WRZ PALLET TRUCK

OWNER'S MANUAL
 series of
WRZ30
Model Number WRZ30540 WRZ30685

Minimum Fork Height 3-1/3in./85mm or 3in./75mm

Lifting Height 7-7/8in./200mm or 7-1/2in./190mm

Capacity 6600lbs./3000kg

Turning Angle 210°

Overall Fork Dimensions 21-1/4×45-1/4in. 27×48in.

(W×L) 540×1150mm 685×1220mm

Warning
1. Read and understand the entire owners manual before using the pallet truck.
2. Do not place hands or feet under the pallet truck at any time.
3. Never allow anyone to ride on the pallet truck.
4. Operate on smooth, level, finished floors only; do not use on ramps or sloping floors.
5. To prevent accidental tipping, make sure load is centered on the fork.
6. Do not lift a load with fork tips only. This may cause damage to the fork and personal injury if the rear
of the pallet truck suddenly tips upward.
7. Do not load pallet truck beyond its rated capacity.
8. Never leave a loaded pallet truck unattended in the raised position. Always lower load to the floor.
9. Pull pump release lever slowly to allow load to descend in a controlled manner.
10. Secure load before transporting.
11. Do not move a loaded pallet truck by other than manual force.
12. The handle is designed to pull and steer the pallet truck only. Do not use the handle as a leverage
tool.
13. Failure to comply with these warnings may result in personal injury and/or property damage.

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Unpacking
Open shipping container and check for shipping
damage. Report any damage immediately to
your distributor and shipping agent. Do not
discard any shipping material until the Pallet
Truck is assembled and working properly.
Individual trucks are assembled and ready to
use. Pallet trucks purchased in crate quantities
(6 units to a crate) require some assembly.
Match the letter label on the handle assembly
to the letter label on the frame prior to
assembly.

Assembly Figure 1
Tools required for assembly:
Hammer
Flat Head Screwdriver
Pliers

1. Insert the base of the handle into the pump

bracket (Figure 1). Align the holes at the
base of the handle with the holes in the
pump bracket.
2. Use a hammer to tap the handle pin into the
holes of the pump bracket and handle
(Figure 2). Use pliers to turn the handle pin
until its holes align with the spring pin holes.
3. Feed the screw head through the center
hole in the handle pin (Figure 3). Using a Figure 2
screwdriver, pry up the cam and slip the
screw head under the notch in the cam.
4. Use a hammer to tap the spring pins (Figure
2) into the holes on the pump bracket and
handle pin.
5. Tap out the pump retainer pin (Figure 1).
NOTE: It is a good idea to remove any air
bubbles that might have accumulated in the
hydraulic system during shipping. Refer to
Cleaning the Release Valve, on page 7.

Pallet Truck Operation

Figure 3
NOTE: Numbers in parentheses refer to item
numbers in the breakdown on page 9.
This pallet truck is designed for use with open
style pallets or skids only. Closed style pallets
must be placed on top of fork prior to use.
1. Insert the fork into the pallet.

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2. To raise the fork, push control lever all the
way down, and pump the handle until the
desired fork height is reached.
3. To move the handle without affecting the
fork setting, set the control lever in the
center neutral position. The load can now be
pushed or pulled using the handle.
4. To lower the fork, pull lever all the way up.
Allow the load to descend slowly in a
controlled manner. The lever is spring
loaded and will return to the neutral position
Figure 4
when released.
Wheel bearings are sealed and require no
When not in use, do not allow lubrication. The crank shaft features oil lite
heavy loads to remain on the fork for an bushings that also require no lubrication.
extended period of time. Always lower fork Lightly oil all other moving parts.
completely when not in use.
Seal and O-Ring Replacement for
Up-Down Cam Adjustment Ram and Plunger Piston
When pumping the handle with the lever in 1. Raise the pallet truck by pumping handle.
neutral position, there should be no movement
of the fork. If there is fork movement, the cam 2. Remove spring pin (82). This will free the
must be adjusted: pump and handle assembly from the pallet
truck.
1. Place lever in neutral position.
3. Remove the oil plug (50), turn pump over
2. Loosen the hex nut (16). and empty the oil into a suitable container.
3. Adjust the socket head cap screw (17) while Pump handle until all oil has drained.
pumping the handle, until there is no longer Dispose of used hydraulic oil according to
any movement of the ram. local disposal regulations.

