Pallet Jack Maintenance

Why maintenance matters

Proper pallet jack maintenance delivers benefits across multiple dimensions.

Safety

Pallet jack failures can cause serious injuries. A hydraulic system that suddenly releases can drop heavy loads onto feet or legs. Worn wheels can cause loss of control on ramps or wet floors. Failed brakes on electric units can lead to collisions. Cracked forks can collapse under load.

Regular inspection catches developing problems before they reach the failure point. Maintenance records also provide documentation that demonstrates due diligence if an incident ever requires investigation.

Reliability

Equipment breakdowns disrupt operations. When a pallet jack fails mid-shift, loads sit in wrong locations, trucks wait at docks, and workers stand idle while someone finds an alternative. In lean operations with minimal equipment redundancy, a single breakdown can cascade into significant delays.

Preventive maintenance dramatically reduces unplanned downtime. Replacing worn components on schedule costs less and causes less disruption than emergency repairs after failures.

Cost control

Minor maintenance costs far less than major repairs. Topping off hydraulic fluid takes minutes and costs almost nothing. Replacing a failed hydraulic pump costs hundreds in parts and labour. Replacing wheels before they damage the floor or load goods costs a fraction of repairing scored concrete or damaged inventory.

Over the equipment lifecycle, operations that maintain equipment consistently spend less on total service costs despite the regular maintenance investment.

Equipment lifespan

A quality manual pallet jack can last 10 to 15 years with proper care. The same model neglected might need replacement in 3 to 5 years. Electric pallet jacks show similar patterns—maintained units deliver value for years beyond poorly maintained equivalents.

Given equipment costs, extending useful life by even a few years through maintenance pays significant returns.

Daily operator inspections

The most important maintenance happens before each shift when operators perform quick inspections. These checks take only a few minutes but catch many developing problems early.

Visual inspection

Walk around the pallet jack and look for obvious problems

• Check forks for visible cracks, bends, or excessive wear at the tips and heels
• Look for hydraulic fluid leaks under the pump unit or around the cylinder
• Inspect wheels for flat spots, chunks missing, or debris wrapped around axles
• Verify the handle moves freely without binding or excessive play
• Check that safety labels and capacity plates are readable

Functional checks

Test basic operations without a load

• Pump the handle and verify forks rise smoothly
• Release the lowering control and confirm forks descend at a controlled rate
• Roll the pallet jack forward and back, feeling for wheel binding or unusual resistance
• Turn the handle through its full range and check for smooth steering
• For electric units, verify the battery charge indicator shows adequate charge
• Test the horn and any warning lights on electric models

Reporting problems

Operators should report any problems found during inspection immediately. Create a simple system—a tag attached to defective equipment, a log book, or a digital reporting tool—that ensures problems get communicated to maintenance staff.

Take defective equipment out of service until repairs are completed. The temptation to use a pallet jack despite known problems leads to injuries and more extensive damage.

Hydraulic system maintenance

The hydraulic system is the heart of a pallet jack. It enables the lifting function that makes the equipment useful. Hydraulic problems are among the most common maintenance issues.

How pallet jack hydraulics work

Manual pallet jacks use a simple hydraulic circuit. When you pump the handle, a piston forces hydraulic fluid from a reservoir into a cylinder. The fluid pushes a ram that raises the forks through a linkage system. A release valve controls lowering by allowing fluid to return to the reservoir at a controlled rate.

Electric pallet jacks use a motor-driven pump instead of manual pumping, but the basic principle remains the same. Some advanced electric units add proportional controls for more precise lift speed management.

Checking and adding hydraulic fluid

Low fluid level is the most common cause of poor lifting performance. Check fluid level monthly or more frequently in heavy-use environments.

To check fluid level

• Lower the forks completely to return fluid to the reservoir
• Locate the fill plug, typically on top of the pump housing
• Remove the plug and check that fluid is visible near the top of the reservoir
• If low, add fluid until it reaches the proper level

Use only the hydraulic fluid type specified by the manufacturer. Most pallet jacks use standard hydraulic jack oil, but some require specific formulations. Using the wrong fluid can damage seals and cause failures.

Bleeding air from the system

Air trapped in the hydraulic system causes spongy operation and prevents full lifting capacity. Air can enter through low fluid levels, loose fittings, or during repairs.

To bleed a pallet jack hydraulic system

• Lower the forks completely
• Open the release valve fully
• Pump the handle rapidly 10 to 15 times
• Close the release valve
• Test lift operation
• Repeat if necessary until operation feels solid

If bleeding does not resolve spongy operation, there may be a leak allowing continuous air entry. Inspect all fittings and seals for the source.

