YAPAR YPT25 User manual

Operator’s Manual
Models: YPT25 & YPT30
2,5 and 3 Tonnes Capacity
Pallet Trucks
Design in accordance with EN ISO 3691-5 Standard
Warning!
READ THIS OPERATORS MANUAL BEFORE USING THE PALLET TRUCK
ALWAYS operate, inspect and maintain the pallet truck in accordance with this manual.
Failure to do so may result in property damage or personal injury.
This manual contains important safety, assembly, operation and maintenance information.
Keep for future reference for the life of the product.

1
Table of Contents:
i.
Notes ……………………………………………………………………..…………...
1
1.
Application Range ………………………………………………………..………….
1
2.
Main Features and Specifications ………………………………………………….
2
3.
Assembling and Disassembling of the Handle …………………………………...
2
4.
Testing Process and Operating The Pallet Truck ………………………………...
2
5.
Inspection Before Use …………………………………….………………………..
3
6.
Using the Pallet Truck …………………………………........................................
3
7.
Loading Way and Capacity …………………………………................................
4
8.
Transporting and Storage …………………………………...................................
4
9.
Oil and Disposal of Waste Oil ………………………………….............................
4
10.
Troubleshooting Guide ………………………………….......................................
5
11.
Maintenance and Repair …………………………………...……..........................
6
12.
Emergencies …………………………………...……............................................
6
13.
Disposal …………………...…….........................................................................
7
14.
Safety Warnings …………..……………...……...................................................
7
15.
Guarantee …………………………………...……...............................................
7
16.
Authorized Service …………………………………...……...................................
7
17.
Declaration of Conformity …………………………………...................................
8
18.
Buyer’s Purchase Record …………………………………..................................
8
Figure 7. Handle Bar Assembly Drawing …………………………………............
9
Table 1. Handle Bar Assembly Parts List (Figure 7) ……………………………..
10
Figure 8. General Assembly Drawing ………………………………….................
11
Table 2. General Assembly Parts List (Figure 8) ………………………………..
12
Figure 9. PumpAssembly Drawing …………………………………....................
13
Table 3. Pump Assembly Parts List (Figure 9 ………………………………….....
14
Table 4. Spare Part List (Figure 8) ………………………………….....................
15
i. Notes:
1. Use, maintain and repair the pallet truck in accordance with this operator’s manual.
2. Do not change the equipment on your pallet truck without ensuring its safety.
3. Do not use the pallet truck without reading the Safety Warnings inArticle 11.
1. Application Range
1.1 The pallet truck is a transport vehicle with a low lift mechanism that restricts the movement of the palletized
load. These kinds of vehicles have the feature of stable lifting, easy and safe operation.
1.2 The work area must be a flat surface that is not slippery, firm and free of potholes or obstacles.
1.3 The pallet truck must be used in sufficiently illuminated places. Ambient lighting should be at least 50 lux.
1.4 The working areas should be properly ventilated.
1.5 Protect the pallet truck against corrosion and dust. This vehicle is not designed to operate in wet weather
conditions. Dry the pallet truck immediately in case of any rainy working condition.
1.6 This is a lifting device only and is not designed or intended to be used for any other purpose.
1.7 Do not use for:
a) Operations in severe conditions (e.g. extreme climates, freezer applications, strong magnetic fields etc.).
b) Operations subject to special rules (e.g. potentially explosive atmospheres, mines etc.).
c) Lifting of persons.

