WMH Tool Group JET HLPT Series Service manual

Operating Instructions and Parts Manual
HLPT Series High Lift Pallet Trucks
Models: HLPT-2045, HLPT-2745
WMH TOOL GROUP
2420 Vantage Drive
Elgin, Illinois 60123 Part No. M-140087
Ph.: 800-274-6848 Revision C 1/05
www.wmhtoolgroup.com Copyright © WMH Tool Group

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This manual has been prepared for the owner and operators of a JET HLPT series High Lift Pallet Truck.
Its purpose, aside from high lift pallet truck operation, is to promote safety through the use of accepted
correct operating and maintenance procedures. Completely read the safety and maintenance instructions
before operating or servicing the high lift pallet truck. To obtain maximum life and efficiency from your
high lift pallet truck, and to aid in using the truck safely, read this manual thoroughly and follow
instructions carefully.
Warranty & Service
WMH Tool Group warrants every product it sells. If one of our tools needs service or repair, one of our
Authorized Repair Stations located throughout the United States can give you quick service.
In most cases, any one of these WMH Tool Group Repair Stations can authorize warranty repair, assist
you in obtaining parts, or perform routine maintenance and major repair on your JET, Performax,
Powermatic or Wilton tools.
For the name of an Authorized Repair Station in your area, call 1-800-274-6848.
More Information
WMH Tool Group is consistently adding new products to the line. For complete, up-to-date product
information, check with your local WMH Tool Group distributor or visit wmhtoolgroup.com.
Limited Warranty
WMH Tool Group (including JET, Performax, Powermatic and Wilton brands) makes every effort to
assure that its products meet high quality and durability standards and warrants to the original retail
consumer/purchaser of our products that each product be free from defects in materials and
workmanship as follows: 1 YEAR LIMITED WARRANTY ON ALL PRODUCTS UNLESS SPECIFIED
OTHERWISE. This warranty does not apply to defects due directly or indirectly to misuse, abuse,
negligence or accidents, normal wear-and-tear, repair or alterations outside our facilities, or to a lack of
maintenance.
WMH TOOL GROUP LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD SPECIFIED ABOVE,
FROM THE DATE THE PRODUCT WAS PURCHASED AT RETAIL. EXCEPT AS STATED HEREIN,
ANY IMPLIED WARRANTIES OR MERCHANTIBILITY 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. WMH TOOL GROUP SHALL IN NO EVENT BE
LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL,
CONTINGENT, SPECIAL, OR CONSEQUENTIAL DAMAGES ARISING 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.
To take advantage of this warranty, the product or part must be returned for examination, postage
prepaid, to an Authorized Repair Station designated by our office. Proof of purchase date and an
explanation of the complaint must accompany the merchandise. If our inspection discloses a defect,
WMH Tool Group will either repair or replace the product, or refund the purchase price if we cannot
readily and quickly provide a repair or replacement, if you are willing to accept a refund. WMH Tool
Group will return repaired product or replacement at our expense, but if it is determined there is no
defect, or that the defect resulted from causes not within the scope of our warranty, then the user must
bear the cost of storing and returning the product. This warranty gives you specific legal rights; you may
also have other rights, which vary from state to state.
WMH Tool Group sells through distributors only. WMH Tool Group reserves 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.

