Awesome 2500Kg Pallet Truck Restoration Project & How Hydraulics work.

In this video I will show you how I restored / repaired a 2500Kg Pallet Truck & explain how a simple Hydraulic system works. The pallet truck was given to me and was in very poor condition. I restored the Pallet Truck for use in my home workshop. The long term plan is to be able to use the Pallet Truck to move machines around in the workshop. Mainly the Milling machine, Lathe and Surface Grinder. Make sure you subscribe and ring the bell to get notifications of more workshop and restoration projects.

[@jeffgrimes7590]

The world needs more tradesmen like you.

[@Chromevulcan]

I've watched several of these. So far, yours is the only video to show the complete actuation of the lever mechanism that raises the forks. You, sir, deserve a comment.

[@No.1ramavadh1990]

Sad roli ka halchal kidhar milta hai uska mere ko link bataiye

[@ThomasHillmanHillman]

This brings back memories. I Worked on pallet jacks in a warehouse I used to work at. I cleaned and painted them different colors with rattle can spray paint. Farm tractor paint. Each part of the warehouse had a different color.

[@Goryuigor]

Здорово, когда есть руки, которые растут из правильного места и хороший инструмент... Браво!!!

[@CloudeAytr]

Nice video and refurbish. I wish there was more narration of what you were doing and why though: what you were using to clean everything; an overall explanation of how the different parts in the jack work, etc.

[@ghandee]

Great video!!! I am about to resurrect an old pallt truck and this was helpful. I did'nt catch what you said on 11:00 . "Never put your finger where you wouldn't put your..." and then I lost it

[@Halfwheelhell]

Well done! I'm not stopping by for coffee.

[@cwixted]

W O W ! Perfect timing for me to see your excellent video. I got an off brand pallet jack two days ago that has a problem. It looks very similar to yours in most aspects. You showed all of the necessary detail to see how it is put together, and more importantly, how to take it apart. The sounds of the shop make it a natural with no musical distraction. Thanks for that. Your video skill are so much better than many studio videos. I never saw the back of your head or back of your hand, only the detail of what was happening on the equipment. Shop made tools to complete the job, and other workarounds, make it a great instructional video. Right down to the tape on the handle, what is that tape? My problem is it will jack up but won't lower, no matter how hard I jump on the forks to give it weight to help it lower. So, I used my tractor, with a front end loader, to weigh down the forks, and I got it to lower. I cycled it again and still needed the FEL to weigh down the forks to lower it. Because of your video. I now have the knowledge to determine if the problem is in the hydraulic pump or the mechanical parts of the pallet jack. A big thanks from this side of the pond. Now that I've subscribed I'm heading out to my shop to begin to determine what is causing the pallet jack to not lower.

[@Handmadeextreme]

Thanks very much. Im really glad you enjoyed the video and got something useful out of it. The tape is road bike handle bar tape, tennis racket handle tape is basically the same thing as well. Just gives it a nicer feel when you are using it I find. Good luck with your own repair and thanks for watching. 👍👍

[@cwixted]

@@Handmadeextreme Got it. I like that idea for handle grips. I checked out my pallet jack and the hydraulics work pretty well but there is a serious binding somewhere in the mechanical part. Some of the shafts are extremely hard to get out. Once out the remaining mechanics seem to work much better. More troubleshooting needed. Your video has been very valuable to understand what is going on with the pallet jack. Thanks, again. Clem

[@johnerway7255]

Great overview to repair the pallet jack, it will help me big time, thank you so much.

[@britishreaction54]

Excellent stuff. Nice lathe you have. That's a great pallet truck now. I have one and it's really useful. I used it to get my ton and a half Harrison Mill into my shop. Would have been impossible without it.

[@Handmadeextreme]

Thanks. It's a Harrison VS330TR, lovely machine. It's 3 phase so I have to run it off the rotary converter. Yep I have similar plans for this pallet truck. I'm planning a future video making some skids to fix to the bottom the the lathe, mill and surface grinder so I can move them about easily and also level them really simply. Glad you enjoyed it and thanks for watching another one of my videos. 👍👍

[@ratystast]

I'm so glad that you are uploading more freuqently ;)

[@Handmadeextreme]

Thanks I'm glad you have noticed and are enjoying the videos. I'm trying to do every other Thursday at 1930 initially. But i'm also juggling this with renovating my house to try and sell it so I can move some where with a bigger workshop. Long term goal is to make this a full time thing but I have to grow the channel a lot before that becomes a reality. Thanks for your support. 👍👍👍

[@cricket0390]

Excellent video! Did the new wheels in the back degrade the weight rating of the jack?

