Common Hand Pallet Truck Problems and Solutions

Hydraulic System Failures

Hydraulic problems are among the most common issues with hand pallet trucks. These problems typically manifest as difficulty lifting loads, forks that won't stay raised, or complete failure to lift.

Insufficient Lifting Power

When your hand pallet truck struggles to lift loads that it previously handled easily, the issue is often related to low hydraulic fluid levels or air in the system.

Start by checking the hydraulic fluid level. Locate the filler plug, usually found on the hydraulic cylinder or pump housing. Remove the plug and check if fluid is visible near the opening. If the level is low, add the appropriate hydraulic fluid as specified in your equipment manual.

If fluid levels are adequate, air may have entered the system. To bleed air from the hydraulic system, pump the handle several times with the forks in the lowered position. This action helps push air bubbles through the system and back to the reservoir.

Forks Won't Stay Raised

When forks slowly descend under load or won't maintain their raised position, internal seal damage or valve problems are likely culprits.

Check the release valve first. If the valve isn't fully closed, hydraulic fluid will continue to flow back to the reservoir, causing the forks to lower. Ensure the control lever is in the fully raised position to close the release valve completely.

If the valve is properly closed but the problem persists, internal seals may be damaged. This repair typically requires disassembly of the hydraulic cylinder and replacement of worn seals. Consider consulting a professional for this repair if you're not experienced with hydraulic systems.

Complete Lifting Failure

When the hand pallet truck won't lift at all, the problem could be a completely empty hydraulic system, damaged pump mechanism, or blocked hydraulic lines.

First, check for obvious fluid leaks around the cylinder, pump, and connecting lines. If you find leaks, address them before adding fluid to the system. Small leaks can often be repaired with new seals or gaskets.

If no leaks are visible, check the pump mechanism. Remove the pump cover and inspect the pump components for damage or wear. Replace any obviously damaged parts, ensuring you use components specifically designed for your truck model.

Wheel and Steering Issues

Wheel problems can make hand pallet trucks difficult to maneuver and can cause uneven load distribution that stresses the frame and hydraulic system.

Worn or Damaged Load Wheels

Load wheels bear the weight of the truck and its cargo, making them susceptible to wear and damage. Worn wheels can cause the truck to ride unevenly, making it difficult to maneuver and potentially damaging floors.

Inspect load wheels regularly for signs of wear, flat spots, or damage. Small chips or rough spots can often be smoothed with sandpaper, but severely worn or damaged wheels should be replaced.

To replace load wheels, you'll typically need to remove the axle pin or bolt that holds the wheel in place. Support the fork assembly properly during wheel replacement to prevent injury and damage to other components.

Steering Problems

Steering issues can make hand pallet trucks dangerous to operate and can lead to accidents or damage to goods and equipment.

Check the steering wheel assembly for proper alignment and smooth operation. The steering wheels should turn freely without binding or excessive play. If steering feels stiff or unresponsive, inspect the steering mechanism for damage or obstruction.

Lubricate steering components according to the manufacturer's specifications. Many steering problems can be resolved with proper lubrication of pivot points and bearing surfaces.

Fork and Frame Problems

The fork assembly and frame must be structurally sound to safely handle rated loads. Damage to these components can be dangerous and should be addressed immediately.

Bent or Damaged Forks

Forks can become bent or damaged from overloading, impact with obstacles, or improper use. Damaged forks can cause loads to shift or fall, creating serious safety hazards.

Inspect forks regularly for signs of bending, cracking, or other damage. Minor bends can sometimes be straightened using hydraulic presses, but severely damaged forks should be replaced.

When replacing forks, ensure that new forks match the specifications of your original equipment. Forks must be properly rated for your truck's load capacity and must be installed according to manufacturer specifications.

Frame Cracks or Damage

Frame damage is serious and can compromise the structural integrity of the entire hand pallet truck. Cracks in the frame can grow over time and may eventually cause catastrophic failure.

Inspect the frame regularly, paying particular attention to weld joints, stress points, and areas where the frame may have been impacted. Small cracks can sometimes be repaired by qualified welders, but extensive damage typically requires professional evaluation.