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.

Steer Wheels - which ones are best for your pallet jack?

There is a host of different materials for steer wheels available. 

Polyurethane and Ultra-Polyurethane treads are the most common wheel treads you'll encounter on a pallet jack.

What's best for your pallet jack depends on where and how you use it.

 

Poly Tread on Nylon Hub

These have a chemical bond that secures the poly tread to a steel core (or hub). This option is ideal for display floors, carpeting, and warehouses. They mark floors the least while rolling easily and quietly. Under really heavy loads (2,500lb +), if left to sit for more than 8 hours, there is a possibility of the wheels flat-spotting.

Ultra-Poly Tread on Aluminum hub

Longer lasting and they roll more easily than regular poly, also a chemical bond on a steel core. Ultra-poly is very hard and won't shatter like nylon if too cold (i.e. in and out of a freezer). They are also non-marking with the possibility of flat-spotting, as mentioned above.

Solid Nylon Wheel 

This is a harder material that is best for cold storage applications. It is also the material of choice for use in environments that may cause rust or corrosion like poultry processing, and working with seafood. It can also be the best choice for refrigerated transport trucks that have grated floors. Lastly, they can be a good choice if the pallet truck is taken outside on the rough pavement. However these are more likely than poly to mark floors, so be mindful when using inside a showroom or a hotel lobby, for example.

Solid Steel Wheel 

When all else fails you may need solid 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. What they lack in their ability for use in a sneak attack (they’re pretty loud) they make up for in sheer durability. These are also a good choice if you need to work outside on rough asphalt. But they can damage nice floors, so avoid use on floors you want to remain "pretty".

One Wheel or Two?

Now that you've got an idea of which type of wheel is best for your specific uses you are faced with another sometimes tough decision. One wheel or two?
First, most pallet jacks have two steer wheels. They are located on the main body of the jack, attached to the hydraulic unit, and therefore the handle. 

Unless a pallet jack is brand new, we always recommend replacing both steer wheels at the same time. There is a legitimate benefit:   
Steer wheels wear down and get shorter the longer you have used them. Steer wheels (like pallet jack load wheels, or the tires on your car) do not act independently but are a portion of a larger machine. Even a small difference in diameter causes stress on the mating (aka connected) parts which then causes issues down the line. 

You find all variation wheels for most pallet jack brands here.

Because we so strongly advocate changing both at the same time we created wheel kits to get you everything you need, even the load wheels, and they are priced so that the hardware comes for free. 

Here is an example:

Complete wheel kit for Crown PTH 50

 Additional resources:

Here are some more links you may find handy as you venture down the road of replacing your steer wheels:

How do I find out the make and model of my pallet jack?

Video: How to turn a pallet over

Step-by-step video on how to replace your steer wheels

Step-by-step video on how to replace your load wheels

And more videos

Have a suggestion for a future blog post?  Need help ordering parts from www.genericparts.com?  

Give our friendly Customer Service team a call at 800-331-0839 or e-mail us at csinfo@genericparts.com 

THE HOLIDAYS ARE COMING

Get your jacks ready for the busy season with this checklist

Here are five important items for your checklist to make sure your warehouse is prepared.

1. Check your warehouse floors and outdoor loading areas to make sure the workplace is clean and clear of any obstacles. Make sure that debris and spills are cleaned and swept up so that your operating environment is safe for your equipment to operate in. Debris and spills can ruin or shorten the life of your wheels or get in the way of your loads. 

2. Inspect the wheels on your pallet jacks and forklifts regularly to make sure that they are rolling easily and that there are no flat spots or delamination. Over time, the poly or rubber on your wheels can crack or wear unevenly resulting in unstable and unsafe loads. This can cause additional stress on your machine and on your workers' hands and arms due to vibration and rolling instability. We offer convenient wheel kits for manual pallet jacks and electric lift trucks. 

3. Have you looked at the forks lately?  Make sure there are no cracks or damage as the forks bear the brunt of the load. Using a damaged jack can cause a load to shift and fall and may damage products or cause injuries to your workers.

4. Check the hydraulic pump for leaks and make sure that it is operating properly. Does it pump up and hold your load? Does it lower safely? 

5. Test the handles, levers, controls, and horn where applicable, so that you are confident everything is working properly before you add a heavy load. 

Check our website for replacement parts you need, and contact us for any technical support.

Here is a list of instructional videos of the most common pallet jack repairs:

How to bleed the hydraulic unit

How to remove corroded or rusty load wheel axles

How to replace load wheels

How to replace steer wheels

and more  How To Instructional Videos

When should I replace my wheels?

A common question we run across in pallet jack maintenance is "When do I replace the wheels on our equipment"? Of course you may need it when if it's dropped off a dock but your equipment will last longer if regular routine maintenance is performed.

To help out our customers we've created this reference guide  for manual pallet jack steer wheels and load wheels.  Below is a brief overview of the process, however we recommend printing it out for the full details and storing with your reference material.  We advise performing the below inspection points every 6 months.