[@andymora5595]

Wonderful! I wonder why about 80% of the pallet trucks in industry have problems with the lever. They don't stay in middle/neutral position. The lever is always down in pump up position. My old pallet truck also have this trouble. Any ideas why this happens and how to fix?

[@ShieyV2komputroniks]

Mostly quality issue , at Work we have a lot newish looking ones with broken neutral Position but Our 17years used Veteran still has neutral position

[@rolfnilsen6385]

With the way the economy is going prices will come down - if you can afford it.. Anyway - your workshop is perfect for showcasing what can be done in a small workshop. You create really good content and know your stuff so it is very enjoyable to watch. And more parental warnings please - we dont want to traumatise the young viewers.

[@Handmadeextreme]

Thanks very much that's really constructive feedback! I really appreciate that as it really helps me to know whether the things i'm trying in the videos are being well received or not. Thanks for watching another video and really glad you are enjoying the channel. Have a great weekend. 👍👍

[@medtassila1763]

just I want to say thank you..really it's a very good job

[@Handmadeextreme]

Thank you. I'm glad you enjoyed it.

[@ShieyV2komputroniks]

That the neutral setting still worked at the beginning is a miracle at 28 of 35 at my work its broken

[@bigbattenberg]

Just bought a beat up BT. Friend of mine said: "The Cosmos will give you the pallet truck you can handle." :) Now, this one would be beyond repair for the majority. I wanted it because it's a BT and it has 90 cm forks. It needs work. Lots of work. Disassembly was tough. It has been sitting outside for a long time. Boy can those pins and axles get rusted in place. The central shaft running in the transverse direction still won't budge... will need some serious heat for that. I found a company not far away that can reline wheels, which is nice because the original BT wheels are very nice but original parts are quite expensive.

[@DanKoning777]

I found your channel about 3-4 weeks ago, and subscribed after the first video. I then started watching a few each day from oldest to newest; today was the first time I disappointed. Not by the outcome of the restoration; I thought you did a great job, but the decision to add the unnecessary crude humor which I'd never share with anyone I know as you suggested. I hope the next few are void of the needless innuendo b/c I did enjoy giving a thumbs up each time.

[@Farm_fab]

A good tip for when you are cutting something with threads, if you put a nut on above where you are cutting, after cutting, remove the nut, and it will help to clean up the threads.

[@Handmadeextreme]

Great tip thanks 👍 and thanks for watching 👍

[@Mister_banana]

Parental advisory. You made my day

[@CForged]

What would cause the hydraulic to lose its pressure? When the slave cylinder is in the max position. Heavy weight is applied to the forks of the pallet Jack and won’t hold the pressure.

[@AndyCPugh]

Good physics explanation. Good edit. Gratuitous slow-mo sparks. What's not to like!

[@Handmadeextreme]

Hi Andy. Great to hear from you. Thanks for the feedback. Anything you think could be better?? Thanks for watching. 👍👍

[@carlmcgee1623]

Grat job creating this cutom jack !!!!!!

[@candeservices1]

That is a funny way to make coffee ! But Ill try it.

[@pschimurkar2594]

Really nicely explain, can we share dismentaling part of cylinder to know internal MSM of same

[@SOUTHWEST778]

3.00, or 3:00 Best bit, good video, should show how the whole system operates the small wheels and pushes up etc on them also I thought to be 100% eould of been good

[@gregorycarson3889]

Awesome 👏🏾,I’ve got one that doesn’t pump up I’m going to try your methods of checking it out.

[@scarvazquez]

thank u mate! that was good work!.. do u have any suggestions or perhaps an already exiting video about restoring the hydraulic part its self?? thnx again mate, cheers!

[@praveensharma4106]

Thanks, I will be attempting soon. worried about the hydraulic seals and special tool to handle the seals

[@Handmadeextreme]

Good luck! Thanks for watching.

