Pallet Truck Repair

Knowing what you should know about pallet truck repair helps you make smart decisions about fixing versus replacing equipment, tackle simple repairs in-house, and find qualified help for complex problems. Most pallet jack issues fall into predictable categories with established solutions.

Pallet jacks are workhorses that eventually need attention. Understanding common problems, repair options, and costs helps you keep equipment running efficiently while avoiding unnecessary downtime and expense. This guide covers what you need to know about pallet truck repair.

Common pallet jack problems

Hydraulic system issues

Won't lift. Pump failure, low fluid, air in system.
Won't hold load. Internal leak, worn seals, faulty valve.
Lifts slowly. Low fluid, worn pump, cold fluid.
Won't lower. Stuck release valve, debris in valve.
Leaking. Worn seals, damaged lines, loose fittings.

Mechanical issues

Hard to push. Worn wheels, damaged bearings, bent fork.
Steering problems. Worn steer wheel, damaged pivot.
Handle loose. Worn pivot bushings, missing pins.
Forks bent. Overload damage, impact damage.
Noise. Worn bearings, dry pivots, loose parts.

Wheel problems

Flat spots. Brake lock, heavy loads, sitting still.
Chunking. Chemical damage, overloading, debris impact.
Won't roll. Bearing failure, debris wrapped around axle.
Excessive wear. Overloading, rough floors, dragging loads.

Troubleshooting guide

Jack won't lift at all

Check	Possible Cause	Solution
Fluid level	Too low	Add hydraulic fluid to proper level
Release valve	Open or stuck	Close valve, clean if stuck
Air in system	Entered during service	Bleed air from system
Pump	Worn or damaged	Rebuild or replace pump

Load slowly drops

Check	Possible Cause	Solution
Release valve	Not sealing	Clean or replace valve
Cylinder seals	Worn, allowing bypass	Replace seal kit
Check valves	Not seating	Clean or replace
Contamination	Debris in fluid	Drain, clean, refill system

Hard to push/pull

Check	Possible Cause	Solution
Load wheels	Flat spots, damage	Replace wheels
Wheel bearings	Worn or seized	Replace bearings or wheels
Debris	Wrapped around axles	Remove debris
Forks	Bent, dragging	Straighten or replace forks
Overload	Too much weight	Reduce load

Repairs you can do

Adding/changing hydraulic fluid

Lower forks completely
Locate fill plug (usually on pump housing)
Remove plug, check level
Add proper hydraulic jack oil to correct level
Replace plug securely

Note: Use correct fluid type. See our pallet jack hydraulic oil guide.

Bleeding air from system

Lower forks fully, release valve open
Pump handle rapidly 10-15 times
Close release valve
Pump to raise forks
Repeat if necessary

Wheel replacement

Load wheels (fork wheels):

Raise forks fully with no load
Block forks to prevent lowering
Remove axle retaining clip or bolt
Remove old wheel
Install new wheel
Secure axle

Basic lubrication

Apply grease to pivot points as specified
Lubricate handle pivot
Oil linkage connections
Don't over-lubricate—attracts dirt

Repairs requiring professional help

Hydraulic pump rebuild

Requires disassembly of pump unit
Seal replacement and component inspection
Proper tools and knowledge needed
Incorrect assembly causes failure

Cylinder repair

Internal seal replacement
Cylinder bore inspection
Rod straightening or replacement

Fork straightening or replacement

Heat and press required for straightening
Improper repair weakens fork
Welding forks not recommended

Frame repair

Structural welding requires expertise
Improper repair creates safety hazard
Consider replacement for major damage

Repair vs. replace decision

Consider repair when

Jack is relatively new (under 3-5 years)
Problem is minor and specific
Repair cost under 50% of replacement
Rest of jack is in good condition
Quality brand worth maintaining

Consider replacement when

Multiple problems exist
Repair cost exceeds 50-60% of new
Jack is old with accumulated wear
Forks are bent or cracked
Frame is damaged
It's a cheap jack not worth repairing

Cost comparison

Repair Type	Typical Cost
Wheel replacement (pair)	$50-150
Seal kit installation	$75-200
Pump rebuild	$150-350
Complete overhaul	$250-500
New standard jack	$300-600

If repair approaches 50% of new cost, replacement often makes more sense.

Finding repair services

Options for repair

Forklift dealers. Most service pallet jacks too.
Material handling service companies. Specialize in this equipment.
Industrial equipment repair shops. General repair capabilities.
Mobile repair services. Come to your location.
In-house maintenance. If you have qualified staff.

What to look for

Experience with pallet jacks specifically
Access to parts (OEM or quality aftermarket)
Reasonable response time
Fair pricing
Warranty on repairs

Questions to ask

Do you service this brand/model?
What's the diagnostic fee?
Will you provide an estimate before repair?
What's the turnaround time?
Do you warrant your work?
Do you offer on-site service?

Replacement parts

Common replacement parts

Load wheels. $15-50 each.
Steer wheels. $30-80 each.
Seal kits. $20-60.
O-rings. $5-15 per set.
Handle grips. $10-25.
Entry rollers. $15-40 per pair.
Push rods. $30-80.

Parts sources

Equipment dealers (OEM parts)
Industrial supply houses
Online parts specialists
Aftermarket suppliers

See our hand pallet jack parts guide for details.

Preventing repairs

Regular maintenance

Daily inspection catches problems early
Keep wheels clean
Maintain proper fluid level
Lubricate as specified
Address issues promptly before they worsen

Proper use

Don't exceed rated capacity
Avoid impacts and drops
Don't drag loads
Keep forks off the ground when not under pallet
Park properly—lower forks, release pressure

Environment

Keep floors clean
Protect from extreme weather
Store indoors when possible
Clean up spills that damage wheels

See our pallet jack maintenance guide for complete procedures.

Safety during repair

Never work under raised forks without blocking
Release hydraulic pressure before disassembly
Use proper tools
Wear appropriate PPE
Don't use damaged equipment until repaired
Tag out defective equipment
Follow manufacturer procedures