Seal and O-ring replacement

Hydraulic seals wear over time and eventually leak. Signs of seal failure include

• Visible fluid leaks around the pump or cylinder
• Forks that slowly sink when loaded and stationary
• Reduced maximum lift height
• Need to pump more strokes than usual to reach full height

Seal replacement kits are available for most pallet jack models. The job requires disassembling the hydraulic unit, replacing worn seals and O-rings, and reassembling with proper torque and alignment. Many operations contract this work to service providers, but capable in-house technicians can perform it with the right tools and instructions.

Release valve adjustment

The release valve controls lowering speed. If forks drop too quickly, the valve may need adjustment or the seat may be worn. If forks lower too slowly or not at all, debris may be blocking the valve.

Release valve adjustment typically involves a screw or nut accessible on the pump housing. Turn it slightly to change flow rate. Test after each adjustment until lowering speed is appropriate—fast enough to be efficient but controlled enough to be safe.

Wheel and bearing maintenance

Wheels take constant abuse from floor surfaces, debris, and heavy loads. They are among the most frequently replaced pallet jack components.

Types of pallet jack wheels

Understanding wheel construction helps with maintenance decisions. For more details on wheel options, see our guide on pallet jack features.

• Polyurethane wheels offer good load capacity, quiet operation, and resistance to chemicals and oils. They are the most common choice for indoor use on smooth concrete.
• Nylon wheels are harder and more durable than polyurethane but noisier and harsher on rough surfaces. They work well in wet environments where softer materials might hydroplane.
• Rubber wheels provide good traction and shock absorption but wear faster under heavy loads. They suit applications where floor protection or outdoor use matters.
• Steel wheels appear in some heavy-duty applications but damage most floors and create noise. They are uncommon in general warehousing.

Inspecting wheels

Check wheels regularly for

• Flat spots from sitting loaded in one position or from skidding
• Chunks or pieces broken from the tread
• Deep cuts that could lead to failure
• Chemical damage causing softening or swelling
• Debris wrapped around the wheel or axle
• Excessive wear reducing diameter

Worn or damaged wheels increase rolling resistance, damage floors, and can cause steering problems. Replace them before they fail completely.

Wheel replacement

Most pallet jack wheels attach with axle bolts, retaining rings, or press-fit bearings. Replacement procedures vary by model but generally follow these steps

• Secure the pallet jack so it cannot roll during work
• Raise the section being worked on using blocks or a lift
• Remove the retaining hardware—bolts, clips, or cotter pins
• Slide the old wheel off the axle
• Clean the axle and inspect for wear
• Install the new wheel with any required bearings or spacers
• Reinstall and properly torque retaining hardware

Keep spare wheels in stock for common models. Waiting for wheel orders while equipment sits idle costs more in lost productivity than maintaining a small parts inventory.

Bearing maintenance

Wheel bearings allow smooth rotation under load. Sealed bearings require no routine lubrication but should be replaced when they develop roughness or play. Open bearings need periodic greasing.

Signs of bearing problems include

• Grinding or rumbling sounds during rolling
• Visible wobble in wheel rotation
• Increased rolling resistance
• Heat buildup in the wheel hub area

Replace bearings whenever replacing wheels, even if they seem serviceable. The labour to access them is the same, and new bearings are inexpensive insurance.

Fork inspection and care

Forks are structural components that support the entire load. Fork failures can be catastrophic, dropping loads and potentially injuring people.

What to inspect

Examine forks carefully during periodic inspections

• Cracks. Look especially at the heel where forks attach to the frame, and at any welds. Use a flashlight and magnifying glass if needed. Even hairline cracks are serious.
• Bends. Sight along each fork to check for straightness. Compare the two forks—they should be identical in position and angle.
• Wear. Measure fork thickness at several points. If thickness has reduced more than 10 percent from original, the fork is compromised.
• Tip damage. Worn or bent tips make pallet entry difficult and can damage pallets.
• Surface condition. Severe rust, pitting, or gouges weaken the fork structure.

When to replace forks

Replace forks immediately if you find

• Any cracks, no matter how small
• Visible bends or twisting
• Thickness reduction exceeding 10 percent
• Worn tips that cannot be repaired
• Severe corrosion affecting structural integrity

Fork replacement on manual pallet jacks typically requires disassembling the linkage system. On many models, this is straightforward for trained technicians. On others, particularly those with integrated or welded forks, replacement may mean retiring the entire unit.

Fork tip maintenance

Fork tips wear from contact with pallets and floors. Slight wear is normal, but severely worn or bent tips should be addressed.

