How to use a pallet jack safely: step by step

A pallet jack (also called a pallet truck or hand jack) is a wheeled lifting tool that slides under a pallet, raises it just clear of the floor with a hydraulic pump, and lets one person roll it. It is the most common way to move pallets short distances in warehouses, docks, trailers and stores. This guide covers how to operate a manual jack safely, which side of a pallet to enter, and what to check before you start. Your employer's training and the jack manufacturer's instructions take precedence.

#Parts of a pallet jack

#Typical sizes and capacities

Values vary by manufacturer. The capacity on the data plate applies to a load centered on the forks. An off-center or overhanging load reduces what the jack can handle safely.

#Before you start: inspect the jack and the load

1. Check the jack. Forks straight, wheels turning freely with no flat spots or debris, no hydraulic leaks, the handle returns to upright, and the lever works in all three positions. Tag out a damaged jack.
2. Check the load weight. It must be within the jack's rated capacity. If you do not know the weight, find out before lifting.
3. Check the pallet. Broken bottom boards, missing blocks or protruding nails can catch the forks or collapse when lifted.
4. Check the load. It should be stable, wrapped or strapped, and centered. Tall loads should not block your view.
5. Check the route. Floors clear and dry, no cracks or debris, enough room to turn, and doors, dock plates and trailer floors in good condition.

#Which side of the pallet can you enter?

A pallet jack's load wheels must reach the floor through gaps in the bottom deck. That limits which sides you can use.

If the load wheels land on a bottom board, the jack will lift the board instead of the pallet and can break it. See two-way vs four-way.

#Step by step: lifting and moving a pallet

1. Lower the forks fully. Put the lever in the lower position and let the forks drop to their lowest height.
2. Line up square to the pallet, centered between the openings.
3. Push the forks in all the way, until the pallet touches the fork backrest or the forks extend fully through. Short entry leaves the far end unsupported and can put the load wheels on a bottom board.
4. Check the load wheels are in open space in the bottom deck, not on a board.
5. Set the lever to raise and pump the handle with smooth, full strokes. Lift only until the pallet clears the floor, about 1 in (25 mm). Higher lifting raises the center of gravity for no benefit.
6. Set the lever to neutral so the handle moves freely without pumping or lowering.
7. Start slowly. Getting a heavy load moving takes effort; use your legs, not your back, and keep your back straight.
8. Push where possible, with the load in front of you and a clear view ahead. Walk; never ride on the jack.
9. Turn wide and slow. Loaded jacks swing wide at the fork tips. Watch the corners of the load around racks and people.
10. Stop gradually. Most manual jacks have no brake. Slow down early.
11. Lower fully at the destination: lever to lower, wait until the forks are all the way down.
12. Withdraw straight out without twisting, so the forks do not drag boards off the pallet.
13. Park the jack out of walkways, forks fully lowered, handle upright.

#Safety rules

• Keep your feet clear of the wheels and fork tips.
• Never ride the jack or let anyone ride on the load.
• Do not exceed the rated capacity or lift loads that are off-center or unstable.
• Avoid ramps and slopes. If you must use one, move light loads only, slowly, and never stand downhill of the load.
• Check the trailer is secured to the dock and the dock plate is locked before entering a trailer.
• Do not use a jack to push or pull other pallets or to tow.
• Take extra care with tall or top-heavy loads, and wear safety footwear.
• Report and tag out any jack that does not hold its load, leaks or steers poorly.

#Using a pallet jack in a trailer

Loading and unloading trailers is where many pallet jack incidents happen. Before entering, confirm the trailer is secured to the dock (wheel chocks or a vehicle restraint) and the dock plate or leveler is in place and rated for the load. Trailer floors can be damaged or wet, so watch for soft spots. Work from the nose of the trailer toward the door when loading, and keep loads tight together so they cannot shift.

#Manual vs electric pallet jacks

In the United States, powered pallet jacks are powered industrial trucks under OSHA 29 CFR 1910.178, which requires operator training, evaluation, and re-evaluation at least every three years. Manual jacks are not covered by that standard, but general workplace safety duties still apply.

#Pallet design and pallet jacks

If your operation uses pallet jacks, the pallet design should allow for them:

• Specify four-way entry with chamfered bottom boards if jacks will enter from every side.
• On stringer pallets, bottom deck openings at the ends must be wide enough for the load wheels.
• Check that the entry height clears the jack's lowered fork height (about 3 in) with room to spare. A 3-1/2 in stringer gives only about 1/2 in of clearance or less.
• Keep bottom boards sound: they take the wheel impacts.

See parts of a pallet for the terms, or open a template to check openings in the designer.