Total Source TSP5500 Datasheet

Operating Instructions
Parts List
USER MANUAL
Hand Pallet Truck
Note: Operator MUST read and understand this operating manual before
using this Hand Pallet Truck.

Thank you for using our pallet truck. Your pallet truck is made of high quality steel and is designed for the
horizontal lifting and transport of loads on a pallet or standardized containers on a level, xed base. For your
safety and correct operation, please read these instructions carefully before use.
NOTE: All of the information reported in this manual is based on data available at the moment of printing.
The factory reserves the right to modify its own products at any time without notice and incurring in any
sanction. It is recommended to always verify possible updates.
To order replacement parts for this pallet truck, please add the TSP prex to the diagram numbers.

1. TO ATTACH DRAW-BAR TO PUMP UNIT
If you have purchased a pallet truck in a box, some assembly is required. You will need a hammer, pliers
and a spanner. Parts included with the pallet truck are: one axle with hole (105A), two elastic pins (106)
*one is in the axle (105A). These parts are all in a plastic bag in the draw-bar.
NOTE: The number of draw-bars and pumps should be the same.
When attaching the handle:
1.1 Insert the draw-bar onto the pump piston (303). Use a hammer to insert the axle with hole (105A)
into the hydraulic pump. (See g. 2).
1.2 Move the control handle (117 or 120G) to the DOWN position, then pass the adjusting nut (104),
adjusting bolt (103) and chain (102) through the hole of the axle (105A) with your hand (See g. 3).
1.3 Press the draw-bar (110, 110B or 111G) down, take away the pin (#2) (See Fig. 1).
1.4 Move the control handle (117 or 120G) to the UP position, then raise the lever plate (319) with the
pin (#2) and insert the adjusting bolt (103) into the front slot of the lever plate (319). Make sure to
keep the adjusting nut (104) on the under-side of the lever plate.
1.5 Use a hammer to tap another elastic pin (106) into the axle with hole (105A).
1.6 The draw-bar is now attached to the pump.
2. TO ADJUST RELEASE DEVICE
On this pallet truck’s draw-bar, you will nd the control handle (117 or 120G) which can be regulated in
three positions:
UP -handle down
DRIVE-handle in center position
DOWN -handle up, the lever moves back to the drive position when released.
If they have been changed, you can adjust them by doing the following:
2.1 If the forks elevate while pumping in the DRIVE position, turn the adjusting nut (104) on the
adjusting bolt (103) or screw (318) clockwise until pumping action does not raise the forks and the
DRIVE position functions properly.
2.2 If the forks descend while pumping in the DRIVE position, turn the nut (104) or screw (318)
counter-clockwise until the forks do not lower.
2.3 If the forks do not descend when the control handle (117 or 120G) is in the DOWN position, turn
the nut (104) or screw (318) clockwise until raising the control handle (117 or 120G) lowers the
forks. Then check the DRIVE position according to item 3.1 and 3.2 to be sure the nut (104) and
screw (318) are in the proper position.
2.4 If the forks do not elevate while pumping in the UP position, turn the nut (104) or screw (318)
counter-clockwise until the forks elevate while pumping in the UP position. Then check the DOWN
and DRIVE positions according to item 3.1, 3.2, and 3.3.
3. MAINTENANCE
This pallet truck is largely maintenance-free.
3.1 OIL
Please check the oil level every six months. The oil can be hydraulic oil: ISO VG32, its viscosity
should be 30cSt at 400 C, with a total volume is about 0.4lt.
3.2 TO RELEASE THE AIR
Air may get into the hydraulic oil during transportation or pumps in an incorrect position. It can
cause the forks not to elevate while pumping in the UP position. The air can been released in the
following way: move the control handle (117 or 120G) to the DOWN position, then move the draw-
bar up and down several times.

3.3 DAILY CARE
Daily care of the pallet truck can limit general wear and tear. Special attention should be paid
to the wheels and axles as thread, rags, etc. may get caught in the wheels. The forks should be
unloaded and lowered to the lowest position when not in use.
3.4 LUBRICATION
All bearings and shafts are provided with long-life grease at the factory. For proper care, use long-
life grease monthly or after each thorough cleaning of the truck’s lubrication points.
4. SAFE OPERATION
4.1 The operator should read all warning signs and instructions here and on the pallet truck before
using this truck.
4.2 Do not use the pallet truck on a slope.
4.3 Do not operate a pallet truck unless you are familiar with it and have been trained or authorized to
do so.
4.4 Do not operate a pallet truck unless you have checked its condition. Pay special attention to the
wheels, draw-bar unit, fork unit, and the lever plate.
4.5 To pull the truck, always move the control handle into the DRIVE position. This makes the draw-bar
easier to move and depressurizes the hydraulic pump section. This preserves the hydraulic seals
and the valve components.
4.6 Do not carry any people on the pallet truck.
4.7 The operator should wear protective gloves.
4.8 When the goods have been transported, all people should remain 600 mm away from the forks.
4.9 Do not load goods like g. 5/B .
4.10 Do not load over maximum capacity.
4.11 The operator should take extra precaution when operating the pallet truck in special conditions
or terrains.