Some tips can be built up with welding and ground to shape, though this requires skill and proper equipment. Tip protectors or caps are available for some models and can extend tip life in demanding applications.

Lubrication

Proper lubrication reduces friction, prevents wear, and keeps moving parts operating smoothly. Under-lubrication accelerates wear. Over-lubrication attracts dirt and can cause its own problems.

Lubrication points

Common pallet jack lubrication points include

• Pivot pins and bushings in the steering mechanism
• Handle pivot points where the tiller connects
• Lift linkage pins that connect the hydraulic system to the forks
• Axle points if not using sealed bearings
• Chain drives on electric models

Lubrication types

Different points need different lubricants

• Grease for pivot pins, bushings, and heavily loaded points. Use lithium-based grease for most applications.
• Light oil for cables, small pivots, and areas where grease would attract too much debris.
• Chain lubricant for drive chains on electric models.
• Dry lubricant for some applications in dusty environments where wet lubricants would cause buildup.

Lubrication schedule

For typical warehouse use

Increase frequency in demanding environments—dusty conditions, outdoor use, wet areas, or very heavy utilization.

Electric pallet jack specific maintenance

Electric pallet jacks have additional systems requiring attention beyond manual units. For comprehensive information on different models, see our guide on pallet jack types.

Battery maintenance

Battery care is critical for electric pallet jack reliability. Requirements differ by battery type.

Lead acid batteries

• Check water levels weekly and add distilled water as needed
• Clean terminals and connections monthly
• Perform equalization charges as recommended by the battery manufacturer
• Keep batteries clean and dry on top to prevent current leakage
• Monitor for signs of aging—reduced run time, slow charging, excessive gassing

Lithium ion batteries

• Keep charge between 20 and 80 percent when possible for longest life
• Avoid extreme temperatures during charging and storage
• Monitor battery management system alerts for cell imbalances or faults
• Follow manufacturer guidelines for periodic full discharge cycles if recommended

For detailed battery information, see our complete guide on forklift batteries.

Electrical connections

Electrical connections can loosen with vibration and corrode with exposure. Check connections monthly

• Battery terminals and connector
• Motor connections
• Control board connections
• Sensor wiring

Clean corroded terminals with appropriate contact cleaner. Tighten loose connections. Replace damaged wires or connectors.

Drive motor and controls

Electric drive motors are generally reliable but benefit from periodic attention

• Listen for unusual sounds indicating bearing wear
• Check for excessive heat during operation
• Verify throttle response is smooth and proportional
• Test all control functions including lift, lower, forward, and reverse
• Clean debris from motor cooling vents

Braking system

Electric pallet jacks use electromagnetic brakes that engage when power is removed. Check brake function regularly

• Test that the unit stops promptly when releasing the throttle
• Verify the unit holds position on grades
• Listen for unusual sounds during braking
• Check brake adjustment if stopping distance seems excessive

Troubleshooting common problems

Many pallet jack problems have straightforward causes and solutions. This section covers frequent issues and how to address them.

Forks will not lift or lift slowly

Possible causes and solutions

• Low hydraulic fluid. Check level and add fluid if needed.
• Air in hydraulic system. Bleed the system as described earlier.
• Worn pump seals. Replace seal kit.
• Damaged pump. Repair or replace pump assembly.
• Release valve not fully closed. Verify valve position and adjust if needed.
• Overloaded beyond capacity. Reduce load to rated capacity.

Forks sink when loaded

Possible causes and solutions

• Internal seal leak. Replace cylinder seals.
• Release valve not sealing. Clean or replace valve and seat.
• Cracked cylinder. Replace cylinder assembly.

Forks will not lower or lower too slowly

Possible causes and solutions

• Release valve stuck or blocked. Clean valve mechanism.
• Debris in hydraulic system. Drain, flush, and refill with clean fluid.
• Release valve adjustment incorrect. Adjust flow rate.

Difficult steering

Possible causes and solutions

• Dry pivot points. Lubricate steering mechanism.
• Damaged steer wheels. Replace wheels.
• Bent steer axle. Repair or replace axle assembly.
• Floor debris or damage. Clear obstructions, repair floor.

Excessive noise during operation

Possible causes and solutions

• Worn wheel bearings. Replace bearings.
• Damaged wheels. Replace wheels.
• Loose components. Tighten all fasteners.
• Lack of lubrication. Lubricate pivot points and moving parts.

Electric unit will not move

Possible causes and solutions

• Dead or discharged battery. Charge or replace battery.
• Blown fuse. Check and replace fuses.
• Safety switch engaged. Check belly button, key switch, and tiller position.
• Loose electrical connection. Inspect and tighten connections.
• Controller fault. Check for error codes, reset or repair controller.