4. Tighten the hex nut (16). 4. Pull out plunger piston (37) and/or ram
piston (48).
Cleaning the Release Valve (Bleeding the
5. Remove all o-rings and seals. See Figure 5.
Pump)
Over time, the hydraulic pump may become 6. Insert new o-ring or seal one at a time
clogged with debris or air bubbles causing making sure to replace with the same size
improper function. that was removed.

Clean the release valve as follows: Reassemble and fill the oil tank through the oil
plug hole to 80% capacity with new hydraulic
1. Pump handle quickly, raising pallet truck to jack oil, about 2-1/2 deep in pump housing. See
full extent. Pull lever all the way up in order Figure 4.
to lower the fork, while continuing to pump
the handle.
2. When fork has lowered completely, the 32
valve has been flushed. Repeat if
necessary.
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Maintenance 34
Check the oil level annually by removing the oil
plug (50) on top of the pump housing. When
changing or adding oil, fill the tank through the
oil plug hole to 80% capacity with hydraulic jack Figure 5
oil, about 2-1/2 deep in pump housing. See
Figure 4. Do not use any other type of oil. When
finished, replace oil plug (50).

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Troubleshooting
Numbers in parentheses refer to item numbers in the breakdown on page 9.

Trouble Probable Cause Remedy

Make sure there is no oil leakage

from Release Screw , Pressure
Oil level is low.
Adjustment Screw or valve area.
Hydraulic unit does Then add oil.
not lift.
Air in pump. See Cleaning the Release Valve.

Replace o-ring (refer to Seal and O-

Worn o-ring in ram cylinder.
Ring Replacement).

Steel ball has not seated in

See Cleaning the Release Valve.
hydraulic unit.

Replace o-ring (refer to Seal and O-

Worn o-ring in ram cylinder.
Ring Replacement).

Release valve not seated properly. See Cleaning the Release Valve.

Once lifted, truck Pallet truck loaded beyond capacity. Reduce load to within capacity.
lowers by itself.
Adjust valve by Pressure Adjustment
Release valve not adjusted properly.
Screw and Release Screw .

Tighten Release Screw . Replace

o-rings on Release Screw and/or
Oil leakage from Release Screw
Pressure Adjustment Screw. If leakage
or Pressure Adjustment Screw .
continues, contact authorized service
center.

Cam requires adjustment. Refer to Up-Down Cam Adjustment.

Cam is damaged. Replace cam .

Fork does not lower.
Replace damaged parts. (It is
Damaged push rods and/or linkages. recommended that an authorized
service center perform this work.)

Lever does not set at

Cam requires adjustment. Refer to Up-Down Cam Adjustment.
NEUTRAL position.

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WRZ Pallet Truck

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 Parts List: WRZ Pallet Truck
Index No. Description Size Qty

1...........................................Handle................................................................................ .1
2...........................................Spring Pin.............................Φ4 x 30 mm.............................. 1
3...........................................Block Spring................................................................. ....... 1
4...........................................Spring......................................................................... ........ 1
5...........................................Spring Pin.............................Φ4 x 16 mm.............................. .1
6...........................................Roller................................................................................... 1
7...........................................Plastic mat........................................................................... 1
8...........................................Spring Pin.............................Φ6 x 30 mm............................... 1
9...........................................Control Lever....................................................................... .1
10.........................................Release Rod......................................................................... 1
11.........................................Oil Lite Bushing......................Φ15 x Φ17x 17 mm ....................2
12.........................................Roller........................... ........Φ25x 36 mm ............................. 1
13.........................................Roller Pin..............................Φ15 x 65 mm ........................... .1
14.........................................Oil Lite Bushing.....................Φ20 x Φ22x 16 mm ..................... 2
15.........................................Handle Pin............................Φ20 x 100 mm ............................1
16.........................................Spring Pin.............................Φ5 x 30 mm................................2
17.........................................Pump Retainer Pin.................Φ8 x 100 mm..............................1
18.........................................Washer.................................Φ28x Φ20x 1.5 mm....................1
19.........................................Plunger Housing.................................................................... 1
20.........................................U-Packing*............................Φ26 x Φ18x5 mm........................1
21.........................................Dust Seal Ring*..................... Φ26 x Φ18x6 mm....................... 1
22.........................................Spring................................................................................... 1
23.........................................Spring Cap............................................................................ 1
24.........................................Plunger Piston........................Φ18 x 101 mm...........................1
25.........................................Pressure Adjust Screw............................................................1
26.........................................O-Ring*..................................11.8 x 2.65 mm......................... 1
27.........................................Release Screw.......................................................................1
28.........................................Spring...................................................................................1
29.........................................Needle Valve..........................................................................1
30.........................................Steel Ball................................18 mm.....................................1
31.........................................Ram Piston.............................Φ35 x 277mm...........................1
32.........................................Dust Seal Ring*..................... Φ35 x Φ43x6.5 mm.....................1
33.........................................O-Ring*..................................34.5 x 3.55 mm.........................1
34.........................................U-Packing*............................Φ35 x Φ45x6 mm........................1
35.........................................Oil Plug................................................................................. 1
36.........................................Oil Seal................................................................................. 1
37.........................................Pump Housing....................................................................... 1
38......................................... Valve Assembly .................................................................... 1
39.......................................Dust Seal Cap....................................................................2
40.......................................Snap Ring..............................20 mm..................................2
41.......................................Steering Wheel.......................Φ180 x 50 mm.......................2
42.......................................Ball Bearing........................... 6204 mm........................... ..4
43.......................................Wheel Shaft........................... Φ25x 177 mm..................... .1
44.......................................Spring Pin.............................. Φ5 x 30 mm........................ .2
45.......................................Ball Bearing.............................51111............................... ..1
46.......................................Bearing Base.................................................................... 1
47.......................................Spring Pin.............................. Φ8 x 45 mm........................ .1
48.......................................Snap Ring.............................. 52 mm.................................1
49.......................................Table.................................................................................1
50.......................................Table Pin................................Φ16 x 47 mm....................... .2

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Index No. Description Size Qty

51...........................................Socket Head Cap Screw..........M8 x 20 mm....................... ...1

52...........................................Hex Nut................................. M8.................................... ..1
53...........................................Cam .................................................................................1
54...........................................Spring Pin..............................Φ8 x 55 mm...........................1
55...........................................Washer..................................Φ6 mm............................... ..1
56...........................................Socket Head Cap Screw..........M6 x 14 mm....................... ...1
57...........................................Oil Lite Bushing......................Φ18 x Φ16x 15 mm ................2
58...........................................Lifting Yoke........................................................................1
59...........................................Oil Lite Bushing......................Φ29 x Φ25x 25 mm ................2
60...........................................Snap Ring..............................16 mm..................................2
61...........................................joint..................................................................................2
62...........................................Oil Lite Bushing......................Φ18 x Φ16x 15 mm ................2
63...........................................Crank Pin..........................................................................2
64...........................................Hex Nut................................. M20................................... ..2
65...........................................Push Rod ..........................................................................2
66...........................................Crank Shaft.......................................................................1
67...........................................Snap Ring..............................25 mm................................. 2
68...........................................Load Wheel Frame.............................................................2
69...........................................Arm Pin.............................................................................2
70...........................................Spring Pin..............................Φ5 x 30 mm.......................... 2
71...........................................Load Wheel Axle................................................................4
71A.........................................Load Wheel Axle................................................................2
72...........................................Bracket.............................................................................4
73...........................................Spring Pin..............................Φ5 x 35 mm...........................8
74...........................................Load Wheel.......................................................................4
74A.........................................Load Wheel ......................................................................2
75...........................................Ball Bearing...........................6204 mm........................... ...8
76...........................................Rod Pin.............................................................................2
77...........................................Spring Pin..............................Φ5 x 25 mm.......................... 2
78...........................................Socket Head Cap Screw..........M10x 55 mm.........................2
79...........................................Guide Roller...........................Φ50x 37 mm......................... 2
80...........................................Hex Nut.................................M10......................................2
81...........................................Fork..................................................................................1
82...........................................Pump Assembly. ................................................................1
83...........................................Seal Kit(includes items marked with*).............................. ....1
84...........................................Handle Assembly............................................................... 1
85...........................................Pump/Handle/Table/Wheel Assembly......... .........................1
..............................................ID.Label(not shown)...........................................................1
..............................................Logo Label(not shown).......................................................1
..............................................Pump Label(not shown)......................................................1
..............................................Handle Label(not shown)....................................................1

*indicates items in the Seal Kit(#86)