Got your sparkly new pallet jack. But wait: the handle is not attached!

To install a new pallet jack handle, first lower the jack completely by pressing the foot pedal. This will ensure that the unit doesn't come down unexpectedly onto your hands.

Assembly Steps

1. Remove the retaining pin: Use pliers to remove the cotter pin holding the handle axle and slide the axle out partially.
2. Position the handle: Place the handle assembly with the chain behind the roller and set the control lever in the down (pump) position. 
3. Route the control chain: Set the handle into the pump and partially slide the axle in so you can pivot it. Drop the control chain through the center hole in the handle axle. 
4. Secure the axle: Push the axle all the way in and use a hammer & pliers to install the roll pin to lock it into place. 
5. Release the return spring: Pull the handle down and remove the retaining pin holding the handle return spring so the handle can rise fully. 
6. Connect the chain: Attach the chain and connector to the foot pedal, then tighten the jam nut on top of the pedal finger-tight. 

You can follow along our step-by-step video: 

Testing the Jack

Since the handle comes pre-adjusted from the factory, you can test it directly: 

• Pump Mode: Pump the handle to ensure the jack goes up.
• Neutral Mode: Lift the lever into the neutral position; the jack should stay lifted but not rise as you pump. 

Are you replacing the handle? You can follow along this video

 

and get your new handle, and other replacement parts at Generic Parts Service.

ValuJack2 - the best choice pallet jack

• In stock right now
• Cast iron pump with a galvanized finish for superior corrosion resistance and long term reliability

• Poly/steel steer wheels; solid nylon load wheels with options for other wheel materials. 

• Ergonomic rubber grip handle w/3-function hand control and foot release
• Reinforced handle base
• Options are available for backrests and brakes

• Comes with a three-year limited warranty covering manufacturer's defects
• Replacement parts always in stock.

• Protect your feet and order your ValueJack2 with the DuraGuard Toe Guard installed! 

 Call us at 800-331-0839  or email today to order yours. 
                Find more details and specifications on our website.

Generic Parts, Inc.

• Quality replacement parts for electric lift trucks and manual pallet jacks
• Pre-packaged wheel kits for manual  pallet jacks
• Pre-packaged wheel kits for electric lift trucks
• Free online parts catalog with detailed drawings
• Step-by-step How To Videos

www.GenericParts.com  

Safely Operating A Manual Pallet Jack

Manual pallet jacks are used in many places because they help workers move and handle heavy loads. Although manual pallet jacks are not as dangerous as forklifts, they can still cause serious injuries and property damage when operated incorrectly.

There are many ways a person can be seriously injured when using a pallet jack.

• Loads can topple from tight turns, excessive speed, uneven floors and or inclines, causing contusions, abrasions, strains, and sprains.
• Injuries and property damage occur when the load or pallet jack runs into walls, door jams, columns, shelves or run into other employees.
• Injuries can occur when workers trip over the exposed pallet jack forks.
• Back strain or shoulder strains from adjusting heavy loads or pulling the pallet jack.
• A common but serious injury can occur when the pallet jack runs over and crushes the feet of the operator or anyone nearby.

How can you prevent on the job injuries from operating pallet jacks? Here are just a few suggestions.

• Establish and post clear safety rules.
• Know your equipment. Never operate a pallet jack without being fully trained in safe operating procedures.
• Never exceed the load capacity of the pallet jack.
• Consider using a jack that has a brake and or back-rest especially when moving loads on an incline.
  

• Wear proper foot and hand protection.  Keep your back strong and straight.
• Use proper lifting procedures when loading, operating and unloading the pallet jack.
• Inspect your pallet jacks regularly to make sure they are in good operating condition.
• Never place feet, hands or any body part underneath a pallet or pallet jack.
• Use a Toe Guard to reduce injuries to feet from pallet jacks rolling over the operator’s foot.

• No horseplay! Do not ride the equipment or carry riders on your manual pallet jack.
• Push, don’t pull! Pulling puts more strain on the back, shoulders, arms, and legs. The exception is when making small adjustments in the positioning of the load.
• Use a pallet jack stop to prevent the jack from rolling out of control especially on an incline.

You can depend on Generic Parts Service for:

• Quality replacement parts for electric lift trucks and manual pallet jacks
• Free online pallet jack identification tool
• Free technical helpline
• Step-by-step How To Videos  

Order today at www.genericparts.com

Your pallet jack is not lifting properly? Or only half way?

Bleeding the air out of the hydraulic unit is the first step to solving this problem.

The main reason for having air in the hydraulic system is that you have a bad seal that is sucking air in, or the jack was upside down.

All you need is an Allen wrench and a few minutes to watch the step-by-step video:

• Put the jack on a flat level surface and pump it all the way up. Release and retract all the way down.  

• Open the filler plug on the side of the cylinder with the Allen wrench. (Do not remove the screws on the base!) 
• The location of the plug is significant because it indicates the proper fluid level. It may hiss a little as you unscrew the fill plug.  
• Look into the hole and make sure the level is good. It should be right up to the fill plug hole. If it's low, top it off. Most jacks take about 1 pint of oil.
• Screw the plug back in.