Maintenance schedules

Organizing maintenance into regular schedules ensures nothing gets overlooked. Adjust these schedules based on usage intensity and manufacturer recommendations.

Daily (operator performed)

• Visual inspection for obvious damage or leaks
• Functional test of lift, lower, and steering
• Check battery charge level (electric units)
• Report any problems found

Weekly

• Clean equipment of debris and accumulated dirt
• Check wheel condition
• Inspect forks for visible damage
• Check battery water level (lead acid)
• Lubricate chains (electric units)

Monthly

• Check hydraulic fluid level
• Lubricate all pivot points
• Inspect electrical connections (electric units)
• Test all safety devices
• Detailed fork inspection
• Check brake function

Quarterly

• Detailed inspection of all systems
• Wheel bearing inspection and service
• Battery load testing (electric units)
• Hydraulic system service if needed
• Tighten all fasteners

Annually

• Complete equipment inspection
• Fork thickness measurement
• Load testing to verify capacity
• Hydraulic seal replacement if showing wear
• Update maintenance records
• Professional service inspection

Maintenance records

Keeping good records supports several important functions.

What to record

• Equipment identification (serial number, model, location)
• Date and type of each inspection or service
• Problems found and corrective actions taken
• Parts replaced with part numbers and costs
• Name of person performing the work
• Operating hours or date-based usage metrics

Benefits of good records

• Track maintenance history for each piece of equipment
• Identify recurring problems that might indicate design issues or misuse
• Plan parts ordering based on typical replacement intervals
• Demonstrate regulatory compliance where required
• Support warranty claims with documented service history
• Inform replacement decisions based on total maintenance costs

Record keeping systems

Options range from simple paper logs to sophisticated computerized maintenance management systems (CMMS). Choose an approach that matches your operation's size and complexity. The best system is one that actually gets used consistently.

When to call professionals

Some maintenance tasks are appropriate for in-house staff. Others require specialized knowledge, tools, or certifications.

Tasks suitable for trained in-house staff

• Daily and weekly inspections
• Adding hydraulic fluid
• Bleeding air from hydraulic systems
• Wheel replacement
• Basic lubrication
• Battery watering and terminal cleaning
• Simple adjustments and minor repairs

Tasks typically requiring professional service

• Hydraulic pump rebuilds or replacement
• Fork replacement or structural repairs
• Electric motor service
• Controller programming or replacement
• Annual safety inspections where certification is required
• Complex troubleshooting of electronic systems
• Work covered under warranty

Finding service providers

Options for professional pallet jack service include

• Equipment dealers who often have service departments
• Independent material handling service companies
• General industrial equipment repair shops
• Mobile service technicians who come to your location

Establish relationships with service providers before emergencies arise. Know who to call and what their typical response times are.

Parts inventory

Stocking common spare parts reduces downtime when repairs are needed.

Recommended stock items

• Replacement wheels (load and steer) for each model in use
• Wheel bearings
• Hydraulic seal kits
• Hydraulic fluid
• Grease and lubricants
• Handle grips if replaceable
• Fuses (electric units)
• Common fasteners

Inventory management

Track parts usage to maintain appropriate stock levels. Set reorder points so you replace parts before running out. Consider the lead time for ordering when setting minimum quantities.

For operations with multiple equipment brands, consolidating to fewer models simplifies parts inventory and technician training.

Training

Effective maintenance requires trained people at both operator and technician levels.

Operator training

All pallet jack operators should understand

• Pre-shift inspection procedures
• How to identify and report problems
• Proper operating techniques that reduce equipment wear
• What constitutes unsafe equipment that should not be used

Maintenance technician training

Personnel performing maintenance should have

• Understanding of pallet jack systems and how they work
• Skills to perform assigned maintenance tasks safely
• Knowledge of when to escalate problems to professionals
• Familiarity with manufacturer documentation for equipment in use

Equipment manufacturers and dealers often offer training programs. Industry associations provide resources and sometimes certification programs.

Related topics

Explore more about pallet jacks and equipment care

• Pallet jack types and their applications
• Pallet jack features to look for when buying
• Big Joe pallet jack brand guide
• Pallet jack rental considerations
• Forklift batteries comprehensive guide

References

• OSHA powered industrial truck standards and guidance
• Industrial Truck Standards Development Foundation safety standards
• Material Handling Industry association resources
• Toyota Material Handling maintenance guidelines
• Crown Equipment operator and service resources
• Jungheinrich technical documentation