[@scottieboiwalker8390]

Great video. Watched your 3 phase converter which brought me to your channel. Currently gather parts I need. Hope to have it build soon. Thank you

[@Handmadeextreme]

Interesting your the second person to mention that tonight... I'm actually planning a follow up video which will go into way more technical detail. Hope I can get it done in time for it to be of some help to you. Just need to figure out how to make it a bit less dry off a subject. Anyways, good luck with the project and thanks for watching.👍👍

[@scottieboiwalker8390]

@@Handmadeextreme definitely keep my eye out for that. Thank you

[@Handmadeextreme]

No problem.

[@TheSadButMadLad]

You're white board drawings are on par with Engineering Explained's. He crams everything into his, at least yours are a bit easier to digest. :-)

[@Handmadeextreme]

Cheers, i'm glad you enjoyed it. I thought i'd try something a bit new. Thanks for the feedback, I'll be sure to use the whiteboard again. 👍👍

[@mithileshramteke3882]

Sir you are very good at your work, thank you so much fl

[@sidirule]

How to change hydraulic oil and o rings..please make a video on it

[@GalileonPrime]

Need a sandblaster mate, to remove the rust scale off the forks! The more like new you make it look, the better the resale price. Mate of mine has a side line refurbing and repairing pallet jacks, makes good money at it.

[@Handmadeextreme]

I have a small one but my shop is no where near big enough for a decent size one. It's on the wish list. Nice to hear someone is making some money fixing things in this day and age.

[@grog-i9m]

Nice video! I am glad to see you are getting more active and allow yourself more jokes. Mes amitiés depuis l'autre côté de la Manche.

[@Handmadeextreme]

Thanks, it's good to be back. I'm still not 100% comfortable in front of the camera but i'm learning to relax a bit more. A bit more time and practice and hopefully the videos will get better. Merci beaucoup vous êtes très gentil. 👍👍

[@grog-i9m]

@@Handmadeextreme still wondering where your nice Union Jack bow ties ended. I thought that was a nice feature of your character... 😀

[@Handmadeextreme]

I knew I should have put it one for the pieces to camera, Doh. Better get it back out hadn't I. 👍

[@GiggleBytes2011]

I watched this video hoping you would change the oil seal on the secondary hydraulic pump as mine has gone and i have no idea how to fix it...but i did watch it all the way through, and glad i did, it was a really informative restoration. But i'm still none the wiser on repairing my issue 😕

[@SWTWHITEGSR]

I know this is a dumb question but ill ask. Can a scissor jack be modified to do wooden pallet jack? I tried looking for videos seems no one has showed any example of why you cannot mod it or use it.just wondering.also nice nice video man very nice restoration.

[@Handmadeextreme]

Yeah I recon that would be possible. Thanks for the support.

[@RichDavey]

That’s got to be one of the best refurbishment videos I have watched and believe me I watch loads. Absolutely superb. Very tempted to ask the depot I work at if I can take a broken truck now. I might need to get back to you 👍🤣 Subscribed 👍👍

[@paulfloyd228]

Those wheel bearings sounded rough?

[@Handmadeextreme]

Yeah they were really jammed up when I started. Freed up nicely though with a bit of 'persuasion' 😆 Thanks for watching.

[@jamesdepaul3410]

Excellent work. Great vid.

[@JaswinderSekhon-vw3lo]

great job I got one pallet truck not lifting any chance I can call you for some advice please Jassi

[@jackiemacon2606]

Great job

[@sfbmcouk]

Great Stuff, wating for the next one now.

[@Handmadeextreme]

Hi James. Thanks very much. I don't know if you watched the 'steel shoe' video I did a couple of weeks ago. But lets just say something bad happened to it recently, so I think the next video will be trying to repair / salvage the disaster that happened to it. Then the pallet truck will make a reappearance in a few videos time. Thanks again for watching another video! 👍👍

[@Falney]

The metal on the axel you needed to turn down for the smaller ID bearings.... What is it? I don't recognise the appearance of the glowing lumps of face melting metal. I'm not a machinist fyi.

[@colinross2592]

Cracking videos pal educational more people that watch these videos the better 👍 👌

[@erdetm]

Very nice and relaxing video ;)

[@Handmadeextreme]

Awesome thanks for the feedback and glad you enjoyed it.

[@erdetm]

@@Handmadeextreme You can check my vw bus restoration series that i just started - search for Olek Garage on youtube ;)

[@metalzonemt-2]

Good advice: Never put your finger where you wouldn't put your...

[@crisislord00]

Man your videos are always awesome. Can't wait for more! Although i did not get why you machined down the axle instead of changing the bearing on the wheels to fit the original Shaft size.

