Why inspect my pallet jack regularly?

Why indeed?

• To avoid injury
  
  
• To avoid downtime

• To avoid damage to your pallet jack

• To avoid damage to your inventory

• To avoid damage to your floors

We recommend performing this inspection every 6 months:

1. 

Test raise & lower function. If unit will not lift, bleed hydraulic unit by pumping handle 10 times with control lever in release position.

2.

Once you have verified that the pallet jack will raise and lower, inspect both steer wheels and load wheels. Replace wheels if any points below apply:

● Wheel diameter is worn 0.25" from new.

Use calipers to measure.

Examples:

3" diameter load wheel worn to 2.75".

7" diameter steer wheel worn to 6.75".

● Excessive debris embedded in wheel tread or chunks of the polyurethane tread material are missing.

● String or other material wound around the axle prevents the wheel from turning freely.

● Visible cracking of the steer wheel hub around the bearing.

Here you find a How-to video on replacing the steer wheels.


3.
Inspect the load rollers. If they do not turn freely or are visibly damaged, replace.

Here you find a How-to video on how to replace load wheels.

Note:

Always replace both load wheels or steer wheels even if only one wheel meets the criteria for replacement.

Go to our website to find the wheels you need, and more.

Why are good quality bearings crucial?

Bearings are crucial components in material handling equipment, such as pallet jacks and forklifts, because they minimize friction, support heavy loads, enable precise movement, and extend operational lifespan, directly impacting efficiency, safety, and maintenance costs.

Core Functions of Bearings

Bearings separate moving parts, such as axles, gears, and shafts, reducing friction to enable smooth and efficient operation. By facilitating low-resistance movement, they enhance energy efficiency and reduce wear, which prolongs the operational lifespan of equipment.

Support and Load Distribution

Material handling equipment routinely encounters significant weight and stress. Bearings are engineered to support and evenly distribute these heavy loads, such as those lifted by forklifts, pallet jacks, and stackers, which prevents excessive stress on individual components and increases the equipment’s stability.​

Precision and Safety

Bearings enable controlled, precision movements—essential for loading, lifting, and transporting goods safely. Reliable bearings prevent misalignment, shocks, and vibrations while accommodating harsh working environments like dust, moisture, and temperature extremes.​

Effects of Bearing Failure

Bearing failure results in increased downtime, higher operational and maintenance costs, reduced machine efficiency, and possible safety hazards. Failure can also lead to damage to other equipment components, risking worker injury and costly unplanned repairs.

Routine inspection of wheels and bearings is recommended for all lifting equipment.  

Bearings are indispensable for productivity, safety, and reliability in material handling equipment, making their selection, maintenance, and monitoring vital to any industrial operation.

Find quality bearings for your equipment on our website.

Basics about manual pallet jacks

A manual pallet jack is a hand-operated tool designed to lift and move palletized loads over short distances in warehouses, manufacturing facilities, and retail environments. It consists of forks that slide under a pallet, a handle for steering, and a hydraulic pump mechanism for lifting and lowering the load.

Key Components

• Forks: Long, horizontal arms that support the pallet and lift the load.
• Handle/Tiller: Used for steering, pushing, or pulling the jack; it also houses the hydraulic lever to lift or lower the forks.
• Hydraulic Pump: Allows the operator to raise or lower the forks by pumping the handle.
• Wheels/Rollers: Enable easy movement of the jack and load along the floor.

Basic Operation Steps

• Stand behind the jack and grab the handle.
• Use the lever to lower the forks near the ground.
• Slide the forks under the pallet until the wheels rest on the floor, not the pallet.
• Pump the handle to raise the forks and lift the pallet just enough for transport.
• Push the loaded pallet jack to its destination. Always push rather than pull except for small adjustments. Pushing uses stronger leg muscles and allows better control.
• Use the lever to slowly lower the forks and set the load down.

Uses & Safety

• Ideal for short-distance transport of pallets where forklifts aren’t practical.
• Very common in small warehouses, shops, and locations with tight spaces.
• Manual pallet jacks are simple, reliable, and relatively inexpensive.
• Proper training is crucial to avoid back strain or injury.
• Load capacity usually ranges from 1,000 to 5,500 pounds. Exceeding the load limit compromises stability and increases the risk of tipping or mechanical failure. Always verify the weight of your load before operation.
• Specialized versions exist for heavy loads, elevated lifting (scissor-lift jacks), food-safe environments, and integrated scales.