2
Figure 1
Figure 2
2. Main Features and Specifications
Models
YPT25 / YPT30
Capacity (Kg)
2500 / 3000
Maximum Lift Height (mm)
200
Lowered Fork Height (mm)
85
Height Withoud Handle (mm)
431,5/421,5
Fork Length (mm)
1150
Fork Width (mm)
540
Steer Wheel Diameter (mm)
Ø200/180
Fork Wheel Diameter (mm)
Ø80/74
Noise Level (dB)
<70
Weight (kg)
52~74
3. Assembling and Disassembling of the Handle
3.1 Pull out the round pin (item 1) in Figure 1.
A
3.2 Put the handle (item 3) in the place indicated byA.
3.3 Assemble the handle and the pump body (item 5) with the round pin (item 1).
3.4 Put the handle chain (item 4) across the center hole of the round pin.
Figure 3 Figure 4
3.5. Take the nut on the end of the chain and hook it into the groove of the handle bar (item 6).
3.6. Move the handle to the parallel position and pull out the pin (item 7) (keep the pin for later use).
3.7. Disassemble the handle in the opposite direction of the assembling process.
4. Testing Process and Operating The Pallet Truck
4.1. After assembling the pallet truck, try to swing the handle, operate the
control lever (item 10) in different positions to perform the Lift, Neutral and
Lower functions (See Figure 5). Check if the different positions are normal.
Lower Position
(Lever Up
Neutral
Drive Position
Lift Position
(Lever Down)
Figure 5

3
4.2. Use the screw (item 9) in Figure 4 to adjust the pallet truck. After lifting the pallet truck body, turn the screw a
little counter-clockwise when it drops. Then repeat this process until the body of the pallet truck lifts normally.
The outer hex nut (item 8) on the screw performs the locking function of the pallet truck. Before adjustment,
you must unscrew the nut. Be sure to put the nut back after screwing in.
4.3. If you move the control lever (item 10) to the Lift Position and shake the handle bar, the pallet truck body will
be lifted.
4.4. If you move the control lever (item 10) to the Neutral Position, the pallet truck will move in the drive position.
In this case, the forks will not rise or fall.
4.5. When you lift the control lever (item 10) to the Lower Position, the forks of the pallet truck will lower.
5. Inspection Before Use
If the pallet truck has not been used for a long time, air may have entered the hydraulic system. To correct this,
rotate the lever to the release position and shake the handle 4 to 6 times. This releases the start button. If
necessary, the process can be repeated several times until the pallet truck operates normally.
6. Using the Pallet Truck
•Only trained personnel are to use this Manual Pallet Truck.
•Hand pallet truck is not to be used by an operator that is not physically capable of safely maneuvering the
hand pallet truck with the load.
•Please read and understand the operator’s manual before operating the pallet truck
•Do not operate the Manual Pallet Truck until you have checked its condition. Give special attention to the
wheels, handle, forks, lift and lower control.
•Do not operate damaged or faulty trucks.
•Before using the pallet truck, make sure your load is below the capacity rate of the pallet truck. Do not
overload the truck. Check capacity label and plate for carrying capacity information. Overloading may cause
truck to perform incorrectly and could cause injury.
•Do not use the pallet truck where there is a risk of exceeding the rated capacity.
•Wear safety shoes with steel toe caps and gloves when operating the pallet truck.
•Stay away from pallet truck forks. Never put your hands or feet under the forks.
•Do not lift or carry loads on slopes or ramps.
•The correct way to load and operate the pallet truck is shown in Figure 6.
•Make sure the length of the forks match the length of the pallet.
•The capacity of the pallet truck assumes an evenly distributed load with the centre of the load being at the
halfway point of the length of the forks. The ideal loading mode is that the gravity center of the load is at the
central position of the fork.
•Use both forks to lift a load, never position the load on the fork tips.
•Operate the pallet truck on level, flat solid surfaces which are capable of supporting the fully loaded pallet
truck.
•Operate at a controllable speed. When you get close to the target point, stop pushing the pallet truck and
slow the speed of the pallet truck by pulling the handle towards you. Lower the forks when the pallet truck
completely stops.
•Avoid sudden movements and manoeuvres.
•Always look in direction of travel. Use caution when visibility is obstructed by load.
•Do not load more than one pallet on the truck. Ensure the stability of the load.
•The pallet truck should be used, serviced and repaired according to the manufacturer and should not be
modified or attachments fitted.
•Do not use the pallet truck in places insufficiently illuminated. Operating lighting must be minimum 50 Lux.
•Do not use the pallet truck as a vehicle jack.
•The extremity of fork arms should not be used as a lever to lift a load.
•Do not ride on the pallet truck.
•Do not carry passengers or lift personnel with the pallet truck.
•The pallet truck should not have direct contact with foodstuffs.
•The pallet truck should not be used in a potentially explosive atmosphere.
•The truck should be used, serviced and repaired according to the manufacturer and should not be modified
or attachments fitted.
•Park the pallet truck out of traffic areas in a safe, level place with the forks fully lowered.