[@Handmadeextreme]

Thanks very much, glad you are enjoying them. Plain and simply because that would have cost more money. I agree, that would have been a better solution though. Thanks again for watching.

[@aisha.1179]

What's the pump body material?

[@paddrivers]

Nice work!

[@user-ui2lv5sf6x]

Excellent

[@the7andrea7zio]

This video above beeing interesting was a even greater piece of commedy

[@Handmadeextreme]

Thanks, glad you enjoyed it. 👍👍👍

[@KulwantSingh-ig6pg]

This is a happy experience in Kolkata

[@stormorc2057]

good job

[@shanejohn8736]

Brilliant, thanks, huge help

[@libra10121983]

Nice job!

[@Handmadeextreme]

Thank you! Cheers!

[@Palma02]

Good job 👍👍👍

[@Handmadeextreme]

Thanks very much, glad you enjoyed it. 👍

[@joell439]

Really nice rebuild - sure glad I hit that subscribe button and bell icon. Looking forward to all your content. 👍👍😎👍👍

[@Handmadeextreme]

Hi Joel, I've just seen all you comments. Thanks for the support I really appreciate it. Glad you are enjoying all of the videos and welcome to the channel.

[@mybrotherkeeper1484]

Our Jack seems stuck in neutral. That is, I can’t get the lever handle to go up because of what feels like an obstruction. It also will not pump up, even though it is stuck in the down position.

[@mybrotherkeeper1484]

I found the problem. The piston seems frozen which gets pushed in when you lower the Jack. It was sticking out just a little. I hammered it in, and then was able to raise it a little. After putting the chain back on the toggler which pushes said piston in, and then lets it come out in neutral and raise positions...we’ll I’m back to the piston being stuck in...so no raising can take place. Probably have to take piston and accessories apart now. If I’m wrong, stop me, please! I’m open.

[@richardcrutcher609]

Outstanding!

[@Rubbernecker]

Brilliant!!!

[@Kevin-gx8lc]

Nice refurb! I enjoy your videos very much... your 3 Phase Rotary Converter was particularly interesting... thinking of doing the same thing myself, so thanks for sharing. Greetings from Southport (it's not in the South and it's not a port!). You sound like you're a southerner... I'm from Oxford originally. Cheers matey!

[@Handmadeextreme]

Thanks very much. Hold that thought... Iv'e had so may people ask for more information about the converter that I'm planning a follow up video which will go into way more technical detail. I'm just trying to figure out how to not bore the pants off people by going full nerd!! I'm based in the midlands as it happens, sort of in the centre off the triangle made by Nottingham, Leicester and Derby. Thanks for watching another video and commenting. It's great to hear what you guys think and really helps the channel grow. 👍👍

[@smilewithgourav]

Neat Job buddy !

[@Handmadeextreme]

Thanks 👍 Glad you enjoyed it.

[@Billthebott]

nice job. looks great

[@Handmadeextreme]

Thanks very much. Glad you enjoyed it. 👍👍

[@chrisv4640]

Nobody ever talks about how much oil to put back in these? And how to get the air out. Can you tell me how much oil to use?

[@trentsmillmansion1]

That was awesome. Thanks

[@Handmadeextreme]

Glad you liked it!

[@jorgeivangarciasalazar9672]

Felicitaciones

[@Handmadeextreme]

Thank you.

[@monkeyman8265]

You know your shit man respect

[@MarioKyriacou1]

Nice!!!

[@peter-e2q]

I worked in Hermes warehouse for a while using pallet trucks and it occurred to me that all these warehouses have a lot of not very well maintained pallet trucks! Even thought of trying to get a contract!

[@itsallfabrication]

Good vid. Thanks.

[@Handmadeextreme]

Glad you liked it!

[@unperrier5998]

Oh no the audio cut!... what did he say after: *_NEVER PUT YOUR FINGER WHERE YOU WOULDN'T PUT YOUR..._* your what exacltly? :)

[@CH-pt8fz]

Lol , this is what was always said to us all as apprentices. Always makes me smile.

[@9pracha620]

Thank sir .

[@Handmadeextreme]

Thank you.

[@domiszew5116]

where is the bow tie???

