Pallet Jack Wheels: A Complete Guide & Replacement Tips

Pallet jack wheels play a critical role in the performance, safety, and longevity of your equipment. This guide brings together everything you need to know—from wheel types and materials to maintenance, replacement, and best practices—so you can quickly understand how to keep your pallet jack operating efficiently.

Types of Pallet Jack Wheels

Most pallet jacks use two main types of wheels, each serving a different function. Load wheels are smaller, typically 3 inches or less, and are located under the forks. Their primary role is to support the weight of the load, and they move only in a straight line with the forks, without swiveling.

In contrast, steering wheels—also called steer wheels—are larger, usually around 7 to 8 inches, and are positioned at the front of the jack. These wheels are mounted on a swivel controlled by the handle, allowing the operator to turn and maneuver the pallet jack easily.

Wheel Components Explained

Understanding the components of a pallet jack wheel can make maintenance and replacement much easier. Each wheel typically consists of a tread, which is the outer layer that makes contact with the floor; a bearing, which allows the wheel to rotate smoothly; an axle, which is the steel rod that holds the wheel in place; and an axle roll pin, which secures the axle and prevents it from shifting.

Why Maintenance Matters

Wheel maintenance is essential because it directly impacts how well a pallet jack performs. Worn or damaged wheels can reduce efficiency, damage goods or flooring, increase safety risks, and lead to expensive repairs. Regular inspection and upkeep help extend the life of your equipment and ensure safe operation in daily use.

Materials

Pallet jack wheels are commonly made using steel for the axle and bearings, while the tread is typically constructed from nylon or polyurethane, though rubber or steel may also be used in certain applications.

Nylon vs. Polyurethane Wheels

When comparing nylon and polyurethane wheels, each has its own strengths. Nylon wheels are highly durable, resistant to chemicals and moisture, and ideal for rough, industrial environments or heavy loads. However, they tend to be noisier and can mark floors.

Polyurethane wheels, on the other hand, offer quieter and smoother operation, making them better suited for indoor or retail environments where floor protection is important. They are more sensitive to debris and harsh conditions, so the choice between the two depends largely on the working environment—nylon for heavy-duty use and polyurethane for cleaner, quieter spaces.

Cushotane Wheels
One of the most widely used materials is Cushotane. Below you will find a list with the advantages and disadvantages of each Cushotane type:

* Cushothane Load Wheels 95A & Cushothane EZ 85A Tires (Universal Usage)
Advantages: These are the most reliable and cost-effective solution for roughly 80% of material handling applications, making them ideal for grocery stores, big box retailers, and small, clean warehouses
Disadvantages: They are not designed for demanding environments; if they are under-specified for heavy loads or high speeds, they will suffer from early failure and a shortened usage life

* Cushothane EZ (Cold/Wet Storage & Dirty Floors)
Advantages: This model features a significantly lower glass transition temperature, which prevents the polyurethane from hardening, becoming brittle, or spinning in freezing environments
. It can be grooved and siped to provide better traction in liquid
. Additionally, as a softer material (85A), it offers high cut and tear resistance against floor debris
and provides the maximum operator stability and comfort needed for high orderpicker platforms
Disadvantages: Because it is specifically formulated as the softest compound to handle floor imperfections, it relies on reaching a balance to just satisfy carrying capacity, making it less suitable for extreme heavy-duty cargo weights compared to harder models

* Cushothane XL (Heavy Loads)
Advantages: Built with a higher dynamic compound that generates less heat and has a higher melt-down temperature
. It utilizes a harder polyurethane (93A for tires, 97A for load wheels) and stronger XL3 bonding to limit material movement, preventing the tire from melting or debonding under heavy cargo weights
. The harder 97A wheel is also highly resistant to cuts and chunking from uneven dock plates or debris
Disadvantages: Harder compounds like this can magnify floor vibrations and imperfections, which worsens ride comfort and safety for operators riding high on elevated platforms

* Cushothane XL-AC (Long Empty Runs)
Advantages: Features a highly dynamic, low-rolling-resistance compound that will not generate heat beyond its melting point
. It is the specific solution for counterbalance trucks traveling long distances at high speeds when they are completely empty
Disadvantages: This is a highly specialized application compound restricted to CL-I steer or CL-II drive tires

