JET PT-2036JA, PT-2042J, PT-2048J, PT-2742J, PT-2748J Operating Instructions and Parts Manual

Operating Instructions and Parts Manual

“PTJ” Series Pallet Trucks

WALTER M EIE R (Manufa c turing) Inc.

1.0 Warranty and Service

Walter Meier (Manufacturing) Inc., warrants every product it sells. If one of our tools needs service or repair, one of our Authorized Service Centers located throughout the United States can give you quick service. In most cases, any of these Walter Meier Authorized Service Centers can authorize warranty repair, assist you in obtaining parts, or perform routine maintenance and major repair on your JET® tools. For the name of an Authorized Service Center in your area call 1-800-274-6848.

MORE INFORMATION

Walter Meier is consistently adding new products to the line. For complete, up-to-date product information, check with your local Walter Meier distributor, or visit waltermeier.com.

WARRANTY

JET products carry a limited warranty which varies in duration based upon the product (MW = Metalworking, WW = Woodworking).

WHAT IS COVERED?

This warranty covers any defects in workmanship or materials subject to the exceptions stated below. Cutting tools, abrasives and other consumables are excluded from warranty coverage.

WHO IS COVERED?

This warranty covers only the initial purchaser of the product.

WHAT IS THE PERIOD OF COVERAGE?

The general JET warranty lasts for the time period specified in the product literature of each product.

WHAT IS NOT COVERED?

Five Year Warranties do not cover woodworking (WW) products used for commercial, industrial or educational purposes. Woodworking products with Five Year Warranties that are used for commercial, industrial or education purposes revert to a One Year Warranty. This warranty does not cover defects due directly or indirectly to misuse, abuse, negligence or accidents, normal wear-and-tear, improper repair or alterations, or lack of maintenance.

HOW TO GET SERVICE

The product or part must be returned for examination, postage prepaid, to a location designated by us. For the name of the location nearest you, please call 1-800-274-6848. You must provide proof of initial purchase date and an explanation of the complaint must accompany the merchandise. If our inspection discloses a defect, we will repair or replace the product, or refund the purchase price, at our option. We will return the repaired product or replacement at our expense unless it is determined by us that there is no defect, or that the defect resulted from causes not within the scope of our warranty in which case we will, at your direction, dispose of or return the product. In the event you choose to have the product returned, you will be responsible for the shipping and handling costs of the return.

HOW STATE LAW APPLIES

This warranty gives you specific legal rights; you may also have other rights which vary from state to state.

LIMITATIONS ON THIS WARRANTY

WALTER MEIER (MANUFACTURING) INC., LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. WALTER MEIER SHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL, CONTINGENT, SPECI AL, OR CONSEQUENTIAL DAMAGES ARI SING FROM THE USE OF OUR PRODUCTS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. Walter Meier sells through distributors only. The specifications in Walter Meier catalogs are given as general information and are not binding. Members of Walter Meier reserve the right to effect at any time, without prior notice, those alterations to parts, fittings, and accessory equipment which they may deem necessary for any reason whatsoever. JET® branded produc ts are not sold in Canada by Walter Meier.

2.0 Table of contents

Section Page

1.0 Warranty and Service ....................................................................................................................... 2

2.0 Table of contents .............................................................................................................................. 3

3.0 Safety warnings ................................................................................................................................ 3

4.0 Introduction ....................................................................................................................................... 4

5.0 Specifications ................................................................................................................................... 4

6.0 Setup and assembl y ......................................................................................................................... 5

7.0 Operations ........................................................................................................................................ 5

7.1 Lifting Load ................................................................................................................................ 6

7.2 Moving Load ................................................................................................................................. 6

7.3 Lowering Load............................................................................................................................... 6

7.4 Up-Down Cam Adjustment ............................................................................................................ 6

8.0 Maintenance ..................................................................................................................................... 6

8.1 Cleaning Release Valve ................................................................................................................ 6

8.2 Lubricati on .................................................................................................................................... 6

8.3 Piston Seal/O - Ring Replacement .................................................................................................. 7

9.0 Troubleshooting the PTJ Series Pallet Trucks ................................................................................... 8

10.0 Replacement Parts ......................................................................................................................... 8

10.1.1 PTJ-Series Pallet Trucks – Exploded View ............................................................................... 9

10.1.2 PTJ-Series Pallet Trucks – Parts List ...................................................................................... 10

5. Do not place hands or f eet under the pallet truck at any tim e.

3.0 Safety warnings

1. Read and understand the entire owner's manual before attempting assembly or operation of the pallet truck.

2. Read and understand the warnings on the pallet truck and in this manual. Failure to comply wit h all of these warnings may cause serious injury.

