How to Replace the Handle Return Spring on a Pallet Jack

Follow these step-by-step instructions to safely and effectively replace the handle return spring on an AC Series pallet jack:

Tools Needed

6–8” C-clamp

3/16” pin punch

Hammer

Needle nose pliers

Long screwdriver (or hold-down pin)

Seal pick (if replacing seals)

Step-by-Step Process

1. Lower and Secure the Pallet Jack

Lower the jack completely.
Secure it in place using a pallet jack stop or a sturdy block to prevent movement

2. Disconnect the Chain Linkage

Remove the chain linkage from the release pedal under the handle.
Pull the control chain free from the handle axle.

3. Remove the Roll Pin

Use a 3/16” pin punch and hammer to remove the roll pin that secures the handle in place.

4. Relieve Spring Tension

Pull the handle down to compress the return spring.

Insert a long screwdriver or hold-down pin through the pump body to hold the spring in a compressed state, relieving tension from the handle axle.

5. Remove Handle Axle and Handle

Slide out the handle axle.
Lift the handle free from the pump assembly.

6. Compress and Remove the Spring

Use a 6–8” C-clamp to compress the spring further, allowing you to safely remove the hold-down pin.
Carefully loosen the C-clamp to let the spring decompress slowly.
Remove the old spring and spring cap from the pump

7. Replace Seals

Using a pair of pliers install lightly oiled U-cup into cylinder with wide side facing down towards pressure. Install Wiper seal with lip facing up.

8. Install the New Spring

Place the new handle spring and spring cap onto the cylinder.

Place lightly oiled piston thru cap and into cylinder.
Compress the assembly with the C-clamp, then insert the hold-down pin to keep it in place. Remove C-clamp.

9. Reassemble the Handle

Position the handle back onto the pump.
Reinstall the handle axle and secure it with the roll pin.

10. Release Spring and Reconnect Chain

Pull the handle down compressing spring, remove the hold-down pin, and allow the handle to return to its upright position.
Feed the chain back through the handle axle and reconnect it to the release pedal.

11. Test the Pallet Jack

Squeeze the handle and pump it several times to bleed air from the system.
Test the handle’s return action and ensure proper operation

12. Additional Tips

Always relieve spring tension carefully to avoid injury.
Use the correct tools to prevent damage or accidents.
Adjust the control chain if needed to ensure smooth operation after reassembly.

You can follow along this whole process in our step-by-step video.

Need seals? 
Or any other parts that need replacement? Head on over to our website.