Routine Maintenance Checklist for Pallet Trucks: Keep Your Equipment Running Smoothly
- Carey
- Jul 3
- 3 min read
Pallet trucks are an essential part of day-to-day warehouse and logistics operations, helping teams move loads quickly, safely and efficiently. But like any piece of equipment, they require regular maintenance to keep them performing at their best. A well-maintained pallet truck reduces downtime, improves safety, extends the life of your investment and cuts repair costs.
Whether you're using a manual hand pallet truck or a powered electric pallet truck, having a maintenance routine is crucial. In this post, we’ve outlined everything you need to know to keep your pallet trucks in top condition—and we’ll also recommend a few reliable models from our range that are built for performance and durability.
Why Pallet Truck Maintenance Matters
Routine maintenance isn’t just about keeping your equipment working—it's about:
Reducing long-term repair costs
Improving operational efficiency
Ensuring operator safety
Minimising downtime
Extending equipment lifespan
A poorly maintained pallet truck can lead to breakdowns, workplace injuries and costly interruptions to your operations.
Maintenance Checklist for Hand Pallet Trucks
Hand pallet trucks are simple and reliable, but they still need regular checks to ensure safe operation.
Daily/Weekly Checks:
Visual inspection – Check for visible damage, cracks, or bent forks.
Wheels and rollers – Inspect for wear or flat spots, and ensure smooth rolling.
Hydraulic pump – Make sure the truck lifts and lowers smoothly; check for oil leaks.
Handle and controls – Ensure the handle returns to the upright position and operates smoothly.
Lubrication – Grease pivot points and axles as per the manufacturer’s recommendation.
Monthly Maintenance:
Oil level check – Top up hydraulic oil if necessary (use the correct oil type).
Tighten bolts and nuts – Vibration during operation can loosen fittings.
Clean thoroughly – Remove dust, dirt and debris from the truck, especially moving parts.
Maintenance Checklist for Electric Pallet Trucks
Electric pallet trucks offer speed and efficiency for larger operations, but they also have more components to maintain.
Daily/Weekly Checks:
Battery check – Inspect for proper charge, leaks, and corrosion on terminals.
Tyres and castors – Examine for tread wear, cuts or embedded debris.
Safety switches and controls – Test emergency stop, horn, and control functions.
Forks and chassis – Inspect for damage or wear.
Hydraulic system – Check for leaks and smooth lifting action.
Monthly Maintenance:
Battery water level – For lead-acid batteries, ensure electrolyte levels are within range.
Brake inspection – Check the responsiveness and condition of electric braking systems.
Motor and wiring – Look for frayed wires or signs of overheating.
Grease and oil – Lubricate moving parts and apply anti-corrosion treatments if needed.
Software diagnostics – Some models may require a software health check or firmware update.
Tips for Efficient Pallet Truck Maintenance
Train your operators – A trained team will spot issues early and use equipment correctly.
Keep a maintenance log – Record checks, issues found, and servicing dates.
Use genuine parts – Always replace worn-out components with original or approved parts.
Set a servicing schedule – Have regular professional inspections, especially for electric models.
Store correctly – Keep trucks in dry areas to prevent rust and corrosion.
Product Recommendations
Lift-It 25/20 Pallet Truck
Heavy-duty hand pallet truck with 2000mm forks, ideal for extra-long or multiple pallets. Smooth handling, durable build, and 2500kg capacity for reliable everyday use.
Heavy Duty NDPYP Pallet Truck Weigher with Printer
Tough pallet truck with built-in weighing scale and thermal printer. 2000kg capacity, perfect for fast, accurate weighing and labelling during handling. Ideal for warehouses and logistics.
EP F-Series F4 Li-ion Powered Pallet Truck
Compact and powerful electric pallet truck with 1500kg capacity. Features a long-lasting Li-ion battery and lightweight design, ideal for tight spaces and efficient daily handling.
EP EPL185 Powered Pallet Truck
Versatile electric pallet truck with 1800kg capacity and maintenance-free Li-ion battery. Compact, efficient, and ideal for retail, warehouse, and delivery operations.
Routine maintenance isn’t optional—it’s essential for the efficiency and safety of your operations. By following a regular maintenance checklist, you’ll reduce breakdowns, avoid costly repairs, and make the most of your equipment investment.
Need help choosing a pallet truck that fits your needs—or advice on maintenance? Contact the team at Nationwide Handling. We’re here to help you keep your operations moving.
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