Hand Pallet Jack Parts

Understanding pallet jack components helps with maintenance, troubleshooting, and repair decisions. While hand pallet jacks appear simple, they integrate hydraulic, mechanical, and structural systems that work together to lift and transport heavy loads reliably. Knowing the parts—and what fails—keeps equipment in service longer.

A typical hand pallet jack contains 50-100 individual components, from major assemblies like forks and hydraulic pumps to small items like O-rings and pins. This guide covers the major component groups, their functions, common failure modes, and replacement considerations.

Major component groups

Hand pallet jacks consist of several major assemblies:

Frame and forks. The structural foundation.
Hydraulic system. Pump, cylinder, valves, and fluid.
Handle assembly. Control mechanism and operator interface.
Wheel assemblies. Steer wheels and load wheels.
Linkage and hardware. Connecting components.

Frame and fork components

Forks

The two parallel arms that slide under pallets.

Construction. Formed steel channel, typically 3-5 mm wall thickness.
Length. Standard 1,143 mm (45 inches), options from 914-1,219 mm (36-48 inches).
Width. Inside fork typically 150-180 mm (6-7 inches) wide.
Spacing. Outside width typically 540-685 mm (21-27 inches).
Failure modes. Bending from overload, cracks from fatigue, wear on bottom surface.

Push rods

Connect the hydraulic cylinder to the fork lifting mechanism.

Function. Transfer cylinder motion to raise/lower forks.
Material. Steel rod, typically 12-16 mm diameter.
Failure modes. Bending from overload, wear at pivot points.

Lift links/rocker arms

Mechanical linkage that multiplies cylinder travel to lift forks.

Function. Convert cylinder motion to fork lift.
Pivot points. Multiple pins and bushings.
Failure modes. Worn bushings, bent components, broken welds.

Entry rollers

Guide rollers at fork tips for smooth pallet entry.

Function. Guide forks into pallet openings.
Material. Steel or nylon rollers.
Replacement. Easy—typically press-fit or bolt-on.

Frame/pump housing

The central structural component housing the hydraulic pump.

Construction. Cast or fabricated steel.
Functions. Houses pump, provides structural rigidity, mounts steer assembly.
Failure modes. Cracks (rare), stripped threads.

Hydraulic system components

Hydraulic pump

The heart of the lifting system.

Type. Single-acting piston pump, typically.
Operation. Pumping handle creates pressure to extend cylinder.
Key components. Piston, cylinder bore, check valves, seals.
Failure modes. Worn seals (won't hold pressure), worn bore, damaged check valves.
Repair. Seal kits available; severe wear requires pump replacement.

Hydraulic cylinder

Converts hydraulic pressure into lifting force.

Type. Single-acting with spring return.
Construction. Steel tube with internal piston.
Stroke. Typically 100-150 mm (4-6 inches).
Failure modes. Seal leaks (internal or external), scored bore, bent rod.
Repair. Seal replacement if bore is good; otherwise replace cylinder.

Release valve

Controls lowering speed and holds load.

Function. Allows controlled release of hydraulic pressure to lower forks.
Operation. Handle lever actuates valve via linkage.
Types. Ball valve, poppet valve, or needle valve.
Failure modes. Won't seal (load drops), won't open (won't lower), stuck.
Repair. Clean, replace seals, or replace valve assembly.

Check valves

One-way valves that direct fluid flow.

Function. Allow flow in one direction, block reverse flow.
Location. In pump and between pump and cylinder.
Types. Ball check, poppet check.
Failure modes. Debris preventing seal, worn seat, stuck open/closed.
Repair. Clean or replace—inexpensive parts.

Hydraulic fluid

The working fluid that transfers force.

Type. Hydraulic jack oil, typically ISO VG 22 or VG 32.
Capacity. Usually 200-400 ml per jack.
Maintenance. Check level, change every 2-3 years or when contaminated.

See our pallet jack hydraulic oil guide for details.