Maintenance

• Inspections. Routine inspections help identify issues like worn-out components. Handling minor problems as they arise extends the overall lifespan of your pallet jacks and helps prevent downtime and injuries. The most worn parts are usually the load and steer wheels. We recommend having an extra set on hand. We offer pre-packaged wheel kits, containing all the parts you need to replace worn wheels.

• The wheels, levers, joints, and other moving elements of your pallet jacks need to stay lubricated to prevent friction-related wear.
• Proper traction and maneuverability are important with pallet jacks, so regularly clean and inspect the wheel treads to extend the wheels’ lifespan and help prevent accidents caused by poor traction or maneuverability.
• When you are not using your pallet jacks, make sure they are stored in a protected area that helps shield them from harsh environmental conditions. Doing so reduces rust, corrosion, and other  damage.
• You can find easy to follow videos on basic repairs and how to replace parts on our YouTube channel.
• Trying to find out what make or model pallet jack you have? We’ll help you!

Manual pallet jacks remain a staple in material handling due to their simplicity, affordability, and ease of use, making them a practical solution for everyday pallet transport tasks.

 

How to replace the load wheels on a manual pallet jack

This is probably the most common maintenance repair on a manual jack. It's easier than you think!

Here is a step-by-step guide to follow for most standard models:

Tools needed

Hammer

3/16" Pin punch

Pliers, helpful for handling and inserting pins.

New load wheel assemblies.

Flip or lay the pallet jack securely on its side, ensuring stable access to the wheel area for safety.

Here is a video how to safely flip the jack.

Removal:

Remove the load wheel axle fastener with 3/16” pin punch and hammer driving out axle roll pin.

Slide or tap out the axle and remove the old load wheels from the fork bracket. 

When removing a badly rusted or damaged axle use a 1/2" pin punch and hammer to drive the axle out. If wheels are corroded or stuck, a hacksaw may be used to cut between the bearing and bracket.

Clean the axle and surrounding bracket, removing any accumulated dirt.

Always replace both wheels!

Installation:

Install sleeve into load wheel bearing and position washers on sleeve - one on each side of the wheel.

Place load wheel, sleeve, and washers inside bracket assembly in line with holes in the bracket with sleeve.

Insert axle through bracket, securing load wheel. Install lock nut and tighten. Same on the other fork.

Secure the axle by driving the spring or tension pin back through its hole with the hammer and pin punch.

Repeat the process for the second fork.

You can also watch 

our step-by-step video on how to replace the load wheels.

Additional Tips

Use load wheel kits for best results, as these include new axles and fasteners.

And if you need new steer wheels too, order the pre-packaged wheel kits:

you get high quality wheels, and the hardware - axles, washers, etc. - comes for free. 

We recommend to have an extra kit on hand to avoid costly downtime.

Regularly inspect wheels to prevent future issues.

Proper replacement will keep the pallet jack running safely and extend its service life.

The Holiday rush is upon us. Is your equipment ready?

Wobbly & squeaking shopping carts? 

Your caster might be damaged or worn. Average lifespan of shopping cart casters is 2 years.

Here is more information on casters.

You can order your casters and hardware right here.

Pre-Season Inspection & Maintenance

To prepare your pallet jacks, walkies, and lift trucks for the holiday rush, focus on targeted steps that ensure reliability, safety, and efficiency:

Check for Wear & Damage

Inspect forks, wheels, handles, and hydraulic systems for cracks, bends, leaks, or excessive wear.

Lubrication

Apply suitable lubricants to pivot points, wheel axles, lift chains, and moving joints to prevent seizing and ensure smooth operation.

Battery Health (for electric units/walkies):

Inspect battery cables/connectors for corrosion and tightness.

Top off fluid levels as needed and equalize batteries if applicable.

Make sure batteries are fully charged, connections are secure, and backups are available.

Hydraulics: 

Check fluid levels for leaks (especially in lift trucks), inspect hoses and seals, and replace any worn components.

Tires & Casters: 

Look for flat spots, embedded debris, or uneven wear. Inflate pneumatic tires to proper PSI and replace worn wheels or tires.

