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Pallet trucks are valuable helpers when heavy loads or bulky transport containers need to be moved. They facilitate work in sales areas and warehouses and rarely break down thanks to their robust design. With proper handling and regular pallet truck maintenance, industrial trucks can usually be used for a long time without any problems.

Occasionally, however, this type of equipment may develop issues, for example, when the truck does not lower or cannot be manoeuvred as usual. This can pose safety risks during operation. However, before you hire a specialist repair technician, you can carry out simple repairs yourself, such as bleeding the hydraulic system as part of a regular pallet truck inspection. Read on to learn more about pallet truck repair and maintenance.

Which pallet truck repairs can you carry out yourself?

Many of the issues that occur with pallet trucks can usually be repaired quickly. This is especially true for hand pallet trucks with hydraulic lifts. Operation and performance can be affected over time if regular pallet truck maintenance is not carried out. The following minor repairs are essential to ensure your pallet truck continues to function smoothly:

Bleeding a pallet jack

If the pallet jack can no longer be lowered or no longer pumps up, it is usually a problem with the hydraulics. This can usually be remedied by bleeding air from the hydraulics system. In our step-by-step guide, you can learn how to do this and exactly which tools you need for the process.

Read our guide: how to bleed a pallet jack

Refilling or changing pallet truck oil

If bleeding air from the hydraulics system did not improve the situation, the oil level is probably too low or the hydraulic oil is contaminated, meaning that the pallet truck no longer lifts or lowers. In this case, you should check whether the oil level complies with the manufacturer’s specifications and top up the oil accordingly.

Step-by-step guide: how to refill pallet jack oil

Replacing pallet truck wheels

The wheels of a pallet truck are exposed to enormous loads and can therefore wear out quickly. That is why you should regularly carry out a full inspection of your pallet truck, checking both the load and steering wheels and replacing them if necessary. It’s easy with our step-by-step instructions.

Instructions: pallet truck wheel replacement

Pallet truck inspection checklist: testing the pallet truck

Regular checks of the pallet trucks and other material handling equipment ensure that they are in perfect condition and that your employees can work safely and efficiently. The checks can also quickly determine if the lift truck needs repair. In the long run, regular inspection of your pallet trucks will also increase service life in the plant. For a legally compliant inspection of the trucks, an inspection should be carried out once a year by a specialist.

The following functions and technical conditions should be checked at least once a week:

  • Are all lines and cylinders tight?
  • Does the fill level of the oil tank comply with the advised standard?
  • When did the last oil change take place on the pallet truck?
  • Does the seal of the lift truck function faultlessly?
  • Are the transport rollers of the truck in order?
  • Are electrical components defective?
  • Are there any obvious damages, cracks, or deformations on the pallet truck?

Please note: For optimal safety in the workplace and the best possible maintenance of industrial trucks, it is crucial that your employees know exactly how to operate the pallet truck correctly at all times.

Pallet truck repair: when to involve a specialist

While many of the issues that commonly arise with pallet trucks can easily be repaired yourself, there are some that may require specialist assistance. In the case of damage that is more complex to repair or that affects the electrical components of an electric pallet truck, you should always commission a specialist technician or repair centre. In accordance with the regulations of the trade associations, and also the manufacturers, such work may only be carried out by trained and certified specialist personnel. Only in this way can the functionality and operational safety of the pallet jack be properly restored.

If, for example, hydraulic oil escapes through leaking lines or cylinders, these must be replaced in a specialist workshop. Damage to the hydraulic pump must also not be repaired by the operator but should be handed over to the appropriate specialist personnel for repair.

If you’re unsure about whether to carry our pallet truck repairs yourself or commission a specialist, our professionally trained staff with be happy to advise you on any questions you may have.

FAQ for pallet truck repairs

What damage can I repair myself on the pallet truck?

You can usually repair simple malfunctions and maintenance repairs on pallet trucks yourself: bleeding air from the hydraulics system, topping up or changing the oil or replacing pallet truck steering and loading wheels are simple procedures for which you do not usually need to commission a repair workshop.

When does it make sense to hire a specialist to carry out pallet jack repairs?

If your efforts to repair the pallet truck are unsuccessful or if the damage is more severe, you should call in a professional repair service. For example, if oil is leaking, if the chassis is damaged, if electrical components are affected or generally if you need to repair an electric pallet truck.

How often should I service a pallet truck?

Carry out a comprehensive function check at least once a week using an up-to-date pallet truck inspection checklist. Regular pallet truck maintenance is essential for safety reasons and to ensure optimal function and performance.

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