Zero Pro Hand Truck User manual

Zero Pro Hand Truck
User Manual
This manual contains important information for setting up your
hand truck correctly and the safe use of your hand truck
Ensure you read and understand this manual before you attempt
to assemble or operate your hand truck. Remember to keep this
manual as you may need to refer to it at a later point.

Part
No.
Name Qty. Picture
1 Upper Frame 1
2 Lower Frame 1
3 Toe Plate 1
4 Wheels 2
5 Axle 1
6 Wheel Spacers 2
7 Flat Washers 6
8 Slotted Nuts 2
9 Split Pins 2
Package Contents

Part
No.
Name Qty. Picture
10 M6 x 45 screws 2
11 M6 nyloc nuts 2
12 Lock Pins 2
You will require:
Spanner or Socket – 10mm and 30mm
Allen Key – 5mm

Assembly
Step 1
The hand truck will have plastic stops in the ends of the axle tube, holding it
in place at the bottom of the lower frame(2) (shown in the picture below) and
they must be removed before you begin assembly.
Shipping Plug
Step 2
Slide the 20mm axle(5) through the hole of the lower frame(2) (where you
have just removed the plastic stop) and through the axle tube, so that there is
the same amount of space on each side of the lower frame. You may need to
apply pressure to the axle tube onto the springs in order to thread the 20mm
axle through.

Step 3
Next place on each end of the axle, the flat washers(7), spacers(6) and wheels(4)
in the order shown on the diagram below. Screw a slotted nut(8) onto each
end and then tighten them, ensure when you tighten them that a slot in the
nut lines up with the hole in the axle.
7
7
7
77
7
8
8
6
6
4
4
9
9
Step 4
To ensure the nuts cannot come loose, insert a split pin(9) through the slot
in the nut and the hole in each end of the axle, open the ends of the split pin
and fold back against the nut.

Step 5
Place the toe plate(3) onto the exposed ends of the lower frame and fasten
with the M6 x 45mm screws(10) and M6 nuts(11) using a 10mm spanner and
5mm Allen key. The sockets on the toe plate have a large hole on the outside
of the socket and a smaller hole on the inside. The screws should be inserted
from the outside so that the screw head sits in the large hole.
Step 6
Insert the upper frame(1) into the lower
frame and secure with the locking pins(12).
The upper frame can be located by using
either set of the two uppermost holes, to
get the most comfortable height.
To fit the locking pins, pull the wire loop
clear of the pin and rotate it out of the way.
Insert the pin then rotate the wire loop back
and over the end of the pin.
The setup is now complete – Please read
the safety guidelines before use.

How to Safely Use Your Zero Pro Hand Truck
Recommended Load Capacity: 300kg
Check Before Using
1. Make sure there is no damage to the frame or toe plate before each use.
Bends, fractures and cracks could cause a fault in the truck.
2. Check the wheels for damage and make sure they both spin freely on the
axle.
3. Check all bolts and nuts to make sure they are intact and tightly secure. Do
not use if a bolt or nut has come loose or is missing.
4. Make sure the pivot springs are intact and in the correct position. Any
bends or deformities could cause the truck to fail.
5. Check the nuts on the end of the wheels are still secure and held in place
by the split pins. Check that the split pin is not broken and cannot come
out. Do not use if the nut is loose or split pin missing.
6. Make sure the springs and roller bearings are always lubricated. Any unusual
noises from the wheels or springs can be solved by adding grease to the
components.
Use of the Truck
1. Be sensible about the load you place on the truck. Never exceed the
recommended load capacity of 300kg.
2. Make sure you can always see over the load on the truck. Do not place a
load higher than the frame of the hand truck.
3. When stacking a load onto the truck make sure larger and heavier items are
placed at the bottom of the truck and smaller and lighter items are placed
at the top.
4. For loads that are much larger than the toe plate and frame of the hand
truck (i.e. white goods) use restraints such as cam buckle or ratchet strap
and wrap around the load and the upright of the truck.
5. When transporting over uneven surfaces, make sure you use restraints to
secure the load to the truck.
6. When lifting the loads make sure you have both feet on the ground and
stand slightly back from the truck, Zero Hand Trucks do not require you to
place a foot on the axle.
7. Keep your back straight or with a slight bend when lifting and manoeuvring
the hand truck. Never operate in an awkward or bent over position.
8. Always make sure the load is balanced over the wheels. The operator is
only there to stabilise and push the load. Never take the brunt of the load
yourself, let the truck do the work.
9. When transporting the load, only ever push forward. Never pull the load
backwards – if you trip, the load will fall on top of you and could cause
serious injury.