3. Replace the warning labels if they become obscured or removed.

4. Do not use this pall et truck for other than it s intended use. If used for other purposes, Walter Meier (Manuf acturing) Inc., discl aims any real or im plied warranty and holds it self harmless from any injury that may result from that use.

6. Do not operate a loaded pallet truck on ramps or incli nes.

7. Do not tip load pallet truck forks. This may cause damage to the forks and personal injury if the rear of the pallet tr uck suddenly pops up.

8. Never leave a loaded pallet truck unattended in the raised position. Always lower load to the floor.

9. Do not load pallet truck beyond its rated capacity of 5,000 l bs.

10. S ec ur e load before transporti ng.

11. To prevent accidental tipping, make sure load is centered on the f or k s.

12. Do not mov e a loaded pallet truck by other than manual force.

4.0 Introduction

Congratulations on your purchase of a JET Pallet Tr uck. To better underst and the proper use and saf e operati on of this pallet tr uck, please take a few minut es to

carefully read and follow the instructions contained in this manual. When finished reading and understanding the manual, pl ease file i n a safe and conv enient locati on for the lif e of the pall et truck. If the pallet truck transfers ownership, the manual should accompany it.

This pallet truc k i s designed to push and pull palletized m aterial loads up to 5,000 pounds only. You will notice several important features about your JET Pallet T ruck. For example, its 2-1/2” lowered

height and tapered f ork tips allow easy entry into pall ets. The heavy-gauge steel frame is rei nforced wit h cross-welded steel pl ates to prevent fork s from bending and solid steel pu sh rods are used for added strength. The pum p features top-of-the- stroke and ov erload by-pass valv e systems. A dur able powder coat finish provi des long l asti ng steel prot ecti on. Ext ra wide polyur ethane cov er ed steel steer wheels and nylon load wheels feat ure lifetim e lubricated, double seal ed bearings to provi de smooth, quiet rolli ng and added stability.

If there are questions or c omments, please contact your local suppli er or Walter Meier. Walt er Meier can also be reached at our web site: www.walt er meier.com.

5.0 Specifications

Net

Model # Stock # W1 W2 L1 L2 H1 H2 A (dxw) B (dxw) C

PT-1636J 151003 16” 6” 36” 51” 6-1/4” 2-1/2” 6-1/4”x2-3/4” 2-1/2”x3-3/4” 45-1/8” 135

Wt.

(lb.)

PT-2036J 151004 20-1/2” 6” 36” 51” 6-1/4” 2-1/2” 6-1/4”x2-3/4” 2-1/2”x3-3/4” 45-1/8” 150 PT-2042J 151005 20-1/2” 6” 42” 57” 6-1/4” 2-1/2” 6-1/4”x2-3/4” 2-1/2”x3-3/4” 45-1/8” 161 PT-2048J 151006 20-1/2” 6” 48” 63” 6-1/4” 2-1/2” 6-1/4”x2-3/4” 2-1/2”x3-3/4” 45-1/8” 172 PT-2742J 151008 27” 6” 42” 57” 6-1/4” 2-1/2” 6-1/4”x2-3/4” 2-1/2”x3-3/4” 45-1/8” 185 PT-2748J 151009 27” 6” 48” 63” 6-1/4” 2-1/2” 6-1/4”x2-3/4” 2-1/2”x3-3/4” 45-1/8” 196

Figure 1

The specifications in this manual were current at time of publication, but because of our policy of continuous improvement, Walter Meier (Manufacturing) Inc., reserves the right to change specifications at any time and without prior notice, without incurring obligations.