5. TROUBLESHOOTINg
# Problem Cause Solution
1 The forks will not rise to
maximum height
Not enough hydraulic oil Add oil
2 The forks cannot be
raised
• No hydraulic oil
• The oil has impurities
• The nut (104) is too high and keeps
the pumping valve open
• Air got into the hydraulic oil
• Add oil
• Change the oil
• Adjust the nut (104) or the screw
(318). (See item 3.4)
• Release the air (See item 4.2)
3 The forks cannot be
lowered
• The piston rod (328) or pump (322)
is deformed from improper loading
or overloading
• The fork was left at maximum
height for a long time and the
piston rod rusted or jammed
• The adjusting nut (104) or the screw
(318) is in the wrong position
• Replace the piston rod (328) or
pump (322)
• Keep the fork in the lowest position
when not in use and lubricate the
rod
• Adjust the nut (104) or the screw
(318). (See item 3.3)
4 Leaks • Sealing parts are worn or damaged
• Some parts are cracked or worn
• Replace the worn or damaged parts
• Replace the cracked or worn parts
5 The forks lower without
the release valve
• Impurities in the oil cause the
release valve to be unable to close
tight.
• Some parts of the hydraulic system
are cracked or worn
• Air got into the oil
• Sealing parts are worn or damaged
• The adjusting nut (104) or the screw
(318) is in the wrong position
• Replace with new oil
• Inspect and replace the damaged
parts
• Release the air (See item 4.2)
• Replace the worn or damaged parts
• Adjust the nut (104) or the screw
(318). (See item 3.2)
NOTE: DO NOT ATTEMPT TO REPAIR THE PALLET TRUCK UNLESS YOU ARE TRAINED
AND AUTHORIZED TO DO SO.

No. Description Qty. Remark
101 Release Rod 1
102 Chain 1
103 Adjusting Bolt 1
104 Adjusting Nut 1
105A Axle with Hole 1
106 Elastic Pin 2
107 Bushing 2
108 Roller Pin 1
109 Pressure Roller 1
109A Bushing 1
110A Handle Plain 1 Climax Handle
110B Handle Complete 1 Climax Handle Type WP
111 Stop Rubber 1
112 Elastic Pin 1
113 Blade Spring 1
114 Spring 1
115 Elastic Pin 1
116 Elastic Pin 1
117 Control Handle 1
118 Roller 1
119 Elastic Pin 1
121 Pull Board 1
122 Pin 1
List of Draw-Bar

List of Fork Frame
No. Description Qty. Remark
201 Fork Frame 1
202G Bolt 1 For Type G
203 Rock - Arm 1
204 Bushing 2
205 Shaft 2
206 Bushing 4
207 Bushin 2
208 Retaining Ring 2
210 Pin 2
B209 Joint 2
For Type BB211 Nut 2
B212 Pushing Rod 2
213 Retaining Ring 2
214 Shaft 1
216 Shaft 2
217 Intermediate Roller 4
218 Extending Roller 2
219 Elastic Pin 2
220 Elastic Pin 4
221 Shaft 2
222 Frame-Load-Wheel-Sngl 2
222L Frame-Load-Wheel-Sngl 2 Low Prole
223* Shaft 4
For Type E
224* Tandem Mounting with Pin 2
228* Tandem Mounting 2
229* Spring Washer 4
230 Elastic Pin 8 or 2
No. Description Qty. Remark
201 Fork Frame 1
223D* Shaft for Roller 4
For Type D224D* Linking Plate 4
230 Elastic Pin 8 or 2
225 Washer 8 or 4
226 Bearing 8 or 4 Low Prole
226L Bearing 4 Poly
227 Roller-Load Tandem 4 Nylon
227N Roller-Load Tandem 4
231 Bolt 2
232 Enter Roller 2
233 Locking Nut 2
234 Roller-Single Load 2
234N Roller-Single Load 2 Poly
234S Roller-Single Load 2 Nylon
234L Roller-Single Low Prole 2 Steel
235# Shaft for Roller 2 Poly
236 Washer 2
237 Grease Cup 1

Type A Hydraulic Pump
Version Number: 111201
No. Description Qty. Remark
301 Spring Cap 1
302 Spring 1
303 Pump Piston 1
304 Dust Ring 1
305 Seal 1
306 Dust Cover 2
307 Locking Ring 2
308 Washer 2
309 Bearing 4
310 Loading Wheel 2
311 Elastic Pin 1
312 Elastic Pin 2
313 Thrust Plate 1
314 Retaining Ring 1
315 Bearing 1
316 Shaft of Loading Wheel 1
317 Nut 1
318 Screw 1
319 Lever Plate 1
No. Description Qty. Remark
301 Spring Cap 1
320 Elastic Pin 1
321 Valve Cartridge 1
322A Pump Body 1
323 Seal Washer 1
324 Screw Plug 1
325 Seal 1
326 O-Ring 1
327 Dust Ring 1
328 Piston Rod 1
329 Steel Ball 1
330 Screw Plug 1
331 O-Ring 1
332 Bolt 1
333 Spring 1
334 Spindle of Safety Valve 1
335 Grease Cup 1
336 Cylinder 1
337 Cover of Bearing 1