Max Hydraulic Truck

Owner, Operation, & Parts Manual

Models
Max Hydraulic Truck
 TABLE OF CONTENTS
ASSEMBLY.............................................................................3 MAINTENANCE...................................................................8
SAFETY...................................................................................4 SERVICE AND ADJUSTMENTS.......................................9
CONTROLS AND FEATUES..............................................5 PARTS LIST.........................................................................12
OPERATION..........................................................................6 WARRANTY........................................................................18

INTRODUCTION
THE MANUAL PURCHASE INFORMATION
Before using the unit, carefully and completely
read your manual. The contents will give you an Please record the following information about your
understanding of safety instructions and controls unit and have it available before contacting us.
during normal operation and maintenance.
Serial Number:
All reference to left, right, front, or rear is given
from the operator’s position, facing the direction
of forward travel. Dealer/Distributor’s Name:

ENGINE MANUAL
A separate manual specific to the engine covers Date of Purchase:
the engine on this unit. This manual is included
in the literature package that shipped with the
unit. Refer to this manual for engine service Year of Manufacture:
recommendations. If the engine manual is not
available, contact the engine manufacturer for a
replacement manual. European Community Design Registration Number 002967828-001

DECLARATION OF CONFORMITY
The undersigned of Muck Truck UK Ltd, declare that the Pedestrian Dumper Trucks:
Category: Petrol, 4-Stroke Pedestrian Dumper
Model: Max Hydraulic Truck
Conform to the essential Health and Safety requirements of the EEC Directive.
98/37/EC (Edition L 207)
Previously 89/392/EEC – 93/94/EEC Amendment
Basic Noise Emission Standard – EN ISO 3744 – dB 98 Lwa

H.A.V.s
Machinery Directive 89/392/EEC
The supply of (Safety) regulations 1992 (as amended: 1994), for conformity in an EU market
Left Hand Idle: 2.79 m/s2 Right Hand Idle: 3.10 m/s2
Racing : 4.95 m/s
2
Racing : 5.86 m/s2
Specified testing unit to: ISO 8041, ISO 5349 and BS 6842
The notified body is AV Technology Ltd.
Avtech House, Birdhall Lane, Cheadle Heath, Stockport, SK3 0XX, England
Name and signature of Managing Director of Muck Truck UK Ltd.

Terry Rowlands
2
 ASSEMBLY

Install Handles
Handles are shipped in downward position (see Figure 1) with all levers and cables correctly positioned.

1. Cut tie-straps retaining handles. 4. Insert M8 x 50 hex bolt from Manual

Package into remaining hole and secure
2. Remove M8 x 75 shipping hex bolt securing with washers and nut removed from
handle to unit. Retain nut and washers; shipping bolt.
discard 75mm hex bolt.
5. Tighten hardware securely.
3. Align handle with the holes in the cowling
cover and attach with two M8 x 50 bolts, 6. Repeat steps 2 – 5 for remaining side.
washers and M8 Nyloc nuts removed earlier.