[@Handmadeextreme]

Dammit. I even thought to myself when I was doing my piece to camera at the end ' I really ought to put the bow tie on' and low and behold iv'e been pulled up on it!. Note to self.. must try harder... Hope you enjoyed it regardless? Thanks for watching another video!. 👍👍

[@domiszew5116]

@@Handmadeextreme Just like all movies. Regards

[@Handmadeextreme]

Thanks very much. 👍👍👍

[@wannadia3628]

very enjoy

[@Maker_of_Things]

A great video but.... Noooooo!!!!!!!! Bore out the wheels to take bigger bearings!!!! ;-) I bought an old pallet truck to repair for use and found the master cylinder was bent. I cut it off and welded on one I cut from an old bottle jack. Tested to 2 tons and it was fine. It just takes more pumps to lift it up as the master cylinder is now smaller. I fancy getting another one to play with now, maybe a high lift one.

[@Handmadeextreme]

Yep that's an option haha. For what i'm doing in my home shop this should be fine. If it was being used commercially yeah i'd be using bigger bearings (the correct size, shhhh don't start talking about load ratings and bending moments.. haha) That's a nice way to fix one. Use what you have to get the job done, I like it. I recon it's going to be a really handy addition to the workshop. Thanks for watching!

[@Maker_of_Things]

@@Handmadeextreme Yep, for your own use it is fine, you know that you will not be reaching it's limits. Same with mine. I thought I was going to burst the weld open when I lifted my car off the ground, but it worked. Rated 2500kg, it has only really been used for 1000kg of bulk bag a couple of times, and about 500kg thereafter.

[@Handmadeextreme]

Yep basically the same here. I'm planning on using it to move the machines around mainly. The heaviest of which is just over 1000Kg so well within the safe limits.

[@Maker_of_Things]

@@Handmadeextreme All down to common sense and knowing our limits with equipment. For more pallet truck fun have a look at this thread on twitter, my bit of miniatures fun outside of the big workshop. twitter.com/HarrietMaker/status/1229862751197126656?s=20

[@Deutschehordenelite]

sweet!

[@Handmadeextreme]

Thanks. Glad you enjoyed it.

[@That_random_idiot]

wait i have an ho scale pallet that's in blue

[@Joan-ot9nf]

11:01 :DD

[@karlthompson1961]

Are you a teacher or tutor? I assume you must have an electrical and or mechanical degree..

[@Handmadeextreme]

I did a bit of part time teaching when I was at Uni. My degree is in Automotive engineering but I also have a background in electrical and manufacturing. Bit of jack of all trade master of none really.

[@karlthompson1961]

@@Handmadeextreme I just knew you were or had done some teaching, I'm glad i guessed right!! Me and my Father were talking about you on the phone the other night - I sent him a link to your rotary phase converter video- and he commented on how talented he thinks you are; that's a great comment coming from a (retired) Chartered engineer.. Keep those videos coming!

[@Handmadeextreme]

@@karlthompson1961 Thanks very much I really appreciate the support.

[@DonQuichotteLiberia]

Excellent videos, and full of bonmots!

[@Handmadeextreme]

Cheers, thanks for watching. Glad you enjoyed it.

[@897aa33]

I am not sure why every one upset with hammarite very basic paint super easy washed away by road salt and other chemical compounds when moving pallets

[@jeffdavis7319]

I am thinking you could have bought a new one cheaper considering the time you spent . Nice work though

[@alitoumiat4703]

tricheur

[@neuronneuron3645]

Never put your finger where you wouldn't put your?

[@colinstu]

parental advisory lol

[@Handmadeextreme]

Haha, wondered if someone would spot that. Glad you enjoyed it and thanks for watching. 👍

[@richardsmith6430]

One ISO 9001 M10x1.5 Comment.

[@Handmadeextreme]

😂👍😂 Thanks for the support Rich.

[@cragonaut]

Those replacement wheels look suspiciously like lawnmower wheels. If so then they won't be taking the 2,500kg that the rest of the truck is rated to. But perhaps okay for whatever you have in mind for it. Nice reno, otherwise.

[@Handmadeextreme]

They do look it don't they haha. They are proper ones though. Each one is rated at 800Kg so 1600Kg for the axle. The then each of the front wheels carries 225Kg (assuming) centre point loading on the truck. Great feedback, thanks for watching and glad you enjoyed it!! 👍👍👍

[@mazigree]

سعبد برؤية هذا الفيديو و شكرا لك

[@iznogudsurfer5911]

never put your finger where you not put your........looool