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Table of Contents Page
Warranty .................................................................................................................................... 2
Specifications............................................................................................................................. 3
Introduction................................................................................................................................. 3
Assembly and Adjustment .......................................................................................................... 4
Safety Precautions ..................................................................................................................... 4
Operation ................................................................................................................................... 4
Maintenance............................................................................................................................... 5
Trouble-Shooting........................................................................................................................ 5
Parts Lists and Breakdowns................................................................................................... 6-11
Specifications High Lift Pallet Truck
Model Number..........................................................HLPT-2045...............................HLPT-2745
Stock Number..................................................................140087......................................140088
Capacity (lbs) .....................................................................2,200.........................................2,200
Min./Max. Fork Height (in)............................................3-3/8 / 32...................................3-3/8 / 32
Fork Width (in).................................................................... 6-1/4......................................... 6-1/4
Overall Fork Dimensions L x W (in)...........................20-1/2 x 45......................................27 x 45
Load Wheel OD x W (in) ...........................................3 x 2 Nylon................................3 x 2 Nylon
Steer Wheel OD x W (in)....................................6 x 2 Poly/Steel.........................6 x 2 Poly/Steel
Overall Dimensions L x W x H (in).....................63 x 20-7/8 x 50......................63 x 27-3/16 x 50
Net Weight (lbs).....................................................................208............................................238
Introduction
Congratulations on your purchase of a JET High Lift Pallet Truck.
This high lift pallet truck is designed to reduce lifting injuries and increase productivity by easily lifting,
lowering, and transporting heavy loads up to 2,200 pounds on open pallets and skids only. It does not
operate with closed pallets unless the pallet is placed on top of forks.
The welded steel frame features a powder coat finish to inhibit rust. A powerful two-stage hydraulic
pump features quick lifting action with no load, and automatic overload bypass protection. The pump
may be operated with a pallet truck style handle or foot lever. An automatic floor brake engages when
the forks are raised. An optional steel platform converts the high lift pallet truck to a convenient mobile
workstation. With regular maintenance, your high lift pallet truck will provide years of dependable
service.
The specifications in this manual are given as general information and are not binding. WMH Tool Group
reserves the right to effect, at any time and without prior notice, changes or alterations to parts,
fittings, and accessory equipment deemed necessary for any reason whatsoever.

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Assembly & Adjustment
(refer to parts breakdown, pages 6-11)
Note: Individual pallet trucks are assembled
and ready to use. Pallet trucks purchased in
crate quantities require some assembly. Match
the "number" label on the handle to the
"number" label on the frame, prior to assembly.
1. Insert handle (22) over square steel tabs on
pump assembly (30), and align the holes.
2. Fasten handle to pump assembly with two
handle pins (28), two bushings (29) and two
spring pins (27). Move handle up and down
several times to confirm that it moves
freely.
3. Hook the release rod (50) into the cam (72).
Set the lever on the handle to neutral, and
turn the cam nut (47) while pumping the
handle. When lifting stops, give the cam
nut one more turn. The cam nut is properly
adjusted when pumping the handle in the
neutral position causes no movement of the
hydraulic ram.
4. Press foot lever (45) or pump handle (22)
repeatedly to lift the forks to the highest
position. Then pull and hold pump release
lever (25) on pump handle while pumping
handle up and down to lower the forks to
their lowest position. Repeat this procedure
3 to 4 complete cycles to release any
possible trapped air in the hydraulic system
and to confirm all components are
functioning properly.
5. The pallet truck has a “closed” oil plug (89A)
installed in the pump body. This plug was
for shipping purposes only. It should be
removed and replaced with the provided oil
plug that has a hole in the top. This will
allow the correct atmospheric pressure to be
maintained in the hydraulic system.
Safety Precautions
1. Read owner's manual before operating high
lift pallet truck.
2. Do not exceed rated capacity.
3. Before using pallet truck, lift and lower the
forks several times with no load to release
any air that may be trapped in the hydraulic
system.
4. Never allow anyone to ride on the pallet
truck.
5. Operate on smooth, level, finished floors
only; do not use on sloping floors.
6. Always keep hands and feet clear from all
moving parts including forks, legs, wheels,
piston rod (96) and mid-cylinder (90).
7. Always secure load equally on the forks
nearest the bulkhead before lifting or
lowering. Do not lift load with fork tip only.
8. Automatic overload safety valve will open if
pallet truck is overloaded.
9. When transporting load, always keep people
clear from pallet truck and transport load in
the lowered position only.
10. Pull pump release lever slowly to allow load
to descend in a controlled manner.
 WARNING
Failure to comply with all of these safety
precautions may result in loss of load,
damage to pallet truck, personal injury
and/or property damage.
Operation
The pallet truck is designed for use with open
style pallets or skids only. Closed style pallets
must be placed on top of forks prior to use.
The handle is designed to pull and steer the
pallet truck only. Do not use the handle as a
leverage tool.
 WARNING
Do not attempt to move pallet truck with
forks in raised position. Lower forks before
moving pallet truck with load.
1. To raise forks, pump foot pedal or handle up
and down until desired height is reached.
NOTE: The hydraulic pump assembly
features a safety overload bypass system.
If pallet truck load exceeds rated capacity,
only the mid-cylinder (90) will extend; the
piston rod (96) will not.
2. To lower the forks, pull the pump release
lever on the handle slowly to allow load to
descend in a cautious and controlled
manner.