* Dual and Triple Wheel Assemblies (Tight Turns)
Advantages: These assemblies solve the geometric problem of cornering by allowing the inside and outside wheels to rotate independently at different speeds
. This prevents the wheels from skidding, scuffing, wearing unevenly, and generating destructive heat on rider pallet trucks
Disadvantages: They are restricted by wheel width dimensions; dual wheels are only for short load wheels (5 inches or less), while triple wheels are specifically for single long wheels (5.91-6.5 inches)

* Cushothane XL-AcS (Maximum Stability)
Advantages: Specifically designed as a 90A tire to pair with EZ load wheels to maximize efficiency and stability for straddle and furniture orderpickers
. When combined with the SuperSmooth option, it creates a "Zero TIR" tire that completely eliminates out-of-round bouncing
Disadvantages: The sources do not mention explicit material disadvantages, but its usage is narrowly tailored to specialized elevated operator trucks

* Cushothane ULTRA-ES (ULTRA Performance)
Advantages: This is the most advanced compound available, offering the highest cut and tear resistance and a significantly longer work life
. It is built specifically to survive "worst-case scenarios" that combine heavy loads, high speeds, over-duty cycles, dirty floors, and blast freezers
Disadvantages: It is intended as the final solution "when everything else fails or requires a frequent replacement cycle"
. Using this tire for light, clean warehouse duties would be considered over-specifying, resulting in poor cost efficienc

Repair vs. Replacement

While it is sometimes possible to repair pallet jack wheels by replacing individual components like bearings, full replacement is usually the better option. Attempting repairs can damage the wheel further and often leads to higher overall costs.

Signs of Wheel Damage

Recognizing when a wheel is damaged is key to avoiding larger issues. Common signs include cracks or breaks, flat spots on the tread, difficulty turning, worn-down tread, or damaged bearings. As a general rule, wheels should be replaced when they have worn down by about a quarter inch (0.6 cm).

When to Replace Wheels

You should replace pallet jack wheels whenever you notice visible wear, reduced performance, debris buildup that affects movement, or structural damage such as cracked hubs or missing tread. It is also important to replace wheels in pairs to prevent uneven wear and unnecessary strain on the equipment.

How to Replace Pallet Jack Wheels

Replacing pallet jack wheels involves a straightforward process. First, identify the correct replacement parts and gather the necessary tools, such as a hammer, mandrel, and replacement kit. Then, carefully turn the pallet jack onto its side or back, remove the tension pins and axle, install the new wheels, and finally reassemble the axle and pins.

Cost of Replacement Wheels

The cost of replacement wheels can vary depending on the material and type. Load wheels typically range from about $45 to $60 or more, while steering wheels cost around $50 to $60 or more. Full replacement kits generally fall between $150 and $200, with nylon wheels usually being less expensive than polyurethane options.

Reducing Wear and Tear

To reduce wear and tear, it is important to choose the right wheel material for your environment, keep floors clean and free of debris, avoid overloading the pallet jack, lubricate moving parts, and inspect the wheels regularly—ideally every six months. Avoiding rough or uneven surfaces can also significantly extend wheel life.

Measuring Pallet Jack Wheels

Measuring pallet jack wheels accurately is important for proper replacement. A digital caliper can be used by opening it wider than the wheel, placing it across the center, closing it snugly around the tread, and reading the measurement. If the diameter has been reduced by a quarter inch (0.6 cm) or more, it is time to replace the wheel.

Best Practices for Longer Wheel Life

Following best practices can greatly extend the life of your pallet jack wheels. Keeping floors clean, removing debris from wheels, avoiding drops or curbs, staying within load limits, and not leaving heavy loads parked for long periods all help reduce stress on the wheels. Regular lubrication of axles and bearings, along with routine inspections, is essential. In many environments, replacing wheels every six to eight months—or sooner under heavy use—is recommended.

Need Help?

If you are unsure about selecting or replacing pallet jack wheels, consulting a material handling expert or supplier can help ensure you choose the right solution for your specific needs.