6.0 Setup and assembly

Note: Individual trucks are assembled and ready to use. Pallet trucks purchased in crate quantities (6 units to a crate) require some assembly. Match the “number” label on the handle to the “num ber” label on the f rame, prior to assembly. Proc eed with instructions below.

If you received an individual truck, proceed to section 7.0 – Operat ions .

Tools Needed for Assembly

• Hammer

• Flat Head Screwdriver

• Pliers or 17mm Wr enc h

4. Insert handle pins (E, Figure 3) into the holes of the pump brac k et and handle. Align the spring pin holes (F, Figure 3) in the handle pin and the pump brac k et.

5. Tap the handle pins into place with a hammer.

Figure 3

6. Using a hammer, tap the spring pins (A, Figure 4) into the pum p bracket and handle pins.

Figure 1

1. Insert the base of the handle (A, Figure 2) into the pump brack et (B, Figure 2).

2. Align the holes (C, Fi gure 2) at the base of the handle with the holes in the pump bracket.

3. Using a screwdriver, pry the cam (D, Figure

2) up and slip the bol t head under the not ch in the cam. Do not adjust the nut.

Note: If the holes aren’t lined up, use a 17mm wrench or pli er s to turn the handle pin until the spring pi n holes li ne up.

7. Repeat for the opposite side handle pin.

8. Pull handle down and remove retaining tube (B, Figure 4) by pul ling str aight out. Di scard retaining tube.

Figure 4

Figure 2

Note: If the pallet truck does not raise or lower properly, y ou may hav e air bubbl es in the pum p from shipping. Refer to section 8.1 – Cleaning

Release Valve.

7.0 Operations

To raise forks, pl ace handle in the UP position (bottom part of the handle slot), See Figure 5.

To lower forks, pull lever handle to DOWN position (upper par t of slot).

To freely move the handle, set lever in Neutral (center notch of sl ot ).

Figure 6

Figure 5

7.1 Lifting Load

1. Lower forks to lowest position, Figure 5.

2. Insert forks under load, or into pallet.

3. Place lever in UP position (bottom part of slot), Figure 5.

4. Move handle up and down until f orks reach desired height.

7.2 Moving Load

1. Place lever in NEUTRAL position (center notch of slot), Figur e 5.

2. Pull or push pallet truck to desired loc ation.

7.3 Lowering Load

1. Pull lever to DOWN position (upper part of slot), Figure 5.

2. Pull forks away from load.

7.4 Up-Down Cam Adjustment

8.0 Maintenance

8.1 Cleaning Release Valve

Over time, the hydraulic pump assembly may become cl ogged with debris or ai r bubbles, and not function properly.

To clean the release v alv e and bleed the pump:

1. Pump handle qui ckly, raising pall et truck to full extent. While c onti nuing pumping action, pull lever to down position.

2. W hen forks reach total down position, v alve is flushed. Repeat if necessary.

8.2 Lubrication

Check oil level annually by removing oil plug found on top of pump housing. When changing or adding oil, fill the tank through the oil plug screw hole to 80% capacity with hydraul ic jack oil, about 2” deep in pum p housing, see Figure

7. Do not use any other ty pe of oil.

1. Set lever in NEUTRAL position, Figure 5.

2. Turn cam nut while pumping the handle, Figure 6.

3. When lifting stops, give the nut one more turn.

4. The cam nut is properly adjusted when pumping the handle in NEUTRAL position causes no movement of the hydraulic ram.

Figure 7

There is one grease fitting (#55B, section

10.1.1) loc ated on the table. Lubricate t his point

on a semi-annual basis. Wheel bearings are sealed and require no

lubrication. The crank shaft features Oil Lite bushings which al so require no lubrication.

Lightly oil all other m ov ing par ts.

8.3 Piston Seal/O-Ring Replacement

Figure 8

1. Rai se pal let truck by pumping handle.

2. Remove screws #70, sect. 10.1.1. This will free the pump and handle assembly from the pallet truck .

3. Empty the oil into a suitable container. Pump handle until all oil has drained. Dispose of used hydraulic oil or fluid according to loc al r egulations.