Pallet Jack Wheel Inspection 

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 worn down .25" from new, debris is embedded in material or inhibiting the wheel from turning freely.

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

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

Pre-Packaged Wheel Kits

Once you know you need to replace a set of Load Wheels, Steer Wheels (or both), a Pre-Packaged Wheel Kit is the best option on the market.  We were the first in the industry to create Pre-Packaged Wheel Kits.  They are in stock and ready to ship same day for most manual and electric pallet jack models.  Our goal is to make routine maintenance as easy as possible and we are excited to see how popular they have become among technicians.

Pre-Packaged Load Wheel kits for electric and manual lifts come ready to install.  You'll receive a pair of load wheels assembled with bearings plus the axles and fasteners.  Have you ever encountered rusted axles that had to be cut off? Maybe you are cursed with roll pins or snap rings that flew away. Complete every job the first time by showing up with all the components you need.

Pre-Packaged Complete Wheel Kits for manual pallet jacks come with all components you receive in a Load Wheel Kit, plus both steer wheels, bearings, steer wheel axle and fasteners. It's a great idea to have a couple extras in stock to stay ahead of emergencies, (as in the jack fell off the dock and now can't unload that shipment).


We do understand customers who want to be frugal by re-using axles if possible. To that end, in many cases the kits are less expensive than ordering even just the wheels separately.  After 30+ years of putting our customers first we feel bad when an additional order has to be placed for a second load wheel or axles (or those air-born roll pins!).  No one wants to pay shipping twice and wait days for delivery.

Check out the Extensive model lists we carry Wheel Kits for:

Manual pallet jacks

Electric lift trucks

What to do if you find the axles are rusted or frozen in place and you need some guidance?  We've got you covered there as well. We have a collection of YouTube videos to guide you.  Check out the links below!                             

How-to videos:

• Replace the load wheels on your pallet jack
• 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

Save ...
...Time with Same-Day Shipping
... Money with Free Shipping on Orders over $450*


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

Ready to learn more or place an order? 

Call our highly knowledgeable customer service  (800)331-0839 

or email csinfo@genericparts.com      

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!

Safely turn over a jack

Sometimes we encounter a question like "Is routine maintenance really needed on a pallet jack?" The simple answer is yes, routine maintenance is important when it comes to getting the most out of your pallet jack.  Depending on the size of your operation a pallet jack may be replaceable or it may very well be an integral part of the the livelihood of your whole company.  Where ever you may land in the spectrum we can all agree throwing money away through lack of maintenance can negatively impact the bottom line. 

Most of the parts you'll need to keep an eye on are found in the underbelly of the unit. We want to give you practical instructions on how to safely to get to the underside of your pallet jack for two reasons.  First,  let's get rid of a potential excuse to put off the inspection for lack of know-how.  Second, because the breaking toes, twisting of wrists or damaging of the pallet jack defeats the goal to support your bottom line. (No one wants a Worker's Comp Claim).

The best way to turn over your pallet jack and expose the undercarriage keeps you and your equipment safe. We've created a line of instructional 'How To' videos and below you'll find a link to one on safely flipping over a manual pallet jack.  


YouTube - How to flip your jack.

Once you have it turned over and still have full use of all your fingers and toes the next question is "What should I be looking for?"

Start with the Pallet Jack Wheel Inspection (Load and Steer)
Measure the Wheel diameters. Are they worn down 0.25” or more from new?  (I.e. 3” diameter load wheel worn to 2.75” or 7” diameter steer wheel worn to 6.75”)

Is there excessive debris embedded in the wheel tread or chunks of the polyurethane tread material missing?

Are there strings or other material wound around the axle preventing the wheel from turning freely?

Do you see visible cracking of the steer wheel hub around the bearing?

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

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

We recommend performing the above inspection every 6 months


Be sure to check out Generic Parts Service YouTube channel for more 'How To' Videos:

Remove load wheels 

Install load wheels

Replace the load wheels on a pallet jack

Turn the manual jack back upright

Replace the steer wheels on a manual pallet jack

© Copyright 2016, Generic Parts Service Inc.

Are all new Pallet Jacks the same?

This blog focuses a lot on helping folks be as efficient as possible when having to repair their pallet jacks.  

BUT - Sometimes the jack is just dead.  No number of helpful tips, perfectly priced kits or incredibly helpful customer service reps will save this pile of junk.

We get it.

But what is the time crunched busy person supposed to do?  The internet is full of cheap jacks.  What's really the difference?

Here are some really important factors to consider when looking at buying a new jack.

1st - You get what you pay for.  Seriously. Cost should honestly NOT be the only factor in your decision making process.  Why?  Because we hear far to often the frustration in a customer's voice when they call 6-12 months after purchasing a pallet jack and the handle bent, or it won't lift.  We are pretty awesome with our replacement parts coverage (have you read the post about how we can help you ID your replacement parts?) but no one wants to work on a new piece of equipment that soon.

2nd- Does the company you are considering carry replacement parts? Do they have real people you can talk to who can help you find what you need?