3
 SAFETY
SAFETY ALERT SYMBOL DO NOT operate near drop-offs, ditches, or
These are safety alert symbols. embankments. Unit can suddenly turn over if
They mean: wheels move over the edge of a cliff or ditch, or if
an edge caves in.
• ATTENTION!
• YOUR SAFETY IS INVOLVED! Read the entire Owner/Operator manual. If
When you see this symbol: the operator or the mechanic cannot read the
manual, it is the owner’s responsibility to explain
• BECOME ALERT! it to them. Only the user can prevent, and is
• OBEY THE MESSAGE! responsible for accidents or injuries occurring to
themselves, other people or property.
SIGNAL WORDS
The safety alert symbols above and signal words Only trained adults may operate or service unit.
below are used in this manual. Training includes actual operation.
Read and understand all safety messages.
NEVER operate unit after or during the use of
medication, drugs or alcohol. Safe operation
DANGER: IMMINENTLY HAZARDOUS requires your complete and unimpaired attention
SITUATION! If not avoided, WILL RESULT at all times
in death or serious injury.
Wear adequate safety gear, protective gloves and
footwear. NEVER place your hands or any part of
WARNING: POTENTIALLY HAZARDOUS your body or clothing inside or near any moving
SITUATION! If not avoided, COULD part while unit is running.
RESULT in death or serious injury.
DO NOT touch parts that are hot. Allow parts
to cool.
CAUTION: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, MAY RESULT ALWAYS keep hands and feet away from all
in minor or moderate injury. It may pinch points.
also be used to alert against unsafe
Read, understand, and follow all instructions in
practices.
the manual and on the machine before starting.
Understand:
SAFETY RULES • How to operate all controls.
Read, understand, and follow all safety practices • The functions of all controls. `
in Owner/Operator Manual before use. Failure to • How to STOP in an Emergency.
follow instructions could result in personal injury • Braking and turning characteristics.
and/or damage to unit.
Keep safety devices or guards in place and
Complete a walk around inspection of unit and functioning properly. NEVER modify or remove
work area to understand: safety devices.
• Work area • Your unit • All operational decals. Never carry passengers. Use only attachments
Inspect unit before each use for: missing or and accessories designed for your unit.
damaged decals and shields. Replace or repair as
needed. Know the weight of loads. Do not exceed
maximum capacity of unit.
Keep children out of work area and under
watchful care of a responsible adult. Use caution when backing up. ALWAYS back up
slowly. Always look down and behind before
Check for weak spots on docks, ramps or floors. and while backing. Check all hardware at regular
Avoid uneven work areas and rough terrain. Stay intervals. Keep all nuts, bolts, and wheel nuts
alert for hidden hazards or traffic. properly tightened.

4
Disengage unit drive by releasing clutch lever exhaust system is equipped with a spark arrester
before changing gears. meeting applicable local, state or federal laws.
Never leave a running unit unattended. ALWAYS A spark arrester, if used, must be maintained in
shut off engine before leaving unit. This product effective working order.
is equipped with an internal combustion
type engine. DO NOT use unit on or near any Fumes from engine exhaust can cause injury
unimproved, forest-covered or brush covered land, or death. Ensure proper ventilation. Do not run
dirt, grease, oil of other flammable material, unless engine in a confined area.

CONTROLS AND FEATURES

1. Parking Brake Lever 7. Recoil Starter Handle

2. Throttle Lever 8. Fuel Tank/Cap

3. Gear Selection Lever 9. Air Cleaner

4. Clutch Lever 10. Fuel Shut-off Valve

5. Skip 11. Silencer

6. Oil Level Dipstick/Fill

5
 OPERATION
CONTROLS AND FEATURES Clutch Lever
See CONTROLS AND FEATURES on page 5. (Figure 6)
With a forward or reverse gear selected, gently
Throttle Lever engage (squeeze) the clutch lever to move the
(Figure 4) unit forward or backward. Release the clutch lever
The throttle lever controls to stop motion.
the choke position and the
engine speed. To choke the
engine for startup adjust to:
1. CHOKE (startup)
To increase or decrease the
engine speed, adjust to:
2. FAST
3. Part-Throttle
4. SLOW To stop the engine,
adjust to
5. STOP (engine is off )

Parking Brake Lever

(Figure 5)
Engage the parking brake by releasing the
lever when not traveling with the unit or while
emptying the skip. The parking brake lever must
be disengaged (pressed down against handlebar)
any time that the unit is in motion.
Gear Selection Lever
CAUTION: Avoid damage. Unit has The gear selection lever controls forward and
sufficient power to overpower the reverse motion of the unit and adjusts the
parking brake. Not releasing parking forward travel speed. Select the desired gear
brake while traveling will lead to based on travel conditions.
overheating and premature wear of
the parking brake.

