Jet Ptj-a series Service manual

Operating Instructions and Parts Manual

PTJ-A Series Pallet Trucks

JET

427 New Sanford Road

LaVergne, Tennessee 37086 Part No. M-161003

Ph.: 800-274-6848 Edition 2 04/2020

1.0 IMPORTANT SAFETY INSTRUCTIONS

WARNING – To reduce risk of injury:

Read and understand the entire owner’s manual before using the pallet truck.

Read and understand all warning and instruction labels on the truck.

Do not place hands or feet under the pallet truck at any time.

Do not operate a loaded pallet truck on ramps or inclines.

Do not tip load pallet truck forks. This may cause damage to the forks and personal injury if the rear of the

pallet truck suddenly “pops up.”

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

Do not load pallet truck beyond its rated capacity.

Secure load before transporting.

To prevent accidental tipping, make sure load is centered on the forks.

Do not move a loaded pallet truck by other than manual force.

Do not transport persons with a pallet truck.

Failure to comply with these warnings may result in personal injury and/or property damage.

Replace warning labels if they become obscured or removed.

2.0 Table of contents

Section Page

1.0 IMPORTANT SAFETY INSTRUCTIONS .......................................................................................................2

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

3.0 Introduction ....................................................................................................................................................3

4.0 Specifications .................................................................................................................................................4

5.0 Assembly (for crate quantity purchases only) ................................................................................................5

6.0 Operation .......................................................................................................................................................6

7.0 Maintenance...................................................................................................................................................6

7.1 Lubrication..................................................................................................................................................6

7.2 Cleaning relief valve ...................................................................................................................................6

7.3 Adjusting relief cam ....................................................................................................................................6

7.4 O-Ring and seal replacements...................................................................................................................6

8.0 Troubleshooting PTJ-A Series Pallet Trucks .................................................................................................8

9.0 Replacement Parts.........................................................................................................................................8

9.1.1 PTJ-A Series Pallet Trucks – Exploded View..........................................................................................9

9.1.2 PTJ-A Series Pallet Trucks – Parts List ................................................................................................10

10.0 Warranty and Service.................................................................................................................................12

3.0 Introduction

Your JET Pallet Truck is designed with most efficient features for warehouse or dock.

The 2.56-inch lowered height, tapered fork tips and wide polyurethane entry/exit rollers combine for easy entry

and exit of pallets. The 180turning radius allows maneuverability in confined spaces. Ball bearings on steer

and load wheels are lifetime lubricated, double-sealed, and promote smooth, quiet travel.

The cast iron pump features top-of-the-stroke and overload by-pass valve systems, and single point valve

service for easy replacement.

The chassis is heavy gauge steel, reinforced with cross-welded plates to prevent forks from bending; solid steel

push rods provide additional strength. Paint finish is powder-coated for superior protection of the underlying

steel.

In summary, your JET Pallet Truck is designed to offer consistent, long-term operation with minimal

maintenance and service attention. If there are questions or comments, please contact your local supplier or

JET. JET can also be reached at our web site: www.jettools.com.

Retain this manual for future reference. If the pallet truck transfers ownership, the manual should accompany it.

If there are questions or comments, please contact your local supplier or JET. JET can also be reached at our

web site: www.jettools.com.

Read and understand the entire contents of this manual before attempting assembly

or operation. Failure to comply may cause serious injury.

http://www.jettools.com/us/en/service-and-support/warranty/registration/

4.0 Specifications

Table 1

Model number PT-1636JA PT-2036JA PT-2042JA PT-2048JA PT-2742JA PT-2748JA

Stock number 161003 161004 161005 161006 161008 161009

Load Capacity 5,500 lbs. (2495 kg.)

Turning Radius 180 deg.

Overall Fork Length L1 36 in. (914mm) 42 in. (1067mm) 48 in. (1219mm) 42 in. (1067mm) 48 in. (1219mm)

Overall Forks Width W1 16 in.

(406mm) 20-1/2 in. (521mm) 27 in. (686mm)

Fork Width W2 6-1/4 in. (159 mm)

Lowered Height H2 2.56 in. (65 mm)

Maximum Height H1 6.69 in. (170 mm)

Number of Strokes to

Reach Maximum

Height

Force Required to

Pump at Maximum

Load

77 lbs. (35 kg)

Steer Wheel Size

(Dia. x W) A 7 x 2 in. (180 x 50.8 mm)

Load Wheel Size

(Dia. x W) B 2-1/2 x 3-11/16 in. (63.5 x 94 mm)

Force Required to

Move Maximum Load 120 lbs. (54.5 kg)

Overall Height C 45-1/8 in. (1146 mm)

Overall Length L2 51 in.