4
Figure 6
•The handle should be left in the up position to eliminate tripping hazards.
7. Loading Way and Capacity
The ideal loading mode is to place the center of gravity of the load at the central position of the forks. Do not place
the load at the tip of the forks. The correct way to load and operate the pallet truck is shown in Figure 6. Avoid
loading more than one pallet on the truck. Ensure the stability of the load. Load capacity is shown on the capacity
label and name plate.
8. Transporting and Storage
For transporting the pallet truck, remove the load, lower the pallet truck to the lowest position and lash it safely
with lashing straps. Cover the pallet truck with a waterproof tarpaulin during transportation to protect it from
possible rainy and humid weather conditions.
For storage, remove the load, lower the pallet truck to the lowest position, grease all the mentioned greasing
points and eventually protect the truck against corrosion and dust. Store the pallet truck out of traffic areas in a
safe, level place with the forks lowered. Store in dry weather conditions. The storage areas should be properly
ventilated. The handle should be left in the up position to eliminate tripping hazards. For long storage periods, you
may disassemble the handle from the pallet truck body and cover the vehicle with a waterproof tarpaulin to protect
it from possible humid weather conditions and dust.
9. Oil and Disposal of Waste Oil
9.1 Always wear gloves and goggles when dealing with hydraulic fluid
9.2 The oil capacity of the pump is about 400 ml (or ~0,40 kg) Please check the oil level every 3 months. Use the
hydraulic oil type according to the information below.
Temperature
Type of Oil
-5°~ 40°C.
#32 Hydraulic Oil
-35°~ -5°C.
Low Temperature Hydraulic Oil
9.3 Removing Waste oil:
a) Ensure forks are in lowered position.
b) Lay pallet truck on either side. Position drain plug of hydraulic cylinder down. Place a wide pot under the
hydraulic cylinder.
c) Remove drain plug. Wait until all the oil is drained.
d) For adding new oil, follow the steps inArticle 9.4.

5
9.4 Adding hydraulic oil to the pump reservoir:
a) Ensure forks are in lowered position.
b) Lay pallet truck on either side carefully. Position drain plug of hydraulic cylinder up.
c) Remove drain plug.
d) Add necessery amount of hydraulic oil.
e) Close and tighten the drain plug. Upright the pallet truck.
9.5 Waste hydraulic oil must be disposed of in accordance with applicable laws. It is forbidden to discharge the oil
anywhere.
9.6 First Aid recommendations
a) In case of contact with skin: Wash area with soap and water. Remove affected clothing and wash. If
irritation persists, seek medical advice.
b) In case of ingestion: Wash out mouth with clean water and seek medical advice. Do not induce vomiting.
c) In case of contact with eyes: Thoroughly flush eyes with clean water for 5 to 10 minutes and seek medical
advice.
d) Other Situations: Seek medical advice immediately.
10. Troubleshooting Guide
No
Problem
Possible Cause
Action
1
The forks are unable to reach
maximum height
Not enough hydraulic oil
Add oil to maximum level
2
Pallet truck does not completely
lower
1. Too much hydraulic oil.
2. Rotating part is distorted and gets
stuck
1. Pump off appropriate amount
of hydraulic oil.
2. Replace the parts.
3
Pallet truck does not lower after
lifting
1. The lowering device is abnormal
2. Components are damaged
1. Re-adjust the lowering
device. See (Section 4.2)
2. Replace damaged parts
4
Hydraulic oil leaks
1.Seals worn or damaged.
2.Parts cracked or worn.
3. Loose joints
1. Replace seals.
2. Replace the damaged parts.
3. Tighten the loose joints.
5
The forks cannot be lifted up
1. No hydraulic oil.
2. The oil has impurities.
3. Air in the hydraulic oil.
1. Fill up the hydraulic oil
2. Change the oil.
3. Purge the air from the
hydraulic oil.
6
The handle has large
resistance or the pallet truck
automatically descends after
lifting
The valve is stuck
Take the valve out and clean the
parts. Re-install the valve and
parts to their original position.

