BORMANN BWR2511 Pallet Truck 2.5Ton User Guide

BORMANN BWR2511 Pallet Truck 2.5Ton User Guide

Introduction

Before operating this hand pallet truck, read this ORIGINAL INSTRUCTION HANDBOOK carefully and understand the usage of the hand pallet truck completely. Improper operation could create danger. This handbook describes the usage of a specific hand pallet truck. When operating and servicing the hand pallet truck, make sure, that it applies to this specific pallet truck. Keep this handbook for future reference. If this or the warning/caution labels are damaged or got lost, please contact your local dealer for replacement. Some described functions are optional and therefore not absolutely necessarily equipped with your truck.

ATTENTION: Environmentally hazardous waste, such as batteries, oil and electronics, will have a negative effect on the environment, or health, if handled incorrectly. The waste packages should be sorted and put into solid dustbins according to the materials and be collected disposal by 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 products, the user should prepare some absorbable materials (scraps of wooden or dry duster cloth) to absorb leaking oil in time. To avoid second pollution to the environment, the used absorbable materials should be handed in to special departments in terms of local authorities. Our products are subject to ongoing developments. Because this handbook is only for the purpose of operating /servicing the hand pallet truck, therefore please have understanding, that there is no guarantee out of particular features out of this handbook.

Correct Application

It is only allowed to use this hand pallet truck according to this instruction handbook. This truck is a manually operated hand pallet truck designed to lift and transport the rated load on industrial pallets. Do not lift or carry person and don’t use this truck for other purpose than its intended use. A wrong usage can cause human injuries or can damage equipment.The operator/ the operating company has to ensure the correct usage and has to ensure, that this truck is used only by staff, which is trained and authorized to use this truck.

WARNING: The truck has to be used on substantially firm, smooth, level and prepared surfaces. Driving with the load on slopes is not allowed. The load must be placed approximately on the longitudinal centre plane of the table and must be in satisfactory condition.

The capacity is marked on the identification plate and depending on the version eventually additionally on the capacity sticker. The operator has to consider the warnings and safety instructions. The hand pallet truck is intended to be used for indoor applications with ambient temperatures between +5o C and + 40o C.
Operating lighting must be minimum 50 Lux.

Modification
No modifications or alterations to this hand pallet truck which may affect, for example, capacity, stability or safety requirements of the truck, shall be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof. This includes changes affecting, for example braking, steering, visibility and the addition of removable attachments. When the manufacturer or its successor approve a modification or alteration, they shall also make and approve appropriate changes to capacity plate, decals, tags and operation and maintenance handbooks. By not observing these instructions, the warranty becomes void.

Description of the Hand Pallet Truck

Main components, safety devices and warning labels

1. Chassis
2. Tiller arm
3. Hydraulic pump
4. Lifting mechanism
5. Steering (Front-) wheels
6. Load wheels (single/tandem)
7. Lever
8. Identification plate (ID-plate)
9. Company logo and/or capacity sticker
10. Lifting function instruction sticker
11. Eventual capacity sticker

Technical Data

Type|  | BWR2511
Load Capacity| Q (t)| 2,5
Tyre size, front| mm| 200×50
Fork dimensions| L (mm)| 1150
Distance betw. forks| b5 (mm)| 540

Warnings and Safety Instructions

DO NOT: Allow other person then the operator to stand in front of or behind the truck when it is moving or lifting/lowering.
Overload the truck.
Put foot in front of rolling wheel, Injury could result.
Use the truck on a slope or inclined surface, the truck may become uncontrollable and create danger.
Lift or carry people. People could fall down and suffer severe injury.
Use truck with unstable, unbalanced loosely stacked load.
Use the truck in explosive atmospheres.

Watch difference in floor levels when moving the truck. Load could fall down or the truck could get uncontrollable. Keep watching the condition of load. Stop operating table if load becomes unstable. Practice maintenance work according to regular Inspection. This truck is not designed to be water resistant, therefore use it in dry atmospheres.

Commissioning, Transporting, Storage / Reassembling

A. Commissioning – Tiller assembling: after receiving our new hand pallet truck you may have to do following before firstly operating the truck

• Check if are all parts included and not damaged
• Do the work according to the daily inspections as well as functional checks.
• Eventually assemble the truck according to following instructions.

