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Pallet trucks are valuable helpers when it comes to moving heavy loads or bulky transport containers. 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 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.
Please note: Our article provides tips exclusively for repairing manual pallet trucks. Other types, such as high-lift or electric pallet trucks, due to their electrical components, should only be serviced by the manufacturer’s pallet truck service.
Which pallet truck repairs can you carry out yourself?
Malfunctions or functional errors that can be self-repaired often affect the mechanical components of a manual pallet truck with hydraulic lift. Typically, the hydraulics or seals are affected. The pallet truck may then fail to provide optimal hydraulic power transmission for moving loads, for example. Therefore, it is important to perform regular pallet truck maintenance to ensure trouble-free operation.
You can perform the following minor repairs yourself to ensure your pallet truck continues to function smoothly:
| Repair | Details | Further information |
|---|---|---|
| Bleeding the pallet truck | If the pallet truck can no longer be lowered or raised, there’s usually a problem with the hydraulics. This can typically be resolved by bleeding the pallet truck. | Learn how to bleed a pallet truck |
| Refilling pallet truck oil | Low oil level or contaminated hydraulic oil can prevent the pallet truck from lifting or lowering. Regularly check if the oil level meets the manufacturer’s specifications and top up if necessary. | Learn how to refill pallet truck oil |
| Changing pallet truck oil | If your pallet truck has been in use for a long time, you should make changing the oil part of your maintenance routine. Our guide makes this process easy. | Learn how to change pallet truck oil |
| Replacing the steering and load wheels | The load and steering wheels of a pallet truck endure heavy loads and can wear out quickly. Check them regularly and replace them if necessary. | Learn how to change pallet truck wheels |
Pallet truck inspection checklist: testing the pallet truck
Regular checks of your pallet trucks and other material handling equipment ensure that they are always in perfect condition, to ensure your pallet jacks are working correctly, and that your employees can work safely and efficiently. The checks are also a good way to determine if you need to repair your pallet truck. In the long run, regular inspection of your pallet trucks will even increase their service life. Remember: For legal compliance, an inspection should be carried out once a year by a specialist.
You should check the following functions and technical conditions at least once a week:
- Inspect steering and load wheels for wear and damage
- Check mounting and fastening
- Ensure the tiller’s return function works
- Inspect the frame and load-bearing elements for damage
- Check all screw connections
- Verify the signage
- Test lifting and lowering functions
- Inspect lubrication points and attend to as needed
- Check seals
Please note: For optimal safety in the workplace and the best possible maintenance of industrial trucks, it is crucial that your employees always know exactly how to correctly operate the pallet truck.
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 more complex damage or damage involving the electrical components of an electric pallet truck, you should always involve a specialist technician or repair centre. In accordance with the regulations of the trade associations and manufacturers, such work must only be carried out by trained and certified specialist personnel. This is the only way to ensure the full functionality and operational safety of your pallet jack.
IIf hydraulic oil escapes through leaking lines or cylinders, these must be replaced in a specialist workshop. Specialist personnel must also take care of repairing damage to the hydraulic pump, rather than being repaired by the operator.
If you’re unsure about whether to carry out your own pallet truck repairs or to commission a specialist, our professionally trained staff are happy to advise.
FAQ for pallet truck repairs
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 needn’t usually commission a repair workshop.
If your efforts to repair your pallet truck are unsuccessful or if the damage is more severe, you should employ a professional repair service. For example, if your oil is leaking, if the chassis is damaged, if electrical components are affected or if you need to repair an electric pallet truck, then you should contact a professional.
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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