6
11. Maintenance and Repair
•The forks should be unloaded and lowered in the lowest position when the pallet truck is out of work.
•Routine checks should be done daily and to be dealt with unusual cases immediately. Please do not use a
defective pallet truck to prolong its service life. If there is any malfunction, please seek professional help.
•If you are not authorized and experienced, do not repair the pallet truck or try.
•Particular attention should be paid to the part between the wheel and the axle.
•To ensure that all wheels are working properly, make sure there are no threads or rags between them.
•Use motor oil or grease to lubricate all moveable parts. All bearings and shafts are prepared with long-life
grease at the factory. Lubrication with long-life grease is needed at monthly intervals.
•When it is necessary to replace parts, new parts must be procured from the original manufacturer. You can
see Spare Part List in Page 15, Table 4. For your spare part requirements please get in contact with the
nearest distributor or contact YAPARLAR:
Company Name: Yaparlar Insaat Ve Tarım Aletleri San. Ve Tic. A.S
Address: Cebeci Cad. No: 115 Kucukkoy, 34250
Gaziosmanpasa, Istanbul, Turkey
Tel: [phone]
Fax: [phone]
Mail: [e-mail]
•After maintenance and repair, please fill and save the following list:
Maintenance and Repair Records:
Usage starting date:
Maintenance
Date
Faults
Replaced Parts
Sign
12. Emergencies
In the event of an accident with the pallet truck, pre-intervention should be made by people who have received
first aid training and medical assistance should be requested as soon as possible. In a possible fire, use foam,
CO2, dry chemicals, sand, soil, water mist to extinguish the fire.
13. Disposal
•After placing out of service, the pallet truck parts must be disposed of or recycled in accordance with legal
provisions.
•At the end of the useful life of the pallet truck or when it can no longer be repaired, drain off the oil and hand
it over to an authorised agent and dispose of the oil and pallet truck in accordance with local regulations.

7
14．Safety Warnings
14.1 Please read and understand the operation and safety manual before operating this pallet truck.
14.2 Check all parts of the pallet truck before use. Make sure that the wheels, handle bar, forks and lower-lift
control lever work properly.
14.3 Wear safety shoes with steel toe caps and gloves when operating the pallet truck.Use goggles during
maintenance.
14.4 Do not lift or carry loads on slopes or ramps.
14.5 Avoid overloading the pallet truck beyond the rated capacity.
14.6 Do not use the pallet truck for transporting or lifting personnel.
14.7 Distribute the load evenly over the width and length of the forks to maintain good balance.
14.8 Use both forks to lift a load, never position the load on the fork tips.
14.9 Operate at a controllable speed.
14.10 Avoid sudden movements and manoeuvres.
14.11 Do not load more than one pallet on the truck. Ensure the stability of the load.
14.12 Stay away from pallet truck forks. Never put your hands or feet under the forks.
14.13 If you are not authorized and experienced, do not repair or try.
14.14 Park the pallet truck out of traffic areas in a safe, level place with the forks lowered.
14.15 The handle should be left in the up position to eliminate tripping hazards.
15. Guarantee
This hand pallettruck is guaranteed for 12 months after the date of invoice against defective materials and
workmanship. The guarantee is only given if the hand pallet truck is used and serviced as instructed in this
Manual. There is no guarantee for consumable parts. Any revision to be made by the user on the pallet truck will
cancel the validity of the warranty. A proof of purchase must be provided. Seller should stamp and sign the
Buyer’s Purchase Record in Article 18 during the sales process to start the guarantee period. Buyer should keep
this Record for future reference.
Should the pallet truck develop a fault, please return it to your nearest distributor or contact YAPARLAR:
Yaparlar Insaat Ve Tarım Aletleri San. Ve Tic. A.S
Address: Cebeci Cad. No: 115 Kucukkoy, 34250 Gaziosmanpasa, Istanbul, Turkey
Tel: [phone]
Fax: [phone]
Mail: [e-mail]
This guarantee will not be valid for any damage caused by misuse, careless or unsafe handling, alterations,
accidents, or repairs attempted or made by any unauthorised person.
This guarantee is an additional benefit and does not affect your statutory rights.
16. Authorized Service
In any service need please return the pallet truck to your nearest distributor or contact YAPARLAR:
Yaparlar Insaat Ve Tarım Aletleri San. Ve Tic. A.S
Tel: [phone]
Address: Cebeci Cad. No: 115 Kucukkoy, 34250 Gaziosmanpaşa
Fax: [phone]
Istanbul, Turkey
Mail: [e-mail]

