Pallet Jack Handle Replacement Guide

Pallet jacks are essential tools for efficiently moving heavy loads in warehouses and distribution centers. However, over time, the handle can succumb to wear and tear or damage due to misuse. In such cases, you don't need to fret; the good news is that you can replace the handle yourself with some basic tools and materials.  

In this guide, we'll walk you through the step-by-step pallet jack handle replacement process. Let’s get started!

Tools Required

Before you begin the repair, gather the following tools and materials:

• A new pallet jack handle with a control chain.
• Hammer
• Phillips screwdriver
• Flathead screwdriver
• Pin punch
• Pliers
• 10mm wrench

Safety First

Before starting any repair work, ensure your safety. Follow these precautions:

• Clear and well-lit workspace: Make sure your work area is free from obstacles and there's adequate lighting.
• Personal protective equipment: Wear gloves and eyewear to protect yourself from potential injuries.
• Avoid tripping hazards: Secure any cords or tools that may cause you to trip while working on the pallet jack.

With safety in mind, let's proceed with the repair.

Assessing the Damage (Inspection)

The first step is to assess the damage to your pallet jack handle. Examine the handle and its components for the following issues:

• Handle Damage: Check for visible cracks or breaks in the handle. If the handle is damaged, you'll need to replace it entirely.
• Roll Pin Inspection: Inspect the roll pin that holds the handle axle in place. If the pin is bent or missing, it must be replaced.
• Control Chain: Examine the control chain that connects the handle to the foot pedal for any signs of damage or wear. If the chain is broken or loose, it will need adjustment.
• Control Components: Ensure that the foot pedal and other control components are functioning correctly.

Once you've assessed the damage, you can proceed with the repair and replacement process.

Steps to Replace a Broken Pallet Jack Handle

Here is a step-by-step video guide on the pallet jack handle replacement process. Check it out. 

Step 1: Relieving Pressure

Pull the handle down and insert a flathead screwdriver into the holes in the pump body. This locks the handle in place, preventing it from springing back.

Step 2: Removing the Roll Pin

Use a pin punch to drive out the roll pin at the bottom of the handle. Be prepared to use some force, but be careful not to damage the pump body or axle in the process.

Step 3: Disconnecting the Control Chain

Once the pin is removed, disconnect the control chain from the foot pedal. Push down on the foot pedal to access the chain more easily, then pull it out from the handle axle.

Step 4: Removing the Old Handle

Slip the handle axle out and remove the old handle from the pallet jack. You can discard the old handle or keep it for spare parts.

Step 5: Preparing the New Control Chain

Grab the control rod at the bottom of the new chain and spin the jam nut about halfway up the control rod. This will aid in the installation.

Step 6: Installing the New Handle

To install the new handle, set it inside the pump. Slide in the axle but leave some space for the chain.

Step 7: Installing the Control Chain

Drop the control chain through the handle axle and fully install the axle from step 6. Ensure it goes through both sides of the pump body.

Step 8: Replacing the Roll Pin

Replace the roll pin that secures the axle in place. Use a pin punch and hammer to drive it in firmly, ensuring it is snug and well-seated.

Step 9: Reconnecting the Control Chain

Connect the chain to the foot pedal (release lever) and turn the jam nut down on top of the pedal finger-tight. This secures the chain and prevents it from slipping off.

Step 10: Removing the Screwdriver

Finally, pull the handle down and remove the screwdriver that was holding it in place. This step is crucial to release the pressure and allow the pallet jack to function properly.

Final Testing

With the new handle in place, it's essential to test its functionality. You can do this by:

• Lift and lower your pallet jack using both the foot pedal and handle lever. Ensure they respond smoothly and correctly.
• If there are issues, such as the handle being too loose or too tight, you can adjust the control chain tension by loosening or tightening the jam nut on the control rod. Aim for about half an inch of slack in the chain when the pallet jack is fully lowered.

Conclusion

Congratulations! You've successfully replaced a broken pallet jack handle and restored your equipment to working condition. With the right tools and a little know-how, you can keep your warehouse equipment in top-notch shape. If you found this guide helpful, please give it a thumbs up and consider subscribing to our channel for more helpful tips and tutorials.

Why Choose Pallet Jackson to Buy Pallet Jack Handle & its Accessories

When it comes to maintaining and repairing your pallet jack, choosing the right supplier for pallet jack parts and accessories is crucial. Pallet Jackson is your trusted partner for all your pallet jack needs. 

Here is why you should buy from us:

1. Wide Range of Products

Pallet Jackson offers an extensive range of pallet jack parts, including handles and its related accessories, catering to various makes and models. Whether you need a replacement handle, control lever, handle axle, handle grip, spring, roll pin, or any other accessory, we have you covered. Our diverse product catalog ensures that you'll find the right parts for your specific pallet jack.

2. Premium Quality Parts

Quality matters when it comes to pallet jack components. We understand that your pallet jack is an essential tool for your business operations. That's why Pallet Jackson is committed to providing premium quality parts. Our products are manufactured using durable materials, ensuring longevity and reliability. You can trust our parts to withstand the rigors of daily use in warehouses and logistics environments.

3. Competitive Pricing

Pallet Jackson offers competitive pricing without compromising on quality. We understand the importance of cost-effectiveness in your business operations. By choosing us, you'll get top-notch pallet jack handles and accessories at prices that won't break the bank. We believe in providing value for your money.

4. Expertise and Knowledge

Our team at Pallet Jackson comprises experts with in-depth knowledge of pallet jacks and their components. We are here to assist you in finding the right parts and offer guidance on repairs and maintenance. If you have any questions or need technical support, our knowledgeable team is just a click or a call away.

5. Easy Ordering Process

We've streamlined our ordering process to make it as convenient as possible for our customers. You can browse our website and easily find the products you need. Our user-friendly interface ensures a hassle-free shopping experience. Once you've made your selection, you can place your order with confidence.

6. Quick and Reliable Shipping

Time is of the essence when it comes to replacing pallet jack handles and accessories. Pallet Jackson understands the urgency of your needs. We offer quick and reliable shipping options, ensuring that your parts are delivered to your doorstep promptly. You can rely on us to minimize downtime in your operations.

7. Customer Satisfaction

At Pallet Jackson, customer satisfaction is our top priority. We take pride in our commitment to delivering exceptional service. Our goal is to exceed your expectations with every purchase. We value your feedback and continuously strive to improve our products and services based on your input.

8. Comprehensive Resource

Pallet Jackson isn't just a parts supplier; it's a comprehensive resource for all your pallet jack maintenance requirements. Alongside pallet jack handles and accessories, you can find valuable information and guides to assist you in repairs and maintenance. We aim to empower you with the knowledge and tools needed to keep your pallet jacks in excellent condition.

In conclusion, when it comes to purchasing pallet jack handles and accessories, Pallet Jackson stands out as the preferred choice for businesses in need of reliable, high-quality, and cost-effective solutions. Our commitment to excellence, wide product range, competitive pricing, and exceptional customer service make us the ideal partner for all your pallet jack maintenance needs. Choose Pallet Jackson, and experience the difference in quality and service for yourself.