The commissioning weight is approximately. 10kg / six- pack higher than the product weight. Before assembling, please make sure, that the following supplied parts are included and not damaged:

• 1 pc axle with hole (4)
• 2 pc dowel pin (5) [one is already assembled with the axle]
• 1 pc pre- assembled tiller arm (1)
• 1 pc pre- assembled chassis with pump unit (6). Note: The marked number on the tiller arm package and the chassis should be the same.

When attaching the handle, you had better squat just in front of the pallet truck.

a)Insert the tiller arm(1) into the pump piston, then use a hammer to insert the axle with hole into the hydraulic pump and tiller arm (Fig. 4).
b)Set the control lever of the handle to the ‘LOWER’ position, then pass the adjusting nut, adjusting bolt through the hole of the axle with your hand (Fig. 3).
c)Press the tiller arm down; take away the pin (2, Fig. 2)
d)Set the control lever of the handle to ‘RAISE’ position, then raise the lever plate with the pin (2, Fig. 2) and insert the adjusting bolt into the front slot of lever plate. Note: Keep the adjusting nut under the lever plate.
e) Use a hammer to insert the 2nd dowel pin (5, Fig. 2) into the 2nd hole of the axle. The draw-bar is now assembled to the pump.

Hydraulic valve adjustment
On the tiller of your pallet truck, you will find the control lever, which can be regulated in three positions:

Lower — handle up, the lever moves back to the neutral, when released
Neutral — handle in center position
Raise — handle down

If necessary, you can adjust the lever according to following steps (fig. 5):

a) If the forks elevate while pumping in the Neutral position, turn the adjusting nut on the adjusting bolt clockwise until pumping action does not raise the forks and the Neutral position works properly.
b) If the forks descend while pumping in the Neutral position, turn the adjusting nut counter-clockwise until the forks do not lower.
c) If the forks do not descent when the control handle is in the Lower position, turn the adjusting nut clockwise until raising the control handle lowers the forks.
Then check the Neutral position according to fig. 5 and be sure that the adjusting nut is in the proper position.
d) If the forks do not elevate while pumping in the Raise position, turn the adjusting nut counter- clockwise until the forks elevate while pumping in the Raise position. Then check the Lower and Neutral position.

C. Transporting
For transporting, remove the load, lower the truck to the lowest position and lash it safe with dedicated lashing straps.

D. Storage/Reassembling
For storage, remove the load, lower the truck to the lowest position, grease all in this handbook mentioned greasing points (regularly inspection) and eventually protect the truck against corrosion and dust. Jack the truck safety, so that there will be no flattening after storage. Reassemble the tiller in the opposite direction of the assembling.

Daily Inspection

This chapter describes pre-shift checks before putting the truck into operation. Daily inspection is effective to find the malfunction or fault on the truck and can maximize the lifetime. Check the truck on the following points before operation.Remove load from truck and lower the forks to the lowest position.

Do not use the truck if any malfunction or fault is found.

Visually check for structural deformation or cracks of arms, forks, or any other component; and unusual noise or binding of the lifting mechanism.
Check if there is any oil leakage.
Check the vertical creep of the lifting mechanism.
Check the smooth movement of the wheels.
Check if there are any particles or damages on the wheels.
Check if all the bolts and nuts are tightened firmly.
If equipped, check the brake. Verify that all labels are in place.

Οperating Instructions

WARNING:
When operating the truck, the operator has to wear safety shoes.
The truck is intended to be used for indoor applications with ambient temperatures between +5OC and + 40OC.
The operating lighting must be minimum 50 Lux.
It is not allowed to use the truck on angled surfaces.
Never leave a loaded pallet truck unattended.

A. Parking
Lower the forks to the lowest position and park the Hand pallet truck on a smooth and even level ground where the truck not disturbs any other operations. If equipped with a brake use the brake for parking the truck acc. to the description further below.

B. Lifting
Check that the load does not exceed the loading capacity of the pallet truck. Roll the pallet truck with its forks slowly under the pallet/load until the back end of the fork rests against the load (Fig.6). Shift the operating lever down to the Lifting position. Lift the load by up- and down movements of the tiller arm.

The load must be evenly distributed across both forks. DO NOT OVERLOAD THE TRUCK!

C. Lowering
Do not put foot or hand under the lifting mechanism. Lower the load by shift the operating lever up to the lowering position carefully. By releasing the lever, the lowering movement will stop. Ensure there is adequate clearance behind, then move the pallet truck away.

D. Moving
Do not operate the truck on a slope or inclined surface.
Watch difference of floor level when moving lifter. Load could fall down.
Make the load stable to prevent it from falling down.
The truck might be not equipped with a brake. In this case the braking distance is longer and depends on the operator.
If equipped, release the brake. Move the truck by pushing or pulling the tiller arm. The tiller arm is connected to the steering rollers. The wheels are steered automatically by moving or steering the tiller arm.

E. Malfunctions
If there are any malfunctions or the truck is inoperative, please stop using it, place the truck at a safe place. Avoid further usage. Inform immediately the manager and, or call your service.

Regular Maintenance

Only qualified and trained personnel are allowed to do service on this truck.
Before servicing the truck, remove the load and lower the forks to the lowest position.
Completely immobilize pallet truck before working on components that might pinch fingers or hands if movement were allowed.
Use approved and from your dealer released original spare parts.
Please consider that oil leakage of hydraulic fluid can cause failures and accidents.
It is allowed to adjust the pressure valve only from trained service technicians.
Waste material like oil, used batteries or other must be probably disposed and recycled according to the national regulations and if necessary brought to a recycling company.
All bushings and bearings have been lubricated at the factory. To increase their life, regular maintenance is recommended. Using the appropriate grease for the application and lubricate each grease fitting every 6 months.
Harsh environments may require more frequent maintenance.
If you need to change the wheels, please follow the instructions above. The wheels must be round and they should have no abnormal abrasion.

A.Maintenance

DAILY
Follow chapter 5.
MONTHLY

Check hydraulic oil level (more frequently for high use applications).
All bearings and shafts are provided with long-life grease at the factory. Long-life grease should be applied to the lubrication points at monthly intervals or after each time the truck is cleaned. Clean off dirt and debris

EVERY SIX MONTHS

Change oil (more frequently if color has substantially darkened or feels gritty). The required hydraulic fluid type is ISO VG32, its viscosity should be 30cSt at 40°C, total volume is about 0.3 l.

NOTE: If hydraulic oil is milky white in color, water is in the hydraulic system. Change the hydraulic oil immediately.

WARNING: Before starting operating the truck, ensure that all markings and decals are on the right place and not damaged (acc. to fig. 3). If necessary replace the decals.

B. Deaeration of the hydraulic system
Air may find its way into the pump during transportation, tilting or usage on uneven ground. It can result in not elevating forks whilst pumping in the Raise position. The air can be removed in the following way: Move the control handle to the Lower position, then move the tiller down several times. Thereafter normal operation can be resumed.

C. Adding hydraulic oil to the pump reservoir
Ensure forks are in lowered position.
Lay pallet truck on either side. Position drain plug of hydraulic cylinder up.
Remove the screw plug.
Add hydraulic oil until level of oil is at bottom of hole.
Replace drain plug, upright the truck.

Troubleshooting

WARNING: If the truck has malfunctions follow the instructions, mentioned under chapter 7.

hydraulic fluid level or impurities in oil.
b.  Control lever is out of adjustment.
c.  Load is too heavy. Overload release valve is being activated.
d.  Temperature is too low and the hydraulic oil has  become too thick.
e.   Air in the hydraulic oil.| a.  Add approved hydraulic fluid or change oil as noted in chapter 7.
b.   Follow the procedure for adjusting the control lever in chapter 4.
c.   Reduce load.
d.   Move truck to a warmer location.
e.   Deaerate the hydraulic pump. (see chapter 7)
2| Forks don’t lower or don’t lower fully| a.  Obstacle located under truck, in fork mech- anism, etc.
b.  Control lever is out of adjustment
c.  Fork was left in a raised position for an ex- tended time causing exposed piston rod to rust.
d.  The piston rod or pump is deformed due to over-loading or uneven loading.| a.     Use caution removing the obstacle
b.     Follow the procedure for adjusting the control lever in chapter 4
c.    Keep fork in the lowest position when not in use and keep piston rod well lubricated
d.    Replace the piston rod or pump
3| Forks lower without putting the control lever in the “lower” position| a.  Oil impurities are preventing the release valve from fully closing.
b.  Some hydraulic components or seals are cracked or worn.
c.  Control lever is out of adjustment.| a.    Drain and replace hydraulic fluid with approved fluid as noted in chapter 7
b.     Inspect and replace components as needed
c.    Follow the procedure for adjusting the control lever in chapter 4
4| Oil leakage| a.     Worn or damaged seals
b.    Other cracked or worn parts| a.  Replace seals
b.  Replace damaged parts

• The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.
• Please note that our equipment has not been designed for use in commercial, trade or industrial applications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.
• To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including  maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.

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