check for oil leaks.
• Check if the lifting and lowering functions work properly.
• Ensure that the instruction manual is complete, legible and available for reference.
• Ensure that all decals are legible and in place.
• Check the entire machine for damage, corrosion or cracks in structural components.
A damaged or malfunctioning machine must never be used. If damage or
malfunctions are discovered during daily inspection or function tests, the machine
must be tagged and removed from service.
3. Lubrication
Oil and grease Reference
Penetraiting oil 144TA9266
4. Oil level, pump
Please check the oil level every six months. The oil capacity is about 0,3 l. Top up the fluid
level in the rubber reservoir to 5 mm below the top; this must be done with the forks in
the lowered position. Use the correct type of hydraulic oil according to the temperature
conditions below.
Type oil Reference
Hydraulic oil ISO VG32 141TA2734
Oil change
Draining the oil:
1. Lower the forks to the bottom position.
2. Remove the screw and turn the pallet truck on its side.
3. The oil now drains out of the hole (collect the waste oil in an oil
receptacle).
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Filling up the oil
1. Pour the oil in the hole.
2. Insert the screw into the hole of the reservoir.
3. Bleed the air from the pump unit.
Bleed the air from the pump unit
1. Set the handle in the LOWER position
2. Move the handle up and down several times
5. Check chain
The chain should be inspected for rupture and wear. The height of the chain should not be
reduces by more than 5%. If the wear exceeds this percentage, the chain must be replaced.
Chain wheels and bearings should also be inspected for wear. Ensure that the traction on
the chain is vertical, in order to avoid lopsided wear. The rollers in the mast profile should
also be inspected.
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8. TROUBLESHOOTING
N° Problem Cause Action
1The forks can’t be
raised up to the
maximum height
The level of hydraulic oil is too low Add hydraulic oil, see chapter7
2The forks can’t be
raised
The level of hydraulic oil is too low Add hydraulic oil, see chapter7
The oil contains impurities (for
example water, sand, dust, rust…)
Change the oil, see chapter7
The nut or screw were tightened too
much, causing the pumping valve to
stay open
Adjust the nut or screw
Air enters the hydraulic oil Bleed the air, see procedure in
chapter7
Control lever is no longer adjusted
correctly
Follow the procedure for adjusting the
control lever in chapter7
Load is too heavy, pressure relief
valve is activated
Reduce load
Temperature is too low and the
hydraulic oil has become too thick
Move truck to a warmer location and
check intended use.
3The forks can’t be
lowered
The piston rod or pump body is
deformed due to partial loading
slanting to one side or due to
overloading
Replace the piston rod or pump body
The forks were kept in their highest
position for a long time with the piston
rod exposed, resulting in rust and
causing the rod to jam
Lubricate the rod. Keep the forks
in the lowest position when not in
use, and pay more attention to the
lubrication of the rod.
The adjusting nut or screw is not in
the correct position
Adjust the nut or the screw
Control lever is no longer adjusted
correctly
Follow the procedure for adjusting the
control lever in chapter6
Obstacle located under truck, in fork
mechanism…
Remove the obstacle with caution
4 Leaks Sealing parts are worn or damaged Replace the parts, see spare parts list
Some parts are cracked or slightly
worn
5The forks
descend without
the release valve
being operated
The impurities in the oil prevent the
release valve from closing properly
Change the oil, see chapter7
Some parts of the hydraulic system
are cracked or worn
Inspect and replace the worn parts,
see spare parts list
Air enters the hydraulic oil Bleed the air, see procedure chapter7
Sealing parts are worn or damaged Replace the seals, see spare parts list
The adjusting nut or screw is not in
the correct position
Adjust the nut or the screw
Control lever is no longer adjusted
correctly
Follow the procedure for adjusting the
control lever in chapter6
If none of these troubleshooting suggestions or solutions were helpful, please contact your
local dealer or the manufacturer.
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9. FINAL DECOMMISSIONING AND DISPOSAL
Final, proper decommissioning or disposal of the product must be performed in accordance
with the regulations of the country in which the product is used. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must be
observed.
Waste packaging should be sorted and put into solid dustbins according to the materials and
needs to be collected by the local special environment protection bureau.
To avoid pollution, it’s forbidden to throw away the waste randomly. To avoid pollution during
the use of the product, the user should prepare some absorbing materials (scraps of wood
or dry duster cloth) to absorb leaking fluids in time. To avoid secondary pollution to the
environment, the used absorbing materials should be handed in at special departments of
local authorities.
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10. ANNEXES
10.1. CE-certificate
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10.2. Hydraulic circuit
Pm
Vr
Vd
V1
1
0
2
S
C
Vm
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