8
17. Declaration of Conformity
The undersigned Company declares under its sole responsibility that the machinery specified below satisfies the
essential requirements of the EC Machinery Safety Directive 2006/42/EC which is apply to it.
The machinery identified below has been subject to internal manufacturing checks assessment by YAPARLAR.
The signatories are in each case individually authorised to compile the technical documents.
Product Name
PALLET TRUCK
Product Type
PEDESTRIAN-PROPELLED PALLET TRUCKS
Models
YPT25, YPT30 and all 2,5 and 3 tonnes capacity Pallet Trucks
Name and address of the person authorised to compile the technical construction file
Selami Ortaköy
Cebeci Cad. No: 115 Küçükköy
34250 Gaziosmanpaşa / İstanbul-TÜRKİYE
Applicable EU Directives
2006/42/EC Machinery Safety Directive
Applicable Standards
EN ISO 12100 :2010;
EN ISO 3691-5:2015/A1:2020
On Behalf of Manufacturer:
Name: Ali Rıza YAPAR
Position: Chairman of the Board
Date&Place: 15.12.2020, Istanbul
Stamp & Signature:
18. Buyer’s Purchase Record
Buyer’s Name and Contact Details:
Buyer’s confirmation of receiving and reading the
Operator’s Manual before use:
Signature:
Serial Number:
Manufacturing Year:
Number of Units:
Date in Service:
Invoice Date:
Invoice Number:
Seller’s Stamp and Sign:

9
Figure 7. Handle Bar Assembly Drawing

10
Table 1. Handle Bar Assembly Parts List (Figure 7)
Drawing Name
Drawing No
Code
Description
Handle assembly
1
YPT25-H-01
Handle Bar
2
YPT25-H-02
Spring plate
3
YPT25-H-03
Pin
4
YPT25-H-04
Pin
5
YPT25-H-05
Pin
6
YPT25-H-06
Bush
7
YPT25-H-07
Pinch Roller
8
YPT25-H-08
Shaft
9
YPT25-H-09
Bush
10
YPT25-H-10
Torsional Spring
11
YPT25-H-11
Control Handle
12
YPT25-H-12
Pulley
13
YPT25-H-13
Pin
14
YPT25-H-14
Connection Strap
15
YPT25-H-15
Rivet
16
YPT25-H-16
Rivet
17
YPT25-H-17
Pull Rod
18
YPT25-H-18
Chain
19
YPT25-H-19
Eyelet Bolt
20
YPT25-H-20
Fastener Nut
21
YPT25-H-21
Hexagon Nut

