How to Troubleshoot an Electric Pallet Jack


Many electric pallet jack problems are caused by either a low fluid level, drained battery or surplus air in the hydraulic system. An inadequate oil level will cause a fork lift to fail to raise or lower completely. The pump station motor will not turn if the jack has a weak battery. Uneven movements or choppiness will occur when the forks are lifted if excess air is trapped in the hydraulic system. To save time, troubleshoot your electric pallet jack by verifying the fluid levels are correct, battery is up and the hydraulic system is free of air.

Things You'll Need

  • Hydraulic oil, as needed
  • Screwdriver
  • Check the hydraulic fluid or jack oil if the forks do not lift high enough. Common level for optimum efficiency is about 1" deep. Press the "Down" button to lower the forks and then add enough fluid without overfilling. If your electric pallet jack does not operate properly, go to the next step.

  • Charge the battery if lifting speed slows down. Press the "Down" button to lower the forks and then use a screwdriver to remove the screws that secure the metal cover hiding the battery charger power cable. Refer to your owner's manual for the exact location of the battery charger power cable.

  • Pull the charger power cable out to lengthen it and put the end plug in a 115-volt single phase, grounded wall socket.

  • Verify that the battery is charging by observing the yellow indicator charging light. A complete charge may take between 4 and 16 hours on the low end for normal charging; on the high end if a battery is totally drained prior to charging it.

  • Remove the battery charger power cable plug from the wall socket, place it back in the housing unit, and then reassemble the battery charger power cable metal cover. If your electric pallet jack does not operate properly, go to the next step.

  • Remove excess air from the hydraulic system to bleed the cylinders. Press the "Up" button and lift forks as high as possible. Push the "Down" button and lower forks as low as possible.

  • Repeat step 6 four times to completely remove excess air from the hydraulic system.

Tips & Warnings

  • Inspect the fuses and replace when needed. Use the recommended amperage for your particular electric pallet jack model.
  • Commonly, an automatic safety valve opens when a jack is filled past recommended capacity. However, the pump station life-cycle will be reduced if you press the "Up" button when the electric pallet jack is overloaded.

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