6
PRE-START NOTE: DO NOT add oil to fuel. DO NOT use
gasohol or gasoline containing alcohol. See
WARNING: AVOID INJURY. Read and Engine Manual for correct type and grade of fuel.
understand the entire Safety section 6. Fill fuel tank to within 1/2 in. (1.2 cm) of
before proceeding. bottom of filler neck with unleaded fuel.
7. Replace fuel cap and tighten.
8. ALWAYS clean up any spilled fuel.
Park unit on level surface. Check and add fuel
if required. Check that the engine crankcase oil STARTING UNIT
is full using dipstick. Refer to Engine Manual for NOTE: A warm engine requires less choking than
detailed instructions. a cold engine.
1. Move the throttle lever into the choke
Fuel Shut-Off Valve position by moving it fully forward.
(Figure 5) 2. Grasp recoil starter handle and pull rope
NOTE: Close the fuel shut-off valve before out slowly until it engages.
transporting the unit. 3. Pull rope with a rapid continuous full arm
The fuel shut-off valve has two positions: stroke. Let rope rewind slowly.
• Closed Position – Use this position to
service, transport, or store the unit. NOTE: DO NOT let starter handle snap back
• Open Position – Use this position to operate against engine.
the unit. 4. Repeat steps 2 and 3 until engine starts.
5. Move throttle lever to the rear to disengage
the choke and set engine speed to idle.
6. Allow engine to warm.
7. Set throttle to desired position based on
travel conditions and gear selected.

OPERATION
To Move Forward
1. Select desired speed with gear selection
lever.
2. Press parking brake lever down to
handlebar.
3. Gently engage clutch lever.
To Move In Reverse
1. Stop forward travel of unit.
2. Move gear selection lever to reverse
position.
3. Press parking brake lever down to
Adding Fuel handlebar.
1. ALWAYS place unit in open or 4. Check behind for obstacles and ensure that
well-ventilated area. travel path is clear.
2. Stop engine and allow to cool. 5. Gently engage clutch lever.
3. Remove accessory or tilt forward to gain To Stop Unit
access to fuel tank. 1. Release clutch lever.
4. Clean fuel cap and surrounding area to 2. Release parking brake lever.
prevent dirt from entering fuel tank. 3. Reduce engine speed with the throttle
5. Remove cap. control lever.
7
 To Empty Skip To Reset Skip

1. Stop unit and release parking brake lever. 1. Pull back the skip lift Hydraulic Lever.
2. Push the skip lift Hydraulic Lever forward.

MAINTENANCE

MAINTENANCE CHECK LIST

Perform routine checks as outlined below. Correct CAUTION: Avoid injury! Explosive
any problems before using unit. separation of tyre and rim parts is
possible when they are serviced
incorrectly:
Component Daily Weekly
• Do not attempt to mount a tyre
Hydraulic Oil Level 8
without the proper equipment and
Drive Belt Tension 8 experience to perform the job.
Parking Brake Adjustment 8 • Do not inflate the tyres above the
Control Cable Condition & recommended pressure.
Adjustment 8 • Do not weld or heat a wheel
Air Cleaner 8 and tyre assembly. Heat can cause
an increase in air pressure resulting
Engine Oil Level * 8
in an explosion. Welding can
Tyre Pressures 8 structurally weaken or deform
Attaching Hardware 8 the wheel.
• Do not stand in front of, or over the
*SAE 10W-30 oil is recommended for general use. tyre assembly when inflating.
Refer to engine manual for engine maintenance
procedures.

Tyre Pressure
• Check tyre air pressures regularly.
Recommended inflation pressure is 2.8
bar (30 psi) for all tyres.

8
 SERVICE AND ADJUSTMENTS
LEVER ADJUSTMENTS
(Figure 10)
Primary clutch cable adjustment is made at the
lever. To adjust:

1. Loosen lock nut (item 1).

2. Adjust cable by rotating adjustment nut
(item 2). Moving adjustment nut
away from the lever will result in earlier
engagement.
3. Tighten lock nut.

Parking Brake Disc

(Figure 12)
If the cable adjustments do not allow parking
brake to fully engage, tighten the lever
attachment nut on the transmission.

SERVICE POSITION
(Figure 13)
ADDITIONAL ADJUSTMENTS To access the drive belt
(Figure 11) and cable attachment
If the clutch cable adjustment at the lever is points place the unit in
insufficient, additional adjustment can be made the service position by
to the cable under the unit: tipping it on its front
wheels and front skip
1. Place unit in service position (See Service
edge.
Position in this section).
Be sure to move the
2. Loosen lock nuts on the cable. fuel shut-off valve to
3. Adjust cable to desire position. the closed position
4. Tighten lock nuts. before placing in service
position (see Fuel
Shut-Off Valve on page 7).

9
 DRIVE BELT REPLACEMENT
(Figure 14)

Removal

1. Remove two M8 hex bolts retaining bottom

panel at front of unit.