3rd - What are the terms of the warranty?  Is there a warranty?  Does the company you want to order from carry the replacement parts at their location or do they have to contact their source?

Generic Parts is the perfect company to chose to order your new pallet jacks from.

1. Although we are not the cheapest (and honestly don't want to be), you'll be hard pressed to find a jack that has the same quality for a lower price.

2. We carry all the parts here in our Beaverton, Oregon warehouse.  You can easily order in a number of formats.  Heck, if your local come drop in for a will call.  Our casa is your casa (between 8am-4pm)

3. We offer a 3 year limited warranty.  Why is this important?  Because this is our jack, and we sell all the replacement parts so we can get you out a warranty replacement Same day.  QA issues are few and far between but you can always trust that we will get you taken care of! 


The new Valu-Jack 2.0 is better than ever. Each unit features a cast iron pump for superior long term reliability. Another improvement we've made is a reinforced handle base with an ergonomic rubber grip.

VJ 27X48-55-2 $ 239.00 each* *for six   Please call for pricing on quantities other than six. 210° steering arc 2.9" height with forks lowered, 7.25" raised height Cast iron pump with galvanized finish for superior corrosion resistance and long term reliability Poly/steel steer wheels; solid nylon load wheels Ergonomic rubber grip handle  3-function hand control and foot release  Reinforced handle base Three-year limited warranty covering manufacturer's defects Equipped with pallet entry and exit rollers Scratch resistant powdercoat and zinc-plated hardware throughout  provides added resistance to corrosion. 12 grease fittings located at all pivot points for easy maintenance Replacement parts always in stock.
Valu-Jack Pallet Jack Version 2 Model Numbers indicate Width x Length of forks PART NUMBER  DESCRIPTION   PRICE (EA) $ VJ 27X48-55-2 5500 lb Capacity Standard Forks  239.00 VJ 27X48-55-2-N 5500 lb Capacity Standard Forks with Nylon Load and Steer Wheels  239.00 VJ 27X48-55-2-S 5500 lb Capacity Standard Forks with Steel Load and Steer Wheels  334.00 VJ 27X48-55-2-B 5500 lb Capacity Standard Forks with Brake only (No backrest)  355.00 VJ 20.5X36-55-2 5500 lb Capacity Narrow Short Forks  229.00 VJ 20.5X48-55-2 5500 lb Capacity Narrow Forks  239.00 All pricing for minimum QTY-6. For individual pricing or higher volume discounts, call today!

Steer Wheels and Axle Inspection Lift-Rite L-50

For your Big/Joe Lift-Rite L-50 manual pallet jack we recommend inspecting the steer wheel and axle before each use. Steer wheels should be free of flat spots and large pieces of embedded material.

Indicators for when steer wheel replacement is necessary:

• Chips in the wheel
• Not turning freely
• Rubs traverse
• Worn more than 1/4"

Note:

If the steer wheel rubs the bottom of the traverse, check for the correct installation of the snap ring underneath the traverse. Replace if it is worn more than 1/4" from the normal outside diameter.

Removal

Steer wheels - Turn the jack on its side and remove the hubcap. Remove the snap ring for the newer style or the roll pin for the older style that fastens the steer wheels to the axle. 

(10 mins.)

Steer wheel axle - Turn the jack on its side and remove the steer wheel. Drive out the roll pin that fastens the axle to the stem of the hydraulic unit and slide the axle out. (15 mins.)

Installation

Steer wheel axle - Slide the axle into the stem of the hydraulic unit and fasten with roll pin. Install the steer wheels. (10 mins.)

Steer wheels - Slide the wheels onto the axle and secure with fasteners (snap rings for the newer style or roll pins for the older style). (10 mins.)

Line drawings available for this unit. Email or call us for your parts (800)331-0839.

Seal kits for repairing your hydraulic unit

Looking to rebuild the hydraulic unit on your manual pallet jack?

Below are outlined the differences between a super seal kit, standard and slim seal kit. 

Super seal kits contain all parts that are included in a standard seal kit, as well as the most commonly needed parts beyond the standard seal kit to do a complete hydraulic unit rebuild.

Standard seal kits have all of the parts included in the manufacturers' standard seal kit.

Slim seal kits include only the most essential and commonly replaced seals. A cost saving option if you know what you need. A Standard or Super seal kit is a better choice if a complete hydraulic unit rebuild is necessary.

Rebuild hydraulic unit program also available. Email or call us today (800)331-0839!

New Improved Valu-Jack 2.0 Manual Pallet Jack

The new Valu-Jack 2.0 is better than ever. Each unit features a cast iron pump for superior long term reliability. Another improvement we've made is a reinforced handle base with an ergonomic rubber grip.

Features:

• Cast iron pump
• Three year limited warranty covering manufacturers defects
• Reinforced handle base with ergonomic rubber grip
• 210 degree turning radius
• 12 grease fittings located at all pivot points for easy maintenance

Email us or call (800)331-0839 today for yours !