7 Must-Do Maintenance Tips to Double Your Manual Pallet Truck’s Lifespan

7 Must-Do Maintenance Tips to Double Your Manual Pallet Truck’s Lifespan

In the fast-paced environment of warehousing and logistics, manual hydraulic pallet trucks (commonly known as “pallet jacks”) serve as the silent backbone, supporting the daily movement of tons of goods. However, many operators often fall into the misconception of “heavy usage, light maintenance”—only realizing the severity of the problem when hydraulic systems leak, wheel axles seize up, or the equipment suddenly fails during operation. These hidden risks not only reduce the equipment’s lifespan by over 30% but may also lead to safety incidents such as falling goods or worker injuries.

The value of preventive maintenance far exceeds your imagination.
A set of comparative data is enough to illustrate the point: regularly maintained pallet trucks experience a 70% reduction in failure rates, while maintenance costs are only 1/5 of major repair expenses. With just 5 minutes of daily basic inspections, 90% of potential failure points can be identified in advance, such as hydraulic oil leaks, loose chains, or wheel hub wear. This habit of “small investment, big return” is directly tied to operational efficiency and the equipment’s service life.

Ready to transform your pallet truck’s reliability? Let’s dive into the seven non-negotiable maintenance practices that every operator should master—starting with the daily inspection routine that takes less than three minutes but saves thousands in repair costs.

1. Check and Refill Hydraulic Oil for the Hand Pallet Truck

It is recommended to check the hydraulic oil level every six months and to refill or replace the hydraulic oil at least once a year. The hand pallet truck should use specialized hydraulic oil with a viscosity of 30cSt at 40°C and a total oil capacity of approximately 0.4 liters (ISO VG32 standard). If other oil products are used, their higher viscosity may make it difficult to pump and lift the truck.

Please follow the steps below to refill the hydraulic oil for your hand pallet truck:

• Lower the forks to the lowest position, then lay the truck on its side.
• Ensure the oil drain plug of the hydraulic cylinder faces upward.
• Remove the oil filler plug.
• Add hydraulic oil until the oil level reaches the bottom of the filler hole.
• Reinstall the oil filler plug and return the truck to an upright position.

If the forks cannot lift when the operating lever is in the RAISE position, this may be due to air bubbles entering the hydraulic oil during transportation or operating the lever while the truck is not upright.

How to bleed air from the hydraulic system? Keep the operating lever in the LOWER position and pump the handle up and down several times. This will expel the air, allowing the forks to lift normally when pumping.

(Note: The original text was already in English, so this is a polished version for clarity and consistency.)

2. Regular Lubrication for Manual Hydraulic Hand Pallet Trucks

Did you know that the bearings and axles of your manual hydraulic hand pallet truck also need “moisturizing care”? These critical components are pre-lubricated with long-lasting grease at the factory, but with continuous use, the lubrication effectiveness gradually diminishes.

We recommend performing monthly inspections and replenishing lubrication for key points such as wheels, axles, and grease fittings—especially after cleaning or exposure to water. Just like skin needs regular care, consistent lubrication maintenance ensures smoother operation and extends the service life of your hand pallet truck.

 

3. Protect the Wheels of Your Hand Pallet Truck

A clean working environment enhances comfort and efficiency. The condition of the floor surface where the hand pallet truck operates is crucial for wheel longevity. Any type of dirt, debris, or cables can get stuck between the wheels, significantly accelerating wear and tear. Regularly cleaning the wheels and removing such obstructions before use can easily prevent this issue.

Additionally, be mindful of curbs and steps. Taking shortcuts may seem like a good idea, but your wheels might disagree. Opting for a slightly longer route instead can prevent cracks and damage to the wheels.

Overloading the hand pallet truck can also have serious consequences for the wheels. Even if it takes a bit more time, making two trips is better than overloading the truck in a single run. This helps prevent flat spots on the wheels, thereby extending their lifespan.

Learn more about how to protect your hand pallet truck’s wheels and recognize when they need replacement.

4. Regularly Check if the Chain is Properly Positioned

The chain is a critical component of the pallet jack’s lifting system, directly affecting the operation of the forks. During daily use, if the forks fail to lower properly, it is often due to chain misalignment. The solution is simple—just reposition the chain onto the designated location of the control lever.

We recommend including chain inspection as part of routine maintenance to regularly verify its correct positioning. This helps prevent operational failures and ensures the equipment remains in optimal working condition. Much like regularly checking a bicycle chain, this small habit can significantly extend the service life of your pallet jack.

5. Adjust the Lowering Valve When the Pallet Jack Fails to Lift or Lower the Forks

Is your pallet jack unable to lift or lower the forks? This is likely due to an issue with the lowering valve. In such cases, you need to adjust the lowering valve to restore proper lifting and lowering functionality.

• If lifting doesn’t work, slightly loosen the lowering valve screw.
• If the forks won’t lower, gently tighten the lowering valve screw.

Tip: After use, always store the pallet jack in the unloaded, fully lowered position.

6. Use Your Pallet Truck Correctly and Safely

Mastering these three techniques will significantly extend your pallet truck’s service life: Avoid operating the pallet truck on slopes, as releasing your grip may cause it to roll backward and collide with objects. When moving the pallet truck, always set the control lever to the DRIVE position—this ensures smoother handle movement while reducing pressure in the hydraulic pump section, protecting hydraulic seals and valve components for long-term durability. Never exceed the maximum rated load capacity, as overloading can cause irreversible damage to the pallet truck’s critical components. Additionally, remember that riding on the pallet truck is strictly prohibited, as it poses serious safety risks and may lead to accidents or equipment damage. By adhering to these practices, you can maintain both operator safety and the pallet truck’s optimal performance over time.

Conclusion

Maintaining your pallet truck for extended durability is actually quite straightforward. Daily attention should focus on several key components: maintaining proper hydraulic oil levels, regularly inspecting wheel wear conditions, ensuring adequate lubrication at grease fittings, and correctly adjusting the lowering valve. These seemingly simple maintenance measures can significantly extend equipment lifespan while helping prevent unexpected breakdowns that lead to operational downtime. In the long run, this approach will save considerable repair costs and time expenditures. Remember: preventive maintenance is always more cost-effective than post-failure repairs.