Quick Guide to Replacing Forklift Wheels

Time：Jul 18,2025

Quick Guide to Replacing Forklift Casters

—Even Beginners Can Do It Right the First Time

Preface

Casters may be small, but they determine how far and how steadily a forklift can travel. This article uses plain language to break down the entire replacement process, translating professional terms into everyday language, so that even those who are doing it for the first time can complete the replacement safely, efficiently, and without errors.

I. Preparation Phase—Tools and Safety

1. Find a flat, dry surface, engage the parking brake, and wedge the wheels to prevent the vehicle from rolling.

2. Tool List:

• 2-ton or more horizontal jack (or forklift-specific lift stand)

• Socket wrench, retaining ring pliers, rubber mallet

• Lubricating spray, clean cloth, disposable gloves

3. Wear: Safety helmet, anti-smash shoes, and safety glasses are essential.

II. Removing the Old Wheel—"Three Steps"

Step 1 Lifting the Vehicle

Position the jack under the forklift's officially designated support point, slowly lift it, ensuring the old caster is 3–5 cm off the ground, and immediately place a safety support under the chassis.

Step 2 Removing Protection

If the caster has a dust cover, gently pry it open with a flathead screwdriver; if there is a retaining ring under the cover, use retaining ring pliers to remove it; if you encounter a rusted bolt, spray lubricant first and wait two minutes before turning.

Step 3 Removing the Wheel

Hold the wheel with one hand and pull out the axle pin or loosen the locking nut, and the old caster can be removed. Place the removed bolts, washers, and retaining rings in order to avoid losing them.

III. Installing the New Wheel—"Reverse Order"

1. Verification: The model, shaft diameter, and load rating of the new caster must be exactly the same as the old one, and the bearing should rotate smoothly without any jamming.

2. Cleaning: Wipe away mud and old oil from the mounting holes with a cloth to prevent damage.

3. Installation:

• Align the caster shaft with the hole and push it into place by hand;

• Insert the washer → retaining ring → dust cover, and gently tap it into place with a rubber mallet until you hear a "click," indicating that it is locked;

• Manually rotate the caster 2–3 times to ensure there is no shaking or misalignment.

4. Lowering the Vehicle: Slowly remove the safety support and lower the jack until the vehicle is completely on the ground.

IV. Verification—30-Second Self-Check

• Shake the caster firmly to check for any gaps or unusual noises;

• Push the forklift to move in a straight line for 2 m to check for any deviation or jolts;

• Brake test: The caster should stop immediately.

V. Additional Tips

1. If it is a drive wheel or load-bearing wheel, the removal steps are similar, but the bolt torque is greater, so it is recommended to use an air wrench.

2. Check the caster wear limit line every six months, and replace it immediately when the mark is reached.

3. If unsure, take photos to record the order of the old parts, or scan the code to watch the manufacturer's official video to avoid the embarrassment of having an extra screw after installation.

Conclusion

Replacing casters is not mysterious; the key is the eight-character mantra of "stable lifting, gentle removal, tight installation, and accurate testing." Following this procedure, you can get your forklift back in action in ten minutes. If you encounter special structures or heavy loads, please contact a professional technician immediately and do not use brute force. Wish you success!

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