MaintenanceLogistics and Warehousing
Pallet Jack Maintenance Checklist
Keep your pallet jacks in optimal condition with our comprehensive maintenance checklist covering hydraulics, wheels, and safety systems for both manual and electric models.
Free Template
Overview
Our pallet jack maintenance checklist helps warehouse managers and maintenance teams conduct systematic inspections and preventive maintenance on manual and electric pallet jacks. This template prevents equipment failures, reduces workplace injuries, and extends the life of your material handling equipment.
Key Benefits
Complete Checklist
Hydraulic System Inspection
- Check hydraulic fluid level and top off if needed
- Inspect hydraulic pump for leaks or damage
- Test lift mechanism for smooth operation
- Check release valve functionality
- Inspect hydraulic cylinders for leaks
- Verify lift does not drift when raised
- Check for proper lifting capacity
- Inspect hydraulic lines and connections
- Test lowering mechanism for controlled descent
- Verify handle returns to neutral position
Wheel and Fork Inspection
- Inspect load wheels for wear and damage
- Check steering wheels for smooth rotation
- Verify wheels are properly lubricated
- Inspect forks for cracks, bends, or damage
- Check fork tips for excessive wear
- Verify forks are parallel and level
- Inspect fork welds and connections
- Check wheel bearings for play or noise
- Verify proper wheel alignment
- Inspect polyurethane wheel condition
Frame and Structure
- Inspect main frame for cracks or damage
- Check all welds for integrity
- Verify frame is not bent or twisted
- Inspect handle attachment and pivot points
- Check load backrest if equipped
- Verify structural integrity under load
- Inspect protective guards and covers
- Check for loose or missing fasteners
- Verify capacity rating plate is visible
- Inspect paint for rust or corrosion
Handle and Controls
- Test handle operation for smooth movement
- Inspect handle grips for damage or wear
- Check lift/lower control lever function
- Verify handle height adjustment if applicable
- Inspect handle return spring operation
- Check for excessive play in handle
- Verify emergency lowering mechanism
- Test steering responsiveness
- Inspect control linkages and cables
- Check for proper ergonomic operation
Electric Pallet Jack Systems (if applicable)
- Check battery charge level and condition
- Inspect battery connections for corrosion
- Test drive motor operation
- Verify lift motor functionality
- Check emergency stop button operation
- Inspect wiring and electrical connections
- Test throttle control responsiveness
- Verify battery charger operation
- Check for error codes or indicators
- Inspect safety sensors and switches
Maintenance and Documentation
- Clean and remove debris from all components
- Lubricate all grease points and pivot points
- Tighten all loose fasteners and connections
- Document inspection findings and date
- Create work orders for repairs needed
- Update maintenance log and history
- Tag out defective equipment immediately
- Schedule next preventive maintenance
- Verify operator training is current
- Review accident or incident reports
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