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.
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