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CAUTION: When not in use, do not allow heavy
loads to remain on the forks for an extended
period of time. Always lower forks completely
when not in use.
MAINTENANCE
For optimum performance, lubricate chain (49)
with light oil periodically.
Trouble-Shooting for HLPT Series Pallet Trucks
Trouble Possible Cause Remedy
(with parts list reference number)
Forks do not lift to
maximum height.
1. Hydraulic oil level low. 1. Lower forks fully and add
hydraulic oil to fill hole (89A) up
to bottom level. [About 0.92
liters]
Forks will not lift.
1. Oil level is low, or oil is too
viscous.
2. Oil has impurities.
3. Hex nut (47) is too high on
anchor bolt (48) and release
valve not closing.
4. Air trapped in hydraulic system.
1. Fill with oil, or change oil.
2. Change oil.
3. Adjust hex nut on anchor bolt to
allow release valve to close
properly.
4. Release air from system by
pulling handle lever (25), then
pumping handle up and down
several times.
Forks will not lower.
1. Lifting piston (90) is deformed
from overloading.
2. The fork was kept in high
position for extended time
resulting in rusting and jammed
of the exposed piston rod.
3. Hex nut (47) not adjusted
properly on anchor bolt (48).
4. Fork frame (1) and fork roller
(6) are jammed.
1. Replace lifting piston.
2. Always keep forks in lowest
position when not in use. Keep
ram and lifting piston lubricated
and away from moisture.
3. Adjust hex nut to allow release
valve to close properly.
4. Correct jam; replace fork roller if
necessary.
Hydraulic fluid leak. 1. Seal parts worn or damaged. 2. Some parts cracked or worn. 1. Replace worn or damaged parts. 2. Replace damaged or cracked
parts.
Forks descend without
pulling release valve
handle.
1. Release valve unable to close
properly due to impurities in
hydraulic oil.
2. Hydraulic system cracked or
bored.
3. Air trapped in hydraulic pump.
4. Seal parts worn or damaged in
hydraulic pump.
5. Hex nut (47) is not in correct
position on anchor bolt (48).
1. Replace with new hydraulic oil.
2. Inspect and replace damaged
parts.
3. Release air from pump by pulling
handle lever (25), then pumping
handle up and down several
times.
4. Replace worn or damaged parts
5. Adjust hex nut to allow release
valve to close properly.

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Parts Breakdown
HLPT-2045 & HLPT-2745 Fork Assembly

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Parts List
HLPT-2045 & HLPT-2745 Fork Assembly
Index Part
No. No. Description Size Quantity
1..........HLPT-1 ........................ Frame (HLPT-2045)............................... .................................. 1
............HLPT-1A...................... Frame (HLPT-2745)............................... .................................. 1
2..........TS-1504011................. Socket Head Cap Screw........................M8 x 10...................... 1
3..........HLPT-3 ........................ Pin......................................................... .................................. 2
4..........HLPT-4 ........................ Bushing................................................. .................................. 2
5..........TS-154010................... Hex Nut.................................................M16............................ 4
6..........HLPT-6 ........................ Fork Roller............................................. .................................. 4
7..........HLPT-7 ........................ Inside Leg (HLPT-2045)......................... .................................. 1
............HLPT-7A...................... Inside Leg (HLPT-2745)......................... .................................. 1
8..........EHPT-10...................... Snap Ring..............................................M20............................ 8
9..........HLPT-9 ........................ Front Wheel Axle................................... .................................. 2
10........HLPT-10 ...................... Spacer................................................... .................................. 4
11........BB-6204ZZ .................. Ball Bearing...........................................6204-ZZ..................... 8
12........HLPT-12 ...................... Front Wheel...........................................72 x 20 x 50............... 2
13........EHPT-12...................... Snap Ring..............................................M22............................ 2
14........HLPT-14...................... Bushing.................................................25 x 22 x 40............... 2
15........HLPT-15 ...................... Outside Leg........................................... .................................. 2
16........HLPT-16...................... Bushing.................................................25 x 22 x25................ 2
17........HLPT-17 ...................... Centrifugal Axle..................................... .................................. 2
18........HLPT-18 ...................... Spacer................................................... .................................. 2
19........TS-155110................... Lock Washer .........................................M16............................ 4
20........AH25C-060.................. Spring Pin..............................................∅4 x 30..................... 2
21........HLPT-21...................... Blocking Spring ..................................... .................................. 1
22........HLPT-22 ...................... Handle................................................... .................................. 1
23........HLPT-23 ...................... Spring Pin..............................................∅4 x 22..................... 2
24........HLPT-24 ...................... Roller..................................................... .................................. 1
25........HLPT-25 ...................... Handle Lever......................................... .................................. 1
26........HLPT-26 ...................... Spring Pin..............................................∅6 x 30..................... 1
............HLPT-107 .................... Foot Lever Assembly (includes #27 thru 29, and 38 thru 46A) .. 1
27........HLPT-27 ...................... Spring Pin..............................................∅5 x 55..................... 2
28........HLPT-28 ...................... Handle Pin............................................. .................................. 2
29........HLPT-29...................... Bushing.................................................17 x 15 x 8................. 4
30........HLPT-30...................... Pump Assembly..................................... .................................. 1
31........HLPT-31 ...................... Table (HLPT-2045)................................ .................................. 1
............HLPT-31A.................... Table (HLPT-2745)................................ .................................. 1
32........HLPT-32...................... Bushing.................................................25 x 22 x 20............... 2
33........HLPT-33...................... Table Pin............................................... .................................. 2
34........HLPT-34 ...................... Wheel Holder Base................................ .................................. 1
35........HLPT-35 ...................... Wheel....................................................150 x 20 x 44............. 2
36........HLPT-36 ...................... Slotted Set Screw w/Cone Point ............M8 x 16...................... 1
37........TS-1541031................. Nylon Lock Hex Nut...............................M8 ............................. 1
38........HLPT-38 ...................... Roller Pin............................................... .................................. 1
39........992313......................... Spring Pin..............................................∅3 x 30..................... 1
40........HLPT-40...................... Bushing.................................................17 x 15 x 15............... 1
41........HLPT-41 ...................... Roller..................................................... .................................. 1
42........HLPT-42...................... Foot Lever Bracket................................ .................................. 1
43........HLPT-43...................... Positioning Roller Axle........................... .................................. 2
44........HLPT-44 ...................... Positioning Roller................................... .................................. 1
45........HLPT-45...................... Foot Lever............................................. ..................................1
46........HLPT-46 ...................... Link Pin .................................................∅8 x 35..................... 1

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Index Part
No. No. Description Size Quantity
46A......EHPT-111.................... Snap Ring..............................................M8 ............................. 1
47........TS-1541021................. Nylon Lock Hex Nut...............................M6 ............................. 1
48........HLPT-48 ...................... Anchor Bolt............................................ ..................................1
49........HLPT-49 ...................... Chain.....................................................05B-1 x 15 ................. 1
50........HLPT-50 ...................... Release Rod.......................................... .................................. 1
50A......140095......................... Optional Steel Platform ......................... .................................. 1
............PT2748J-JET............... JET Logo Label ..................................... .................................. 1
............EHPT-HL ..................... Hazard Label for Legs............................17” x 1-3/4” ................ 4
............HLPT-ID....................... I.D. Label (HLPT-2045).......................... .................................. 1
............HLPT-IDA .................... I.D. Label (HLPT-2745).......................... .................................. 1
............EHPT-LWL .................. Loading Warning Label..........................4-3/8” x 1-9/16” .......... 1

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Parts Breakdown
HLPT-2045 & HLPT-2745 Pump Assembly

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Parts List
HLPT-2045 & HLPT-2745 Pump Assembly
Index Part
No. No. Description Size Quantity
51........HLPT-51 ...................... Bolt........................................................ .................................. 1
52........HLPT-52 ...................... Spring Cap ............................................ .................................. 1
53........HLPT-53 ...................... Spring.................................................... .................................. 1
54........HLPT-54...................... Dust Seal * ............................................20 x 28 x 4.5.............. 1
55........HLPT-55...................... Gasket * ................................................20 x 28 x 6................. 1
56........HLPT-56 ...................... Pump Cylinder....................................... .................................. 1
57........HLPT-57 ...................... Plunger Piston....................................... .................................. 1
58........SB-3MM....................... Steel Ball...............................................3mm .......................... 2
59........HLPT-59 ...................... Spring.................................................... .................................. 2
60........HLPT-60 ...................... Screw.................................................... .................................. 2
61........HLPT-61 ...................... Spring.................................................... .................................. 1
62........HLPT-62 ...................... Spring Base........................................... .................................. 1
63........SB-5MM....................... Steel Ball...............................................5mm .......................... 1
64........HLPT-64 ...................... Screw.................................................... .................................. 1
65........HLPT-65 ...................... Release Plug......................................... .................................. 1
66........HLPT-66 ...................... Copper Washer *................................... .................................. 1
67........HLPT-67 ...................... Spring.................................................... .................................. 1
68........HLPT-68 ...................... Control Valve......................................... .................................. 1
69........HLPT-69 ...................... Valve Base............................................ .................................. 1
70........SB-7MM....................... Steel Ball...............................................7mm .......................... 1
71........HLPT-71 ...................... Copper Washer *................................... .................................. 1
72........HLPT-72 ...................... Cam ...................................................... .................................. 1
73........HLPT-73 ...................... Spring Pin..............................................∅8 x 28..................... 1
74........HLPT-74 ...................... Spring.................................................... .................................. 1
75........HLPT-75...................... O-Ring * ................................................4.8 x 1.9..................... 3
76........HLPT-76 ...................... Nozzle................................................... .................................. 1
77........SB-6MM....................... Steel Ball...............................................6mm .......................... 1
78........HLPT-78 ...................... Spring Base........................................... .................................. 1
79........HLPT-79 ...................... Spring.................................................... .................................. 1
80........HLPT-80...................... Adjusting Screw..................................... .................................. 1
81........HLPT-81...................... O-Ring * ................................................11.2 x 2.4................... 1
82........HLPT-82 ...................... Relief Plug............................................. .................................. 1
83........HLPT-83...................... Dust Seal * ............................................45 x 53 x 5................. 1
84........HLPT-84...................... O-Ring * ................................................44.7 x 3.5................... 1
85........HLPT-85 ...................... Cover .................................................... .................................. 1
86........HLPT-86...................... O-Ring * ................................................77.5 x 3.55................. 1
87........HLPT-87...................... Gasket * ................................................45 x 55 x 6................. 1
88........HLPT-88...................... O-Ring * ................................................53 x 2.65.................... 1
89........HLPT-89 ...................... Pump Body............................................ .................................. 1
89A......HLPT-89A.................... Oil Fill Screw.........................................M5 x 8........................ 1
90........HLPT-90...................... Lifting Piston.......................................... .................................. 1
91........EHPT-163.................... Snap Ring..............................................M25............................ 1
92........HLPT-92...................... O-Ring * ................................................24.7 x 3.5................... 1
93........HLPT-93...................... Bronze Bushing..................................... .................................. 1
94........HLPT-94...................... O-Ring * ................................................28 x 1.8...................... 1
95........SB-18MM..................... Steel Ball...............................................18mm ........................ 1
96........HLPT-96 ...................... Ram Piston............................................ .................................. 1
97........HLPT-97 ...................... Overflow Pin.......................................... .................................. 1