2. Place unit in service position (see SERVICE

POSITION above).

3. Remove remaining four M8 hex bolts

retaining the bottom panel and remove
the panel.

4. Loosen the hex nut retaining the belt guide

tube (item 1) enough to allow belt to be
removed from transmission pulley
(item 2).

5. Remove the belt guide bolt (item 7) from

the idler arm (item 4).

6. Remove the belt from the unit.

Installation

1. Install replacement belt on transmission

pulley (item 2).

2. Tighten belt guide tube (item 1).

3. Route belt to right side of idler pulley

(item 3). Outer flat portion of belt will
contact pulley.

4. Install idler belt guide bolt (item 7).

5. Route belt through opening in reinforcing

plate (item 6) and onto engine pulley
(item 8).

6. Adjust clutch as needed. See LEVER

ADJUSTMENTS on page 9.

7. Install bottom panel.

10
NOTES

11
 PARTS LIST

COWLING, CONTROLS & SKIP

12
COWLING, CONTROLS & SKIP (CONT’D)

Item Part No. Qty. Description

1 18 Hex head setscrew M8 x 20
2 64 Washer, M8 form A.
3 40 Nut M8 Nyloc type P
4 2 Cable Tie 3.6mm x 140
5 MT 15040 1 Cowling Side Left Hand
6 MT 03965 1 Tube, Handle – Left Hand
7 MT 03943 1 Cable, Clutch Control
8 DP0502015 1 Lever, Clutch
9 MT 03943 1 Cable, Brake
10 DP03 2 Grip, Handle 22 mm x 135 mm
11 DP0502016 1 Lever, Brake Control - Red
12 3 Nut M6 Nyloc type P
13 MT 03991 1 Control, Throttle
14 1 Valve Assy
15 Dipstick filler cap
16 2 Washer, M6 form A
17 1 Bolt Hex, M6 x 65 long
18 MT 03966 1 Tube, Handle – Right Hand
19 MT 15041 1 Cowling Side Right Hand
20 4 Bolt, Hex M8 x 50 long
21 MT 15043 1 Cowling Top / Oil Tank
22 2 Coach Bolt M6 x 20 long
23 MT 15049 1 Gear Change Lever
24 DT107 1 Grip, Gear Lever
25 1 Bearing, Flange 008 1603000 02
26 MT 03963 1 Gear Lever Guide Plate
27 MT 15066 1 Skip
28 2 Decal, Skip – H-MAX
29 MT 04016 4 Decal, Maximum Skip Load Capacity
30 MT 04017 1 Decal, Maintenance
31 MT 15074 1 Decal, Operation
32 MT 04018 2 Decal, Muck-Truck

13
 TRANSMISSION AND BELT DRIVE

14
TRANSMISSION AND BELT DRIVE (CONT’D)

Item Part No. Qty. Description

1 1 Bolt, Hex head M12 x 75 long
2 18 Hex head setscrew M8 x 20 long
3 40 Nut M8 Nyloc type P
4 64 Washer, M8 form A
5 8 Bolt, M8 x 65 long
6 MT 03962 1 Gear Change Linkage (Includes items 37, 38 and 39)
7 1 Bolt. M10 x 45 long
8 2 Washer, M10 form A
9 MT 15045 1 Cylinder Mounting Pin
10 6 Washer, M12 form A
11 1 Coach Bolt M12 x 60 long
12 MT 03021 1 Tube, Belt Guide
13 3 Nut, M8 Full
14 5 Hex head setscrew, M8 x 35 long
15 4 Nut M12 Nyloc type P
16 1 Nut M10 Nyloc type P
17 MT 15039 1 Clutch Lever
18 MT 03953 1 Clutch Pulley
19 1 Bolt M8 x 60 long
20 3 Hex head setscrew, 5/16” UNC x ¾” long
21 MT 03942 1 Pulley, Transmission
22 1 Key, Woodruff ¾” x 3/16”
23 DP18 2 Spring
24 MT 03945 1 Brake Arm Link
25 DP21 1 Transmission, Peerless
26 2 Setscrew, Hex head/flanged Self-Tapping
M8 x 20 long
27 MT03020 2 Torque Stay
28 2 Nut M8 Nyloc type P
29 MT 03973 1 Plate, Shifter
30 1 Washer, M6 form C
31 1 Washer M6 Spring Lock
32 1 Hex head setscrew ¼” UNF x ¾” long
33 DP0502018 1 Belt, 51”
34 1 Key, Woodruff 3/32” x 5/8”
35 MT 03001 1 Pulley. Engine
36 MT 15046 1 Cylinder Mounting Assembly
37 2 Ball Joint M8. Part of item 6
38 2 Nut, M8 full Part of item 6
39 1 Rod, Gear Linkage Part of item 6
40 MT 15038 1 Clutch Arm Link
41 MT 03942 1 Spacer, Clutch Pivot
42 1 Pulley - Hydraulic Pump
43 1 Belt 27”
44 1 Belt Tensioner Pulley
15
 MAINFRAME & DRIVETRAIN

