In the busy warehouse center, we often see such a scene: in order to deal with emergency wheel replacement, the management personnel find a “look alike” forklift wheel from the spare parts warehouse to replace it – the same diameter, the same axle hole, and the same width. However, it is precisely this seemingly reasonable practice of “mixing the same specifications” that often sows the seeds of reduced equipment efficiency, increased maintenance costs, and even safety hazards.

Specification is only “ID number number”, performance is “gene map”

When we see the numbers “200 × 50 × 80” on the technical parameter table, it’s like seeing a person’s height and weight, but this doesn’t reflect their physical fitness, athletic ability, or health condition at all. Similarly, the physical specifications of forklift wheels are only the surface identification, and what truly determines their applicability are the inherent characteristics that cannot be directly read from the appearance:

1. Chemical code for material formula
The performance difference between polyurethane wheels may be greater than that between rubber and plastic. There are essential differences between ordinary polyurethane and high-performance polyurethane in terms of molecular structure and filler ratio:

Wheels used in cold chain warehouses must be modified with anti low temperature embrittlement agents

Wheels used in chemical environments require special acid and alkali resistant formulas

High intensity continuous operation scenarios require the addition of wear-resistant reinforcement materials

2. “Dynamic Balance” of Hardness Parameters

Hardness is not only a number (such as 85A vs 95A), but also an art that matches the ground. Using hard wheels on epoxy flooring can cause the ground to crack, while using soft wheels on rough cement flooring can accelerate wear. The correct hardness should create an “elastic contact surface” between the wheel and the ground, rather than a rigid collision.

3. “Safety redundancy” in load-bearing design

The rated load of wheels of the same specification may differ by more than 30%. The dynamic load-bearing coefficient (impact load bearing capacity) of a wheel that appears to bear 1.5 tons may be completely different. Under full load emergency stop conditions, wheels with insufficient load-bearing capacity may experience structural damage.

The Domino Effect of Mixed Use: From Wheel Failure to System Risk

When mismatched wheels are mistakenly mixed, the problem often does not immediately manifest, but rather spreads layer by layer like dominoes:

Phase 1: Invisible Wear and tear

Wheels of different hardness on the same axle can cause uneven load distribution

The diameter of the wheel that wears out quickly decreases, causing other wheels to overload and run

Case: A logistics center caused abnormal wear and tear on four sets of wheels within three months due to the mixing of two types of 85A hardness wheels (with different actual formulas)

Phase 2: Equipment Chain Reaction

Uneven wear causes abnormal vibration of the vehicle axle

The transmission system bears additional impact loads

The steering mechanism has uneven wear and looseness

Data shows that improper wheel matching can lead to a 40% increase in overall maintenance frequency

Phase 3: Systemic Risk

Irregular wear marks appear on the ground, and the repair cost is high

The vibration of the goods intensifies during the handling process, and the damage rate increases

Operators experience fatigue due to abnormal equipment vibration, increasing safety hazards

Beyond the ‘spare parts’ mindset: Building a wheel management system

The real solution is not simply to prepare a few “seemingly usable” spare parts, but to:

1. Establish a wheel “DNA profile”
Establish a dedicated walking system file for each forklift, recording the complete performance parameters of the original wheels

2. Implement intelligent wheelset management
Use QR code/RFID technology to track the service life and replacement records of each wheel

3. Develop preventive replacement strategies
Develop replacement plans based on actual wear data rather than fixed cycles

4. Choose a reliable technology partner
Collaborate with suppliers with complete technical capabilities, rather than just purchasing at a price

A real comparative case:

A certain automotive parts factory is using two identical 200 × 50 wheels at the same time. After intervention by the YALIDE technical team, it was discovered that:

A-round: ordinary polyurethane, hardness 92A, suitable for medium load indoor transportation
B-round: Modified polyurethane, hardness 88A, suitable for frequent start stop under heavy load

Mixing resulted in a decrease in average service life from 18 months to 7 months, and an increase of 35% in annual maintenance costs

Correct selection logic

When you need to replace forklift wheels, please remember this decision chain:
1. First ask “Where did it come from”: clarify the complete technical background of the original wheels
2. Looking at ‘what to do’ again: Analyze actual working conditions and performance requirements
3. What to choose at the end: Choose products that are technically perfectly matched rather than just the same size

YALIDE promises that every wheel we provide is based on a deep understanding of your equipment, operating conditions, and performance requirements. It is not only ‘fit’, but also ‘used well and for a long time’. Because in our view, each forklift wheel is not an isolated spare part, but a crucial link in your logistics system that concerns efficiency, safety, and cost.