Why are there different materials for load wheels? Which one should I choose?

What is the best load wheel material for your pallet jacks or electric lift trucks?

To answer that you’ll first have to answer: 

What are your floors like?

Here a short overview:

Retail / customer-facing floors: choose Poly
Why? They are quiet, non-marking, and gentler on finished floors

General warehouse: choose Ultra-poly
Why? Better rolling and longer life than standard poly while staying quiet and non-marking

Rough floors / debris / dock work: choose Nylon
Why? More durable for rough, wet, or debris-covered surfaces and outdoor ramps/docks

Freezer / cold storage: choose Nylon or ultra-poly
Why? Nylon handles harsh cold-duty environments well, while ultra-poly is noted for cold performance and durability

Heavy-load / high-abuse industrial use: choose Nylon
Why? Strong, durable, and better for demanding conditions than standard poly

Extreme-duty, specialty environments: choose Steel
Why? Best where debris and brute durability matter more than noise or floor protection

More details on each material:

Polyurethane (Poly)

Ideal for display floors, carpeting, and warehouses. They mark floors the least while rolling easily and make very little noise. These wheels can be very durable when used exclusively on smooth surfaces. 

But: Poly is not as tough as nylon, and wheels are easily damaged when running over debris. Moisture, oil or chemicals will easily degrade the material.

Ultra-Poly

They are longer lasting and they roll more easily than regular poly. Ultra-poly is very hard and won't shatter if too cold; and they are also non-marking.

Nylon

A harder material that is best for cold storage applications. And Nylon wheels can support greater weight capacity. Debris on the floor does not degrade the wheel as fast. It is also the material of choice for use in environments that may cause rust or corrosion like poultry processing, and working with seafood.   

But: Nylon wheels make more noise and can leave marks.

Steel Wheels

These are best for use on factory floors where there may be metal shavings or hard debris on the floor, and where noise is not an issue. They are the strongest and most durable - best for extreme loads and rough conditions.

But: very noisy

One or two?  

Replacing the whole load wheel bracket is more time-consuming and expensive than choosing two wheels during regular maintenance.

Because we so strongly advocate changing both at the same time we created wheel kits, and they are priced at a substantial discount.  

And how do I replace the load wheels?

Follow our step-by-step video:

Quality replacement parts for

electric lift trucks  and manual pallet jacks 

Fast Lift Parts is the world's largest supplier

of after-market pallet jack parts.

Order today at www.genericparts.com

800-331-0839     *      csinfo@genericparts.com

We go the extra mile

to make sure you get what you need

- fast.

Some Basics about Forklifts

Used or new forklift? Training? OSHA?

When do my forks NOT meet OSHA standards?

When 10% of the fork heel is worn – results in 20% loss of capacity. And while checking the wear,  always check for cracks and deflection too!

When do I buy a used forklift vs. a new one?

Rough guideline: If you use a forklift 3-4 hours a day, you may be better-served with a used one. More than 4 hours a day, buying a new forklift would be most beneficial. 
Keep in mind, environment, hours used, emission restrictions, and general application may require the purchase of a new forklift.

What kind of training is required to operate a forklift?

You’ll need a valid state driver’s license and on the job operator training. In addition, OSHA requires that each forklift operator completes forklift safety training. OSHA may even conduct surprise inspections and penalties for non-compliance can go up to $7,000. 

Visit www.osha.gov for more information on training compliance.

Where do I get quality replacement parts?

That one is easy. On our website 24/7 

We have replacement parts - like Mast Chains, Seats, Lights, Horns, Backup Alarms, Starters, Alternators, and more  - for all major brands. 

Call us if you don't find what you need!

What do you mean by "bleeding" your jack?

A manual pallet jack is usually bled by pumping the handle up and down the hydraulics with the jack unloaded and the control in the lower position until all air is purged and the lift becomes firm.

Why would I need to do this?

Air can seep into the hydraulic system. This could be caused by improper handling, such as tilting the pallet jack. When air gets into the system, it hinders the hydraulics from working and the pallet jack won’t lift anymore. Bleeding your jack releases the air.

And how do I bleed my jack?

Safety and prep

Park the pallet jack on a flat, stable floor and block the wheels so it won't roll.
Remove any load.

Bleeding

This is the procedure for most standard jacks (no opening screws):

• Set the operating lever to “lift.”
• Push the handle all the way down until it stops.
• Move the lever to “lower.”
• With the lever held in “lower,” pump the handle up and down vigorously 10–20 times.
• Return the lever to “neutral” or “lift” and test lifting the empty forks. If lift has improved, test with a light load.

Repeat the sequence several times if the first cycle only partially improves lift.

What do I do if the jack still will not lift?

Set the lowering valve to its lowest setting, remove or open the reservoir fill plug, and verify the fluid is up to the correct level; top up if low.

After refilling, cycle the handle 10–20 times with the control in “lower” to purge any remaining air.

If it still won't lift, you may have worn seals, a faulty valve, or internal damage that requires a new seal kit or professional service: Email your pallet jack brand and model, and an outline of your problem, to csinfo@genericparts.com and we will provide technical help.

​

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.