4. Pull out piston plunger #33, and/or ram piston #25.

5. Remove all o-rings and seals (see Fi gur e 8) .

6. Insert new o-ring or seal one at a time making sure to replace with the same size that was remov ed.

7. Reassemble and fill oil tank through the oil plug screw hole to 80% capacity with new hydraulic jack oil, about 2” deep in pump housing, see Figure 7.

9.0 Troubles hooti ng the PTJ Series Pallet Trucks

Index number s ref er to parts breakdown, section 10.0.

Symptom Possible Cause Correction

Hydraulic unit does not lift.

Once lifted, truck lowers by itself .

Fork does not lower. Cam #53 broken. Replace cam #53.

Lever does not set at NEUTRAL position.

Oil low in tank. Make sure there is no oil leakage from

Release Plug #36, and add oil.

Air in pump. Place lever in down position and pump

handle repeatedl y .

Worn O-ring in cylinder. Consult authori z ed service center. Steel ball not seated in hydraulic

unit. Worn O-ring in cylinder. Consult authori z ed service center.

Release valv e not seated proper ly.

Oil leakage from Release Plug #36.

Up-down cam nut #15 out of adjustment.

Broken fork rods and linkage. Consult authorized service center, or

Up-down cam nut #15 out of adjustment.

Refer to section 8.1 Cleaning Release Valve.

Tighten Release Plug #36. Replace Orings on Release Plug #36. If leakage still occurs, consult authorized service center.

Refer to section 7.4 Up Adjustment.

replace broken par t s. Refer to section 7.4 Up

Adjustment.

Down Cam

10.0 Replacement Parts

Replacement par ts are li sted on the f ollowing page s. To order par ts or reach our serv i ce departm ent, call 1-800-274-6848 Monday through Friday (see our website for business hours, www.waltermeier.com). Having the Model Number and Serial Number of your mac hine available when you call will allow us to serve you quickly and accurately.

10.1.1 PTJ-Series Pallet Trucks – Exploded View

10.1.2 PTJ-Series Pallet Trucks – Parts List

Index No Part No Description Size Qty

1 ............... PT2748A-001A ........Handle................................................................................................... 1

2 ............... PT2748A-002A ........Handle Cap ........................................................................................... 1

3 ............... PT2748A-003A ........Lever ..................................................................................................... 1

4 ............... PT2748A-004 ...........Spring Pin...........................................................5x16mm ..................... 1

5 ............... PT2748A-005 ...........Bolt.....................................................................M8x20 ........................ 1

7 ............... PT2748A-007 ...........Spring Pin...........................................................3x28mm ..................... 1

8 ............... PT2748A-008 ...........Oil Lite Bushing ..................................................................................... 1

9 ............... PT2748A-009 ...........Roller .................................................................................................... 1

10 ............. PT2748A-010 ...........Roller Pin .............................................................................................. 1

11 ............. PT2748A-011 ...........Release Rod ......................................................................................... 1

13 ............. PT2748A-013 ...........Ch a in .................................................................................................... 1

14 ............. PT2748A-014 ...........Anchor Bolt ............................................................................................ 1

15 ............. PT2748A-015 ...........V-Nut ..................................................................M8 .............................. 1

16 ............. PT2748J-101B .........Dust Seal * ............................................................................................ 1

17 ............. PT2748J-101B .........O-Ring * .............................................................29.8x3.5mm ............... 1

18 ............. PT2748J-101B .........U-Packing * ........................................................30x38x6mm ................ 1

19 ............. PT2748J-101B .........O-Ring * .............................................................4.8x1.9mm ................. 2

20 ............. PT2748J-101B .........Dust Seal * ............................................................................................ 1

21 ............. PT2748J-101B .........U-Packing * ........................................................18x26x5 ..................... 1

23 ............. PT2748J-101B .........O-Ring * .............................................................6x1.9mm .................... 1

24 ............. SB-14MM .................Steel Ball ............................................................14mm ......................... 1