(1295 mm)

57 in.

(1448 mm)

63 in.

(1600 mm)

57 in.

(1448 mm)

63 in.

(1600 mm)

Overall Width W1 16 in.

(406 mm) 20-1/2 in. (521 mm) 27 in. (686 mm)

Net Weight 118 lbs.

(53.5 kg)

127 lbs.

(57.6 kg)

136 lbs.

(62 kg)

138 lbs.

(62.6 kg)

141 lbs.

(64 kg)

147 lbs.

(66.7 kg)

Gross Weight 129 lbs.

(58.5 kg)

138 lbs.

(62.5 kg)

147 lbs.

(66.7 kg)

149 lbs.

(67.6 kg)

152 lbs.

(69 kg)

158 lbs.

(71.7 kg)

Pump Type Integrated

Materials

Pump

Housing Cast Iron

Forks Sheet steel, 11 ga. (3.2 mm)

Chassis Sheet steel, 11 ga. (3.2 mm)

Wheels Polyurethane

Figure 4-1

The specifications in this manual were current at the time this manual was published, but because of our policy of

continuous improvement, JET reserves the right to change specifications at any time and without prior notice, without

incurring obligations.

5.0 Assembly (for crate quantity purchases only)

Note: The following illustrations may not show your exact model.

Individual pallet trucks are assembled and ready to use. Pallet trucks purchased in crate quantities (6 units to a

crate) require some assembly. A hammer and pliers are required. Match the “letter” label on the handle

assembly to the “letter” label on the frame, prior to assembly.

To attach handle assembly to the frame:

1. Align the holes in the handle with the holes in

the pump body. Tap the pivot pin through the

handle and pump bodies.

2. Using pliers, turn the pivot pin until spring pin

holes line up.

3. Using a hammer, tap the spring pin into the

pump body and pivot pin.

4. Lower the handle until the spring cap is

contacted. (This will reduce some of the

pressure on the pump retainer pin, making it

easier to remove.)

5. Tap out the pump retainer pin and discard it.

6. Feed the chain anchor through the hole in the

pivot pin.

7. Position the chain anchor through the fork of

the relief cam, with the lock nut below the fork.

6.0 Operation

To lift a load:

1. Lower forks to lowest position.

2. Insert forks under load or into pallet.

3. Push the lever down.

4. Pump handle up and down until forks reach

desired height.

To move a load:

1. Place lever in center neutral position.

2. Pull or push to desired location.

To lower a load:

1. Pull lever up, and allow load to settle. (The

lever is spring loaded and will return to

neutral position when released.)

2. Pull forks away from load.

7.0 Maintenance

7.1 Lubrication

Check the oil level annually by unscrewing oil fill

plug (Figure 7-1). Oil level should be near the

bottom of the hole.

When adding oil, fill the reservoir through the

plug hole with hydraulic jack oil, until oil comes

to bottom of hole, or begins to slightly seep out

of the fill hole. Do not overfill.

After filling, reinstall plug, then bleed the pump

(see sect. 8.3).

Lubricate pivot points on load wheel frames, as

needed. Do not get oil directly on load wheels.

Also lubricate pivot points on the yoke, such as

the one shown in Figure 7-1.

Figure 7-1

7.2 Cleaning relief valve

(“Bleeding the Pump”)

Over time the relief valve assembly may become

clogged with debris or develop air pockets. This

can result in improper lifting, lifting only half-way,

or similar symptoms.

To clean the relief valve:

1. Hold lever in raised position (fork lowering

position) and pump handle quickly 10 to 12

times.

2. Move lever to lower position, and pump the

handle to raise forks to fullest height.

3. Repeat if necessary.

7.3 Adjusting relief cam

1. Place handle lever in neutral position.

2. Loosen #424 hex nut.

3. Adjust #423 socket set screw while pumping

the handle.

4. The cam is properly adjusted when pumping

handle in neutral position causes no

movement.

5. Re-tighten hex nut (#424) to secure the

setting.

7.4 O-Ring and seal replacements

IMPORTANT: Repairs and seal ring

replacements should be performed only by

qualified personnel. Also, certain procedures

may require specialized tools. You can locate

the nearest authorized JET Service Center on

our website: www.jettools.com.

Numbers in parentheses refer to index numbers

in the parts breakdowns, sect. 10.0.

7.4.1 Ram piston and plunger piston

1. Raise the forks to maximum height by

pumping handle.

2. Remove the socket head screw (#204) to

release the piston assembly from the top of

the frame.

3. Turn the pallet truck on its side. Remove the

steer wheels and wheel shaft. Remove the

Retaining Ring (#305). This will free the

pump and handle assembly from the

platform.

4. Turn the pallet truck upright. Remove drain

plug (see Figure 7-1) and empty the oil into

a suitable container. Pump handle until all oil

has drained.

5. Pull out piston rod assembly (#414). If

plunger piston (#401) is to be pulled out,

remove handle assembly to access.

6. Remove all O-Rings & Seals.

7. Insert new O-Ring or Seal one at a time

making sure to replace with the same size

that was removed. (Order appropriate JET

seal kit.)

8. Re-assemble.

9. Refill oil to bottom of fill hole with hydraulic

jack oil. Install oil fill plug.

7.4.2 Valve cartridge

1. Remove drain plug (see Figure 7-1), and

empty the oil into a suitable container. Pump

handle until all oil has drained.

2. Tap out roll pin (#422).

3. Remove relief cam (#421).

4. Unscrew and remove valve assembly

(#418).

5. Install new valve assembly (see sect. 10.0

for part number) and tighten.

6. Install relief cam with roll pin.

7. Refill oil to bottom of fill hole with hydraulic

jack oil. Install oil fill plug.

8.0 Troubleshooting PTJ-A Series Pallet Trucks

Any disassembly of the pallet truck should be done by qualified personnel. Contact Jet technical service if

further assistance is needed.

Trouble Probable Cause Remedy

Hydraulic unit does not

lift.

Low oil level in reservoir. Make sure there is no oil leakage from

valve, and add oil.

Steel ball not seated in hydraulic unit. Place the lever in the down position and

pump the handle repeatedly.

Worn seal(s) in piston cylinder. Have seal(s) replaced.

Once lifted, truck

lowers by itself.

Steel ball not seated in hydraulic unit. Bleed the pump.

Worn seal in piston cylinder. Have seal(s) replaced.

Relief valve not seated properly. Bleed the pump.

Relief valve not adjusted properly. Reload truck within load capacity and

adjust valve using the set screw (#721).

Oil leakage from each valve. Tighten plug of each valve.

Forks will not lower.

Relief cam setscrew/nut out of

adjustment. Refer to “Adjusting Relief Cam.”

Relief cam or chain element broken. Replace affected elements.

Broken fork rods and linkage. Inspect linkages for breaks or cracks.

Replace elements as needed.

Lever does not set at

neutral position

Relief cam nut on the chain (#108B) is

not positioned correctly. Adjust the nut on the chain assembly.

Truck doesn’t roll

smoothly or evenly.

Wheels have debris embedded, or out

of round due to wear.

Inspect and remove debris. If worn,

replace wheels. NOTE: Always replace

wheels in pairs.

9.0 Replacement Parts

Replacement parts are listed on the following pages. To order parts or reach our service department, call 1-

800-274-6848 Monday through Friday, 8:00 a.m. to 5:00 p.m. CST. Having the Model Number and Serial

Number of your machine available when you call will allow us to serve you quickly and accurately.

Non-proprietary parts, such as fasteners, can be found at local hardware stores, or may be ordered from JET.

Some parts are shown for reference only, and may not be available individually.

9.1.1 PTJ-A Series Pallet Trucks – Exploded View

9.1.2 PTJ-A Series Pallet Trucks – Parts List

Index No Part No Description Size Qty

101A..........PTJA101C................. Handle Body Assembly (includes #101E to 112) .... ...................................... 1

101C.......... PTJA101E ................. Handle Body ........................................................... ...................................... 1

102 ............ PS063000 ................. Roll Pin .................................................................... 6x30 mm ....................... 1

103 ............PTJA103 ................... Pinch Roller ............................................................. ...................................... 1

104 ............PTJA104 ................... Pinch Roller Pin ....................................................... ...................................... 1

105 ............ 1225126 .................... Roll Pin .................................................................... Ø4x30 mm .................... 1

106 ............PTJA106 ................... Torsional spring ....................................................... ...................................... 1

107 ............PTJA107 ................... Hinge ....................................................................... ...................................... 1

108B.......... PTJA108B ................. Chain Assembly....................................................... ...................................... 1

109 ............PTJA109 ................... Finger Lever ............................................................ ...................................... 1

110 ............ PTJA110 ................... Roll Pin .................................................................... Ø4x13 mm .................... 1

111 ............ PTJA111 ................... Roll Pin .................................................................... Ø4x17 mm .................... 1

112 ............PTJA112 ................... Roller ....................................................................... ...................................... 1

201 ............PTJA201 ................... Chassis .................................................................... ...................................... 1

202 ............F006028 .................... C-Retaining Ring, Int ............................................... Ø26 mm ........................ 2

203 ............PTJA203 ................... Spring Gasket.......................................................... Ø6 mm .......................... 1

204 ............TS-1503031 .............. Socket Hd Cap Screw ............................................. M6x12 mm .................... 1

205D..........PTJA205D................. Connecting Pin ....................................................... Ø15.8x48.5 mm ............ 2

206 ............PTJA20627 ............... Lifting Yoke for 685mm/27in.................................... ...................................... 1

..................PTJA206205 ............. Lifting Yoke for 520mm/20-1/2in.............................. ...................................... 1

..................PTJA20616 ............... Lifting Yoke for 400mm/16in.................................... ...................................... 1

207 ............ PTJA207 ................... Axle.......................................................................... Ø15.8x52 mm ............... 2

208 ............PTJA208 ................... Pushrod Fork ........................................................... ...................................... 2

209 ............F006044 .................... C-Retaining Ring, Ext .............................................. Ø16 mm ........................ 2

210 ............ PTJA210 ................... Hex Thin Nut, Fine................................................... M22............................... 2

211 ............PTJA211-27 .............. Long Axle for 685mm/27in....................................... Ø24.5x608 mm ............. 1

..................PTJA211-20 .............. Long Axle for 520mm/20in....................................... Ø24.5x390 mm ............. 1

..................PTJA211-16 .............. Long Axle for 400mm/16in....................................... Ø24.5x250 mm ............. 1

212 ............PTJA21248 ............... Pushrod (1220mm/48in) .......................................... ..................................... 2

..................PTJA21236 ............... Pushrod (914mm/36in) ............................................ ...................................... 2

..................PTJA21242 ............... Pushrod (1066mm/42in) .......................................... ...................................... 2

213 ............ PTJA213 ................... Axle.......................................................................... Ø15.8x82 mm ............... 2

214 ............ F012099 .................... Roll Pin .................................................................... Ø5x26 mm .................... 2

215 ............PTJA215 ................... Load Wheel Frame Axle .......................................... Ø16x152 mm ................ 2

216 ............PTJA216 ................... Axle Sleeve.............................................................. ...................................... 4

217 ............ F012076 .................... Roll Pin .................................................................... Ø5x30 mm .................... 4

218 ............PTJA218 ................... Load Wheel Axle ..................................................... Ø17x120 mm ................ 2

220 ............PTJA220 ................... Load Wheel Frame .................................................. ...................................... 2

222 ............ BB-6204VV ............... Bearing .................................................................... 6204-2RS...................... 4

222A..........BB-6203VV ............... Bearing .................................................................... 6203-2RS...................... 4

223 ............PTJA223 ................... Load Wheel PU (includes #222A) ........................... Ø63x93 mm .................. 2

224 ............ TS-1541041 .............. Nylon Lock Hex Nut ................................................. M10............................... 2

225 ............PTJA225 ................... Inner Roller .............................................................. ...................................... 2

226 ............PTJA226 ................... Hex Cap Screw, Grd C ............................................ M10x65 ......................... 2

227 ............PTJA227 ................... Nylon washer .......................................................... ...................................... 2

300D..........PTJA300D................. DF Pump Assembly (includes #701 to 722) ............ ...................................... 1

301 ............PTJA301 ................... Wheel Axle .............................................................. ...................................... 1

302 ............PTJA302 ................... Dust Cap.................................................................. ...................................... 1

303 ............F006047 .................... C-Retaining Ring, Ext .............................................. Ø20 mm ........................ 1

304 ............PTJA304 ................... Nylon washer........................................................... ...................................... 1

305 ............F006082 .................... C-Retaining Ring, Ext .............................................. Ø55 mm ........................ 1

306D..........PTJA306D................. Steer Wheel PU (includes #222) ............................. 160x50 mm ................... 2

307 ............SR2024N-27 ............. Roll Pin .................................................................... Ø8x45 mm .................... 1

309 ............BB-51111 .................. Thrust Bearing ......................................................... 51111............................ 1

310D..........PTJA310D................. Handle Axle ............................................................. Ø19.8x85.5 mm ............ 1

311D..........PTJA311D................. Steer Wheel Platform .............................................. ...................................... 1

312 ............GB879-5X35 ............. Roll Pin .................................................................... Ø5x35 mm .................... 2

413 ............SB-18MM .................. Steel Ball ................................................................. Ø18 mm ........................ 1

701 ............PTJA701 ................... Small Pump Core .................................................... ...................................... 1

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