11
Figure 8. General Assembly Drawing

12
Table 2. General Assembly Parts List (Figure 8)
Drawing Name
Drawing No
Code
Description
General Assembly
1
YPT25-01
Front Guide Roller
2
YPT25-02
Bolt
3
YPT25-03
Nut
4
YPT25-04
Load Roller (Red)
4
YPTW25-04
Load Roller (White)
5
YPT25-05
Bearing
6
YPT25-06
Bolt
7
YPT25-07
Shaft
8
YPT25-08
Roller Side Plate
9
YPT25-09
Extending Roller
10
YPT25-10
Roller Fork
11
YPT25-11
Roll Ring
12
YPT25-12
Shaft (Small)
13
YPT25-13
Spring Pin
14
YPT25-14
Shaft (Big)
15
YPT25-15
Cotter Pin
16
YPT25-16
Spring Pin
17
YPT25-17
Axle
18
YPT25-18
Spring Pin
19
YPT25-19
Axle Joint
20
YPT25-20
Nut
21
YPT25-21
Circlip
22
YPT25-22
Ball
23
YPT25-23
Pin
24
YPT25-24
Shaft
25
YPT25-25
Shaft
26
YPT25-26
Rock Arm
27
YPT25-27
Pump Supporting Base
28
YPT25-28
Bearing
29
YPT25-29
Bearing Circlip
30
YPT25-30
Chain Shaft
31
YPT25-31
Steer Wheel Shaft
32
YPT25-32
Circlip
33
YPT25-33
Fork Frame
34
YPT25-34
Steer Wheel (Red)
34
YPTW25-34
Steer Wheel (White)
35
YPT25-35
Dust Cover
36
YPT25-36
Shaft Pin
37
YPT25-37
Pump
38
YPT25-38
Handle Bar

13
Figure 9. Pump Assembly Drawing

14
Table 3. Pump Assembly Parts List (Figure 9)
Drawing Name
Drawing No
Code
Description
Pump Assembly
1
YPT25-P-01
Plunger Piston
2
YPT25-P-02
Dust Ring
3
YPT25-P-03
O-ring
4
YPT25-P-04
Guide sleeve
5
YPT25-P-05
O-ring
6
YPT25-P-06
Dust ring
7
YPT25-P-07
Combination ring
8
YPT25-P-08
Sealing screw
9
YPT25-P-09
Locking bar
10
YPT25-P-10
Balls
11
YPT25-P-11
Valve body
12
YPT25-P-12
Valve element
13
YPT25-P-13
Sealing screw
14
YPT25-P-14
Combination ring
15
YPT25-P-15
Universal spring
16
YPT25-P-16
Pump shell
17
YPT25-P-17
Balls
18
YPT25-P-18
Cylindrical head fixed
19
YPT25-P-19
Ball
20
YPT25-P-20
Ball seat
21
YPT25-P-21
Safety valve spring
22
YPT25-P-22
Sealing screw
23
YPT25-P-23
Combination ring
24
YPT25-P-24
Sealing screw
25
YPT25-P-25
Pedal
26
YPT25-P-26
Set screw
27
YPT25-P-27
Universal screw
28
YPT25-P-28
Spring pin
29
YPT25-P-29
Firing pin spring
30
YPT25-P-30
Fire pin
31
YPT25-P-31
O-ring
32
YPT25-P-32
O-ring
33
YPT25-P-33
Combination ring
34
YPT25-P-34
Fire pin seat
35
YPT25-P-35
Sealing ring
36
YPT25-P-36
Dust ring
37
YPT25-P-37
Universal spring
38
YPT25-P-38
Universal spring cap
39
YPT25-P-39
Small pump core

15
Table 4. Spare Part List (Figure 8)
Drawing Name
Drawing No
Code
Description
General Assembly
1
YPT25-01
Front Guide Roller
4
YPT25-04
Load Roller (Red)
4
YPTW25-04
Load Roller (White)
8
YPT25-08
Roller Side Plate
9
YPT25-09
Extending Roller
17
YPT25-17
Axle
19
YPT25-19
Axle Joint
27
YPT25-27
Pump Supporting Base
34
YPT25-34
Steer Wheel (Red)
34
YPTW25-34
Steer Wheel (White)
37
YPT25-37
Pump
38
YPT25-38
Handle Bar
In any service need, please return the pallet truck to your nearest distributor or contact YAPARLAR:
Yaparlar Insaat Ve Tarım Aletleri San. Ve Tic. A.S
Address: Cebeci Cad. No: 115 Kucukkoy, 34250 Gaziosmanpasa, Istanbul, Turkey
Tel: [phone]
Fax: [phone]
Mail: [e-mail]
©2021 Yaparlar A.Ş. All Rights Reserved
Models and specifications are subject to change