25 ............. PT2748J-025 ...........Ram Piston ............................................................................................ 1

26 ............. PT2748A-026 ...........Oil Plug ................................................................................................. 1

28 ............. PT2748J-101B .........O-Ring * .............................................................11.6x2.4mm ............... 1

29 ............. PT2748A-029 ...........Release Screw ...................................................................................... 1

30 ............. PT2748A-030 ...........Spring.................................................................10x2.3x27mm ............. 1

30A .......... PT2748A-30A

31 ............. SB-6MM...................Steel Ball ............................................................6mm ........................... 1

32 ............. PT2748A-032 ...........E-Ring ................................................................15mm ......................... 1

33 ............. PT2748L-033 ...........Plunger Piston ....................................................................................... 1

34 ............. PT2748A-034 ...........Spring Cap ............................................................................................ 1

35 ............. PT2748A-035A ........Spring.................................................................38x5x121mm .............. 1

36 ............. PT2748A-036 ...........Release Plug ......................................................................................... 2

37 ............. PT2748A-037 ...........Washer...............................................................20mm ......................... 1

38 ............. PT2748A-038 ...........Spring.................................................................8x1.5x12.8mm ............ 1

38A .......... PT2748A-038A ........Spring.................................................................4.8x0.7x15mm ............ 1

39 ............. PT2748A-039 ...........Valve Housing ....................................................................................... 1

40 ............. SB-6MM...................Steel Ball ............................................................6mm ........................... 2

40A .......... SB-9MM...................Steel Ball ............................................................9mm ........................... 1

41 ............. PT2748A-041 ...........Spring Pin...........................................................3x28mm ..................... 2

42 ............. PT2748A-042 ...........Spring Pin...........................................................8x25mm ..................... 1

43 ............. PT2748A-043 ...........Snap Ring ..........................................................44mm ......................... 1

44 ............. PT2748A-044 ...........Spring Pin...........................................................8x45mm ..................... 1

46 ............. PT2748A-046A ........Wheel Sha ft (all models except PT-1636J)............................................. 1

................. PT1636J-046A .........Whee l Sh aft (PT-1636J only) ................................................................. 1

47 ............. PT2748J-109A .........Pump Housing Assembly (all models) .................................................... 1

48 ............. PT2748A-048 ...........Handle Pin............................................................................................. 2

49 ............. PT2748A-049 ...........Bearing Base ......................................................................................... 1

50 ............. BB-51109 .................Ball Bearing ........................................................51109 ......................... 1

51 ............. PT2748A-051 ...........Spring.................................................................6.3x1.2x25mm ............ 1

52 ............. PT2748A-052 ...........Release Nozzle ..................................................................................... 1

53 ............. PT2748A-053A ........Ca m ...................................................................................................... 1

* Available only in the repair kit – PT2748J-101B

..........Valve ..................................................................................................... 1

Index No Part No Description Size Qty

54 ............. PT1636J-054 ...........Spring Pin...........................................................6x30mm ..................... 2

55 ............. PT2748A-055A ........Table (all models except PT-1636J) ....................................................... 1

................. PT1636J-055A .........Table (PT-1636J only) .......................................................................... 1

55B .......... PT2748A-055B ........Grease Fitting ........................................................................................ 1

56 ............. PT2748A-056 ...........Snap Ring ..........................................................25mm ......................... 2

57 ............. PT2748A-057 ...........Snap Ring ..........................................................20mm ......................... 2

60 ............. PT2748L-103A .........Steer Wheel Assembly W/Bear ings ........................................................ 2

60A .......... BB-6205VV ..............Steer Wheel Ball Bearing ....................................6205VV ...................... 2

60B .......... BB-6304VV ..............Steer Wheel Ball Bearing ....................................6304VV ...................... 2

61 ............. PTX2748-056 ...........Dust Seal Cap ....................................................................................... 2

62 ............. TS-1550111 .............Washer...............................................................20mm ......................... 2

67 ............. ................................Fork Frame (N/A)................................................................................... 1

69 ............. TS-1551061 .............Lock Was h e r ......................................................8mm ........................... 2