16
MAINFRAME & DRIVETRAIN (CONT’D)

Item Part No. Qty. Description

1 MT 15055 1 Mainframe
2 4 Hex Head setscrew 5/16” UNF x 1” long
3 2 Key, Square 3/16” x 55mm long
4 DP 05041 2 Front Hub
5 MT 15036 1 Bottom Plate
6 64 Washer, M8 form A
7 40 Nut M8 Nyloc type P
8 2 E-Ring .750” x .050”. N1500 Code 0075
9 DP80 2 Cap, Vinyl 1.25 x 1.625
10 5 Bolt, M8 x 40 long
11 16 Wheel nut M10 x 1.25 Pitch
12 DP83 2 Starcap 19mm
13 2 Coach Bolt M12 x 130 long
14 MT 03019 2 Power Drive Bracket
15 4 Nut M12 Nyloc type P
16 DP45 2 Wheel Assembly, Power Drive (4”)
17 6 Washer, M12 form A
18 MT 15065 1 Pump Mounting Plate
19 1 Hydraulic Pump
20 MT 16028 1 Lift Cylinder
21 18 Hex head setscrew M8 x 20 long
22 1 Engine, Honda GXV160
23 DP31 1 Pin, Lynch
24 DP24 RH 2 Wheel Assembly, Right Hand
25 MT 15063 1 Piston Rod Pin
26 DP24 LH 2 Wheel Assembly, Left Hand
27 MT 04018 2 Decal, Muck Truck Logo
28 2 Chrome plated wheel cap
29 2 Circlip EXT0250
30 MT 03980 2 Hub Assembly, Rear Wheel
31 2 Bearing, Ball 25 mm x 52 mm 6205 2RS
32 4 Wheel stud M10 x 1.25 pitch x 35 long
33 1 Hydraulic Pump Pulley

17
 WARRANTY
Serial Number:

Warranty is 12 calendar months from date of sale for Consumers and 90 days for units used in the
Commercial Sector. Under the following conditions:
• Routine maintenance completed in accordance with Owners Manual.
• Returned defective parts are approved by Muck Truck UK Ltd.
• Machine is not abused or operated with known faults or lack of maintenance.
• Repairs are in accordance with Muck Truck UK Ltd.

AT AN AGREED JOB RATE

Only defective parts are covered, and not wearable components that require replacement because of
normal wear; for example puncture, chipped paint, dented skip etc. Muck Truck UK Ltd will not be held
liable for any consequential losses.

PERSONAL CUSTOMER GUARANTEE STATEMENT

If there is any component, or components, manufactured by Muck Truck UK Ltd. that are found to be
defective within 12 months from the date of purchase (or 90 days in the case of a machine used for
hire/commercial purposes), Muck Truck UK Ltd. will replace the faulty component(s) free of charge,
provided they are notified immediately upon date of failure.

THE FOLLOWING ARE NOT COVERED BY THIS GUARANTEE

1. Engines – Engines are guaranteed by their respective manufacturers.
2. A machine which has been subject to operation in excess of recommended capacities, misuse,
negligence or accident, or has been altered or modified in a manner which has not been
authorized by Muck Truck UK Ltd.
3. Wear parts – belts, cables etc.
4. Transportation Charge – to and from the warranty repair site.

Muck Truck UK Ltd operates a policy of continual development and reserves the right to alter
product specifications without giving prior notice

18
NOTES