• Put the handle release on the up position and pump the jack 10-12 times completely up and down to cycle out any air that is in the system. 
• Then place the lever on the handle into the down position and test the jack. It should work noticeably better. 

Anything broken? Or need replacement parts?
Call us at 1-800-331-0839, or order through our website www.GenericParts.com 24/7.  


Have you checked out our other  "How-To" videos? 
Here are some customer favorites:

How-to videos:

• Replace the load wheels on your pallet jack

Pre-packaged cost-effective load wheel kit

• Replace the steer wheels on your pallet jack
• How-to Install the handle on your new pallet jack
• How to remove a corroded load wheel axle

Order and Save ...

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Once you have your parts, our support doesn't stop there!
Any suggestions? Any repair or maintenance you would like to see in a video? Leave a comment here or send an email to csinfo<at>genericparts.com. 
We always appreciate feedback.

*Commercial ground shipping within Continental US Only. Some items excluded

Replacing a Pallet Jack Handle

For the last 15 years most pallet jacks have been manufactured in two main types of handle design. The dimensions and parts themselves will be unique to each brand. The vast majority of pallet jacks have a release lever in the center of the handle frame within the handle loop. This lever controls whether the unit is in lift mode, release mode or neutral. The bottom of the handle can attach to a bracket with the bracket connecting to the pump (style A).  

The second common design is a handle frame that connects directly to the pump (style B – see Valu-Jack photo below). All newer handles have an lower axle with a roller around it. This roller makes contact with a cap or washer that sits on the handle return spring. This spring surrounds the pump piston. As the handle is pumped up and down the roller compresses the spring and piston. This is what causes movement of the hydraulic oil through the pump and forces the pallet jack frame to lift. The spring then returns the handle to the upright position.

If a handle is out of adjustment or damaged it can be difficult to operate while at the same time causing a safety hazard for the operator. Routine maintenance will minimize downtime, extend the overall life of your equipment and ensure safety when used.

Here is the maintenance protocol we recommend every 6 months minimum.  Perform in shorter intervals if your equipment is in a high use environment.

- Inspect the handle frame for cracks and structural integrity.

- There should be minimal side play (from left to right or up and down if you wiggle it) in the handle socket. 

- Check for worn bushings. If bushings are not replaced regularly handle bracket holes can become worn. Damaged holes cause pin failure and may require complete handle replacement.

- Inspect the roller for flat areas and wear.

- Inspect the handle return spring for any cracks or failure to raise the handle completely vertical.

- Test handle release lever in all positions (Lift/Lower/neutral) and check proper tension in the control lever linkage.

- Replace any of the hard parts are worn more than 1/16".

We've created some videos YouTube Channel all about handles to,  check them out below.

* Here is a video on how to adjust the handle on your pallet jack

* Here is a video on installing the handle

* Here is a video on testing your handle



When the time come to replace your handle just follow this link to find your brand and model!

Pallet Mule AA5500 Manual Pallet Jack

For your Pallet Mule AA5500 manual pallet jack we offer both load wheel and complete wheel kits. Complete wheel kits include a steer wheel with two load wheels assembled with bearings, plus all the necessary hardware for wheel replacement.

Did you know...

A simple change of wheels will extend the life of your pallet jack, and reduce industrial waste. That's thinking green.


Part # GWK-PUAA-CK

Complete wheel kit

Part # PU AA-68-Complete

Handle assembly

Don't see what you need? View all other available parts for Pallet Mule AA5500.

Multiton TM 55 Manual Pallet Jack

For your Multiton TM 55 manual pallet jack we have prepackaged load wheel kits available. Each wheel kit contains two load wheels assembled with bearings, plus all the hardware you need for wheel replacement. 

Also available for this unit are seal kits for hydraulic pump rebuilding and hard parts. Ask us about assemblies that will save you time !

Part # GWK-TM55-LW

Load wheel kit

Part # MU 50410142-AM

Handle assembly

Don't see what you need? View all available parts for Multiton TM 55.

Mobile ML45 Mini Pallet Jack

For your Mobile ML45 manual pallet truck we offer load and steer wheel assemblies, complete with bearings. Pallet Jack Pros recommend to always change the wheels in pairs to reduce uneven wear. 

Wheels should be free of flat spots and debris. If the wheel has cracks, loose tread, or does not turn freely, replace both wheels.

Seal kits and handle assemblies are also available.

Part # 203M-A

Poly load wheel assembly

Part # MO 3022-1

Handle assembly

Don't see what you need? View all other available parts for Mobile.

Blue Giant ROI-5, ROI-55, & MTS 2000 Parts

We stock replacement parts for Blue Giant ROI-5, ROI-55 & MTS 2000 manual pallet jacks. Looking for load and/or steer wheel assemblies, handle assemblies, or hard parts?

To keep your material handling equipment moving we stock these items & more!

Part #  BG 300-000-A-D

Load Wheel Assembly

Part #  BG 300-027-N-A

Steer Wheel Assembly

Part #  BG 790-491

Handle Assembly

Don't see what you need? View all our available Blue Giant parts.