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Common Pallet Truck / Pallet Jack Problems and Maintenance Tips

Pallet trucks, also known as pallet jacks, are essential material handling tools in warehouses, factories, retail environments, and logistics operations. They offer a practical and efficient way to transport heavy loads across short distances. Despite their durable design, pallet trucks experience wear and tear over time, especially in high-usage environments.

Understanding common pallet truck/pallet jack problems and implementing proper maintenance practices can significantly extend equipment lifespan, improve workplace safety, and reduce costly downtime. This article explores the most common pallet jack issues and provides practical maintenance tips to keep them operating efficiently.

Hydraulic System Problems

The hydraulic system is the core of a pallet truck, enabling it to lift and lower loads. Issues in this system can render the pallet jack unusable.

Common hydraulic issues include:

Pallet truck fails to lift or lifts very slowly

Forks do not stay raised under load

Hydraulic oil leaks

Inconsistent or jerky lifting motion

Maintenance tips:

Regularly check hydraulic oil levels and top up as needed

Use manufacturer-recommended hydraulic oil only

Inspect seals and valves for leaks or damage

Bleed air from the hydraulic system if lifting becomes inconsistent

Schedule periodic servicing to maintain hydraulic performance

Keeping the hydraulic system in good condition ensures smooth lifting and reliable operation.

Worn or Damaged Wheels and Rollers

Wheels and rollers experience constant contact with the floor and are prone to wear, especially on rough or uneven surfaces.

Common wheel-related problems:

Flat spots or cracked wheels

Difficulty maneuvering the pallet truck

Increased noise during movement

Uneven rolling or vibration

Maintenance tips:

Inspect wheels regularly for wear and damage

Replace worn wheels promptly to prevent further strain on the truck

Choose wheels made from suitable materials for your floor type, such as polyurethane or nylon

Keep wheels clean and free from debris

Avoid dragging the pallet truck across uneven surfaces

Proper wheel maintenance improves maneuverability and reduces operator fatigue.

Handle and Control Lever Issues

The handle and control lever allow operators to steer, lift, and lower the pallet truck. Damage or malfunction can affect both safety and usability.

Common handling problems:

Loose or bent handles

Malfunctioning release levers

Difficulty lowering loads

Stiff or unresponsive controls

Maintenance tips:

Tighten loose bolts and fasteners regularly

Lubricate the moving parts of the handle and lever mechanism

Replace damaged handles or levers immediately

Train operators on proper handling techniques to avoid misuse

Well-maintained controls ensure smooth operation and reduce the risk of accidents.

Fork Alignment and Structural Damage

Forks support the load, and any misalignment or structural damage can compromise safety and efficiency.

Common fork-related issues:

Bent or uneven forks

Cracks in the fork structure

Difficulty entering pallets

Uneven load lifting

Maintenance tips:

Inspect forks for cracks, bends, or warping

Avoid exceeding the pallet truck’s rated load capacity

Do not use the pallet truck to push or pull heavy objects

Repair or replace damaged forks immediately

Ensure loads are evenly distributed before lifting

Maintaining proper fork alignment helps prevent accidents and load instability.

Overloading and Misuse

Overloading is a common cause of pallet truck failure and safety incidents.

Problems caused by overloading:

Premature hydraulic failure

Bent forks or frame damage

Increased wear on wheels and bearings

Reduced maneuverability and control

Prevention tips:

Always adhere to the manufacturer’s load capacity guidelines

Train operators on safe loading practices

Use appropriate equipment for heavier loads

Avoid sudden stops or sharp turns with heavy pallets

Proper usage reduces strain on the pallet truck and extends its service life.

Bearing and Bushing Wear

Bearings and bushings help reduce friction in moving parts, but they wear out over time.

Common symptoms:

Squeaking or grinding noises

Stiff or uneven movement

Reduced lifting efficiency

Maintenance tips:

Lubricate bearings and bushings regularly

Replace worn components promptly

Perform routine inspections to identify early signs of wear

Maintaining bearings ensures smooth operation and minimizes long-term damage.

Environmental and Floor Condition Issues

Operating conditions significantly affect pallet truck performance.

Common environmental challenges:

Rough or uneven flooring

Dust, dirt, and debris buildup

Exposure to moisture or chemicals

Extreme temperature fluctuations

Maintenance tips:

Keep floors clean and smooth to reduce wheel wear

Use pallet trucks designed for specific environments

Clean pallet trucks regularly to remove debris

Store equipment in dry, sheltered areas

Adapting maintenance practices to the operating environment improves reliability.

Routine Inspection and Preventive Maintenance

Regular inspections help identify minor issues before they become major problems.

Recommended inspection checklist:

Check hydraulic function and oil levels

Inspect wheels, forks, and handle condition

Test lifting and lowering controls

Look for visible damage or leaks

Preventive maintenance tips:

Create a scheduled maintenance plan

Maintain service records for each pallet truck

Replace worn parts proactively

Engage professional servicing when needed

Preventive maintenance reduces downtime and repair costs.

Operator Training and Safety Practices

Training operators properly helps prevent common pallet truck problems and improves overall safety and efficiency.

Best practices for operators:

Operate pallet trucks smoothly and avoid sudden movements

Keep hands and feet clear of moving parts

Do not ride on pallet trucks

Park pallet trucks safely when not in use

Training improves safety, efficiency, and equipment longevity.

Choosing Quality Pallet Trucks and Spare Parts

Investing in high-quality pallet trucks and replacement parts reduces long-term issues.

What to consider:

Reputable manufacturers and suppliers

Availability of spare parts

Warranty and after-sales support

Compatibility with your operational needs

Quality equipment performs better and requires fewer frequent repairs.

Final Thoughts

Pallet trucks and pallet jacks are vital tools in material handling operations, but they require regular care to perform reliably. Common problems such as hydraulic failures, worn wheels, handle issues, and structural damage can disrupt operations if left unaddressed.

By implementing routine inspections, proper maintenance, and operator training, businesses can significantly extend the lifespan of their pallet trucks while maintaining a safe and efficient work environment. Preventive maintenance not only reduces downtime and repair costs but also improves productivity and workplace safety.

The Doosan 4500-pound electric walkie truck is perfect for moving heavy loads around your warehouse or facility. It has a lifting capacity of 4500 pounds and a travel speed of 3.7 mph. The pallet jack is also equipped with a low speed/brake override switch, dual lift cylinders, and stability skids for safety and stability. Rent the Doosan electric pallet jack by calling Rentalex at (813)971-9990.