10. When travelling up or down stairs, make sure to keep your back straight
or at a slight angle. If you are bent down and trying to lift you could cause
injury or the weight of the load may pull you down the stairs. Typically, you
should be one extra step above the hand truck when lifting and take an
extra step back at the top of a flight of stairs.
11. In a work environment, always park the truck in a designated area, never
leave in an aisle or area of traffic.
12. Never leave a load stationary on the truck for a long period of time as
this may deform the wheels.
13. Finally, when the Zero Hand Truck is used correctly it is an excellent aid
for material handling. It greatly reduces the chance of injury and strain so
follow these guidelines and let the truck do the work for you.

Use as a Flat Bed Trolley
The hand truck can quickly and easily be used as a flat bed trolley by addition
of the castor wheels that can be purchased separately.
Part
No.
Name Qty. Picture
1 Castor 2
2 Castor Bracket 2
3 M8
Thumbscrew
2
4 M10 x 40
Screw
2
5 M10 Nyloc Nut 2
6 M8 Washer 2
You will require:
Spanner or Socket – 16mm
Allen Key – 8mm

Assembly
Step 1
For each castor, locate the castor
bracket(2) over the stem of the castor(1)
and secure with an M10x40 screw(4) and
M10 nyloc nut(5). The castor bracket has
a larger hole for the bolt on one side than
the other. Insert the M10x40 screw in
through this hole so that the screw head
sits in the hole.
STEP 2
Remove the upper frame from the hand truck by
unclipping the wire loops locking the pins, pulling
the pins out and removing the upper frame.

Step 3
Insert the castor assemblies onto the ends of the upper
frame and secure with the locking pins. The castor
brackets must be positioned pointing away from the
handle at the top of the upper frame. Note that the castor
assemblies are handed. They should be attached so that
the solid plate with the nut welded to it, is on the inside.
Step 4
Slide the castor brackets over the ends of the lower
frame so that the lower frame butts up against the up-
per frame. Clamp the brackets in position by using the
M8 thumbscrews(4). Place an M8 washer(6) onto the
thumbscrew thread and insert the thumbscrew through
the bracket and into the nut welded on the other side.
The thumbscrews should be to the outside.

Swapping Between Trolley & Truck
It is not necessary to remove the castors to swap between the trolley and
truck.
• To swap back to the truck, remove the lock pins and remove the upper
frame from the castor brackets.
• Loosen the thumbscrews on the castors and rotate them inside the frame.
• Insert the upper frame into the lower frame tubes and secure with the
lock pins.

Support Mesh
A support mesh is available as an accessory for use with the trolley or truck
configurations. This is ideal when moving stacks of smaller items.
Part
No.
Name Qty. Picture
1 Mesh 2
2 Clamp 2
3 M6 x 16 Allen
Head Screw
4
4 M6 Nut 4
Place the two mesh sections(1) onto the back straps. Locate the grooves in
the clamps(2) over the mesh. Secure the clamp to the back strap by inserting
the M6 Allen screws(3) through the clamp and the holes in the back strap
and secure with the M6 nuts(4).

Technical Information
For more information and updates on technical information and these
guidelines, please refer to the website or feel free to contact us.
Phone: [phone]
Email: [email protected]
Website: zerohandtruck.com
Patent Pending: PCT/GB2018/050925