Cleaning and Readiness

Remove Debris: Clean out wheel wells and undercarriages of all equipment to prevent obstructions and potential damage. Keep high-traffic floors clear of trip hazards, and check your shelves for instability or damage.

Stock Spares

Keep Extras: Keep an inventory such as extra wheels, batteries, seals, charging cables, and replace any that are showing significant wear.

You can find spare parts at a great price on our website.

Operator Checks and Training

Daily Pre-shift Checklists: Have operators perform walkarounds before use, looking for leaks, loosening components, or unusual noises. Perform deeper inspections weekly. You can find great checklists on the OSHA website.

Operator Training: Re-familiarize staff with safe handling and emergency shutdown procedures. Emphasize best practices for load limits, steering, parking, and charging/refueling.

Document Everything

Log all inspections, repairs, and maintenance actions for equipment monitoring and regulatory compliance.

For most repairs you can follow our step-by-step videos.

Order any replacement parts you need right here. 

We ship the same day! 

(if ordered before 6 P.M. EST) 

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.

Why use XL Poly Wheels?

 XL poly wheels are chosen for their ability to carry heavy loads, last longer under stress, protect floors, and reduce overall maintenance and operational costs—making them the go-to solution for tough industrial and material handling applications.

XL poly wheels (Extra Load polyurethane wheels) are specifically engineered for demanding industrial and material handling environments. 

Here’s why they are a preferred choice:

Superior Load Capacity

• XL poly wheels are designed to support heavier loads and are recommended for use for load wheels on 6000 Lbs. and higher capacity electric pallet jacks and all standup forklift outrigger wheels.
• Deliver a solid balance between load capacity and operator comfort.

Exceptional Durability and Wear Resistance

• The polyurethane used in XL wheels is engineered for excellent wear resistance and toughness in demanding operations and offers outstanding resistance to cuts, tears, and abrasion, even on rough or dirty floors. They are designed to withstand rough conditions, dock plates, and aggressive floor surfaces.
• XL Poly has a low heat build-up and therefore maintains tread integrity during long runs or heavy shifts without breaking down.
• This durability translates to fewer wheel replacements and reduced downtime, making them cost-effective in high-use environments.

Enhanced Safety and Performance

• XL poly wheels provide higher traction and shorter braking distances, improving safety for operators, especially in environments with dust or debris.
• Their balanced hardness ensures reliable performance without excessive deformation under load, maintaining machine stability.
• Precision machining ensures concentricity for smooth, quiet operation.

Floor Protection

• Polyurethane is a non-marking material, which means XL poly wheels protect floors from scratches and marks, a crucial benefit in warehouses, hospitals, and retail spaces.
• Their design also offers a cushioning effect, reducing vibrations and helping to protect sensitive equipment during transport.

Resistance to Environmental Hazards

• Polyurethane wheels are naturally resistant to chemicals, oils, and extreme temperatures, making them suitable for challenging environments such as food processing plants, freezers, and loading docks.

Reduced Maintenance and Operational Costs

• XL poly wheels limit heat build-up during high speeds and long runs, reducing the risk of bond failures and extending wheel life.
• Their low rolling resistance reduces energy consumption and wear on equipment, further lowering operational costs.
• Keeps rolling resistance steady, helping reduce strain on drive motors.

Application Versatility

• These wheels are commonly used in settings with 24/7 operations, such as grocery distribution centers, bottling plants, and manufacturing facilities where reliability is critical and "where all else fails".

Ideal Applications:

 XL Poly is best suited for:

• General Warehouse Use
  Ideal for indoor, moderately abrasive environments with smooth or mixed surface conditions.

• High-Cycle Material Handling
  Perfect for 1-2 shift operations moving heavy loads, pallets, and skids day in and day out.

• Aggressive Floor Environments
  Including warehouses with dock plates, rough concrete, or minor debris.

• Standard Electric or IC-Powered Lift Trucks
  Works across a wide range of forklift types — a great “go-to” compound when versatility is key.

• Manufacturing, Distribution, Automotive, and Building Materials Industries
  Where longevity and reliable traction are required without extreme environmental abuse.

Navigate our website to your lift truck brands and models, or shoot us an email which wheels you need, or call our knowledgeable customer service at 1-800-331-0839.