70 ............. TS-1504031 .............Socket Head Cap Screw .....................................M8x14 ........................ 2

71 ............. PT2748A-071 ...........Crank Shaft (PT-2742J / PT-2748J) ....................................................... 1

................. PT2048A-071 ...........Crank Shaft (PT-2036J / PT-2042J / PT-2048J) ..................................... 1

................. PT1636J-071 ...........Crank Shaft (PT-1636J Only) ................................................................. 1

74 ............. PT2748A-074 ...........Table Pin ............................................................................................... 2

75 ............. PT2748A-075 ...........Oil Lite Bushing ..................................................................................... 2

76 ............. PT2748J-076A .........Lifting Yoke (PT-2742J / PT-2748J) ....................................................... 1

................. PT2048J-076A .........Lifting Yoke (PT-2036J / PT-2042J / PT- 2048J ) ..................................... 1

................. PT1636J-076A .........Lifting Yoke (PT-1636J Only) ................................................................. 1

77 ............. PT2748J-077 ...........Spring Pin...........................................................6x35mm ..................... 1

78 ............. PT2748J-078A

79 ............. PT2748J-079 ...........Spring Pin...........................................................5x25mm ..................... 2

80 ............. PT2748J-080BN ......Black Nylon Load Wheel W/Bearings ..................................................... 2

80A .......... BB-6004VV ..............Load Wheel Bearing ...........................................6004 ........................... 4

81 ............. PT2748J-079 ...........Spring Pin...........................................................5x25mm ..................... 2

81A .......... PT2748J-081A .........Snap-Ring ..........................................................20mm ......................... 4

82 ............. PT2748J-082 ...........Load Wheel Axle ................................................................................... 2

83 ............. PT2748J-083A .........Arm ....................................................................................................... 2

86 ............. PT2748J-086A .........Rod Pin ..............................................................16x96mm ................... 2

88 ............. PT2736J-088A .........Rod (PT-1636J / PT-2036J) ................................................................... 2

................. PT2742J-088A .........Rod (PT-2042J / PT-2742J) ................................................................... 2

................. PT2748J-088A .........Rod (PT-2048J / PT-2748J) ................................................................... 2

89 ............. PT2748A-089A ........E-Ring ................................................................19mm ......................... 2

99 ............. PT2748A-099A ........Release Rod Assembly (index #11,13-15) ............................................. 1

................. PT2748J-101B .........Repair Ki t (index # 16-23, 28) ................................................................ 1

................. PT2748J-109A .........Pump Assembly (all models except PT-1636J) ...................................... 1

................. PT1636J-109A .........Pump Assembly (PT-1636J only) ........................................................... 1

................. PT2748J-110A .........Pump, Handle, Wheel Assembly (all models ex c ept PT-1636J) .............. 1

................. PT1636J-110A .........Pump, Handle, Wheel Assembly (PT-1636J Only) ................................. 1

................. PT1636J-ID-A ..........I.D. Label (not shown)............................................................................ 1

................. PT2036J-ID-A ..........I.D. Label (not shown)............................................................................ 1

................. PT

................. PT2048J-ID-A ..........I.D. Label (not shown)............................................................................ 1

................. PT2742J-ID-A ..........I.D. Label (not shown)............................................................................ 1

................. PT2748J-ID-A ..........I.D. Label (not shown)............................................................................ 1

................. PT2748J-JET ...........JET Logo Label (not shown) .................................................................. 2

................. PT2748J-WL ............Warning Label (not shown) .................................................................... 1

................. PT2748J-PL .............Pump Label (not shown) ........................................................................ 1

2042J-ID-A ..........I.D. Label (not shown)............................................................................ 1

.........Arm Pin ..............................................................16x145 mm ................. 2

WALTER M EIE R (Manufa c turing) Inc.

427 New Sanford Road

LaVergne, Tennessee 37086

Phone: 800-274-6848 www.waltermeier.com

JET PT-2036JA, PT-2042J, PT-2048J, PT-2742J, PT-2748J Operating Instructions and Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual