Electric Hydraulic Pallet Truck Repair Guide: Troubleshooting & Maintenance Tips

Electric hydraulic pallet trucks are indispensable in logistics, warehousing, and manufacturing for their compact design, maneuverability, and cost efficiency. However, frequent heavy-duty use leads to frequent malfunctions. This guide shares a manufacturer’s proven repair strategies, illustrated through a real-world case study.

Case Study: Motor Failure in a Pallet Truck Fleet

A factory’s fleet of electric hydraulic pallet trucks malfunctioned, with trucks unable to operate. Initial diagnostics pinpointed motor failure—a common issue due to prolonged daily use. To resolve this, the factory conducted systematic inspections across all trucks:

Step 1: Inspect the Motor

Visual Check: Replace motors showing burn marks, deformation, or cracks immediately.

Voltage/Current Test:

Low voltage? Recharge the battery.

High current? Check for excessive load or motor overload.

Step 2: Diagnose Electrical Systems

If the motor appears functional but the truck still fails:

Circuit Test: Identify breaks or short circuits in wiring.

Control System Check: Repair or replace faulty control panels, sensors, or circuit boards.

Step 3: Hydraulic System Maintenance

Hydraulic failures often cause operational disruptions. Key checks include:

Fluid Levels: Ensure clean hydraulic oil at recommended levels.

Pump/Motor Integrity: Inspect for leaks, wear, or blockages in pumps, valves, and tubing.

Seal Replacement: Address leaking seals promptly.

Step 4: Tire and Wheel Hub Inspection

Wear Assessment: Replace tires with uneven tread or cracks.

Alignment Check: Ensure hubs rotate smoothly to prevent premature wear.

Step 5: Braking System Safety Audit

Brake Component Test: Examine brake pads, discs, and fluid for leaks or wear.

Functionality Test: Ensure brakes engage smoothly under load.

Preventive Maintenance for Longevity

Schedule monthly inspections of motors, hydraulics, and brakes.Train operators to report early signs of malfunction (e.g., unusual noises, slow response).Partner with certified technicians for complex repairs.