Seals and O-rings

Prevent fluid leakage throughout the hydraulic system.

Types. O-rings, cup seals, piston seals, rod seals.
Materials. Nitrile (Buna-N), polyurethane, leather.
Failure modes. Hardening, cracking, wear, extrusion.
Replacement. Seal kits available for most pumps/cylinders.

Handle assembly components

Handle

The operator interface for steering, pumping, and control.

Construction. Steel tube, typically 25-32 mm diameter.
Length. Usually 1,000-1,200 mm (40-48 inches).
Movement. Pivots for pumping, rotates for steering.
Failure modes. Bending, weld cracks at pivot.

Handle grip

The hand-held portion at handle end.

Material. Rubber, plastic, or foam.
Function. Comfortable grip, control lever access.
Replacement. Easy—typically slides on or screws on.

Control lever

Actuates the raise/neutral/lower function.

Positions. Typically three—raise, neutral, lower.
Mechanism. Connects to release valve via linkage.
Failure modes. Broken spring, worn linkage, sticky operation.

Handle pivot/yoke

Connects handle to pump housing.

Function. Allows handle to pivot for pumping and rotate for steering.
Components. Pivot pin, bushings, retaining clips.
Failure modes. Worn bushings (loose handle), missing clips.

Return spring

Returns handle to upright position.

Function. Raises handle after pump stroke.
Failure modes. Broken spring, stretched spring (weak return).
Replacement. Usually accessible, standard hardware.

Wheel assemblies

Steer wheels

The wheels mounted under the handle/pump housing.

Quantity. Usually one or two wheels.
Diameter. Typically 160-200 mm (6-8 inches).
Width. 40-60 mm (1.5-2.4 inches).
Materials. Polyurethane (most common), nylon, rubber.
Bearings. Ball bearings or roller bearings.
Failure modes. Flat spots, chunking, bearing failure.

Load wheels (fork wheels)

Located inside each fork, support the load.

Quantity. Two per fork (single) or four per fork (tandem).
Diameter. Typically 74-85 mm (2.9-3.3 inches).
Width. 50-90 mm (2-3.5 inches).
Materials. Polyurethane, nylon, or steel.
Bearings. Ball bearings, roller bearings, or plain bushings.
Failure modes. Wear flat, bearing failure, chunks missing.

Wheel materials comparison

Material	Advantages	Disadvantages
Polyurethane	Quiet, floor-friendly, good traction	Can chunk, flat spot
Nylon	Durable, chemical resistant, low rolling resistance	Noisy, can damage floors
Rubber	Soft, floor-friendly, good grip	Wears faster, can swell with chemicals
Steel	Extremely durable	Noisy, damages floors, no cushion

Bearings

Types. Sealed ball bearings, roller bearings, plain bushings.
Sealed bearings. Maintenance-free, replace when worn.
Open bearings. Require periodic greasing.
Failure signs. Noise, rough rolling, play in wheel.

Axles

Material. Hardened steel.
Mounting. Press-fit, bolted, or retained with clips.
Failure modes. Bending (rare with proper use), wear.

Hardware and fasteners

Pivot pins

Connect linkage components
Secured with cotter pins, clips, or snap rings
Replace if worn or bent

Bushings

Reduce friction at pivot points
Materials: bronze, nylon, composite
Replace when worn (excessive play)

Retaining clips and cotter pins

Secure pins and axles
Replace if bent or missing
Critical safety components

Bolts and nuts

Various sizes throughout assembly
Check for tightness during maintenance
Use proper grade replacements

Common replacement parts

Parts most frequently replaced during pallet jack service:

Load wheels. Wear item—replace when flat or damaged.
Steer wheels. Replace when worn or bearing fails.
Seal kits. Address hydraulic leaks and loss of lift.
O-rings. Individual seals for minor repairs.
Handle grips. Wear item—easy replacement.
Entry rollers. Replace if damaged or missing.
Control lever springs. Replace if broken or weak.
Push rods. Replace if bent.