Pallet Jack Safety

Pallet Jack Safety: Hazards

 Electric Pallet jacks are:
◦ Motorized to allow lifting and moving of heavier and
stacked pallets; Motorized pallet truck video
◦ Self propelled and minimizes the amount of physical
operator effort; reduces the risk of injury.
◦ Capacity of 2,800 lbs – 5,000 lbs for electric models
◦ Two categories: Walk behind and jacks equipped with an
operator platform
Hand pallet jacks
 This training information is focused on manual,
hydraulic pallet jack safety which is a:
◦ A jack steered by a tiller lever, which is also a pump handle
for raising the jack
◦ Small handle on the tiller releases the hydraulic fluid,
causing the forks to lower
◦ Front wheels are mounted on levers attached to linkages
going to levers attached to the jack cylinder
Pallet Jack Safety: Hazards
 Pallet jacks aren’t as dangerous as forklifts
 They can still cause serious injuries and damage
materials and structures
 Pallet jacks help workers safely handle heavy loads
 Trying to move heavy material without a pallet jack
could result in even more serious injuries
 If a pallet jack is not used safely, employees can be
injured
◦ Loads can topple from uneven floors, inclines, excessive speed
◦ Striking against door frames, columns, walls and other stationary
objects
◦ Trips from exposed pallet jack “forks”
◦ Running over their feet
Pallet Jack Safety: Injuries
 Loads tipping/falling on employees resulting in
contusions, abrasions, strains and sprains
 Back strain from adjusting loads
 Injuries from running into other employees
 Bodily harm from impacts or from losing control on
inclines
 Abrasions, contusions or fractures from impacting
walls or columns
 Load dropped on foot or foot crushed when the pallet
jack runs over feet
 Strain or dislocation of shoulder due to forceful
pulling of a pallet jack
 Strains from moving a loaded pallet jack .
Pallet Jack Safety
Injury Prevention
 Two factors to prevent injuries:
◦ Clear safety rules
◦ Hands-on training.
 Pallet jacks seem like simple devices and do not
appear to require training
 Imperative: Read and follow the safety rules in the
manual
 Never operate a pallet jack unless you have been
trained
 Before moving loads, first demonstrate safe operating
procedures with an electric or manual pallet jack
Pallet Jack Safety Rules
Safe Operation
Your responsibility as the pallet jack operator:
• Use in the correct manner to ensure your safety
and the safety of the people in the vicinity
• Familiarize yourself with the controls before
using the pallet jack
• Ensure controls are undamaged and responsive
• Plan your journey before jumping straight into
using the pallet jack
• Never carry riders or ride the equipment yourself
• No horseplay, it can cause serious injuries!
Pallet Jack Safety Rules
PPE and body positioning
• Wear proper foot protection and gloves.
• Make sure you have a secure grip on the load,
especially pallet jacks with worn grips
• Never place your feet under a pallet jack
• Feet, hands or any body part should never be
placed underneath a pallet
• Use proper lifting techniques loading/unloading
and operating the pallet jack
• Be wary of pinch points to avoid injuries to your
hand
Pallet Jack Safety Rules
Forks
 Forks:
◦ Center the forks evenly under the load to
maintain good balance and ensure stability of the
load.
◦ Make sure the forks are positioned completely
under the pallet.
◦ Maintain a clearance of about 1 inch between the
floor and the pallet.
◦ The load is more stable if it is kept close to the
floor
Pallet Jack Safety Rules
Forks
• Push or Pull? Pulling allows better maneuverability but pulling
puts strain on the back, always try to push the load instead if
you can
• Pushing the load:
• Keeps the back and spine straight
• Uses the stronger and larger leg muscles and bones
• Pulling the load:
• Employees pulling pallet jacks are using their backs
more than their legs to move the load
• Bending forward creating a curvature in their spine
making them more susceptible to back injuries
• The jack is not designed to be pulled by one or both arms
• Exception: Making small adjustments in the positioning of the
load, while standing erect
Pallet Jack Safety Rules
Inclines/pathways
• Difficult to use on slopes, particularly when the load
is heavy
• Designed for smooth surfaces, difficult to maneuver
on uneven surfaces or in areas with debris
• Avoid inclines but always be uphill of the load on an
incline
• If you absolutely must use an incline be extra
cautious
• Always push when going down an incline and never
stand
downhill of a loaded pallet jack going down a ramp
Pallet Jack Safety Rules
Parking
Park the pallet jack in a level place, forks lowered
 Don’t block exits or emergency equipment, i.e. fire

extinguishers
 Do not leave a pallet jack unattended and elevated
 Put pallet jacks safely away in a predetermined

storage location
when not in use with the handle raised and locked
 Keep the jack out of a traffic area, avoid a tripping

hazard
 Always let pallet jack down when stocking product or

anytime
the pallet jack is left unattended
Pallet Jack Safety Rules
Handling Loads
• Pay attention and never exceed the manufacturer’s
maximum load rated capacity, never overload
 The capacity will be clearly marked on the pallet jack
• Keep your back strong and straight
• Keep the load under control
• Start and stop gradually, prevent the load shifting position
• Stop moving your load if someone is in the pathway—don’t

assume the person sees and can avoid you.

• Use established traffic lanes and exercise caution to
avoid collisions at corners
• Swing wide on corners to avoid striking the door frames,
racking, or other structures, use a spotter if needed
Pallet Jack Safety Rules
Pallets
 Store pallets in a dry place
 Inspect the pallet for loose or rotting sections
◦ Make sure the pallet is in ggood condition and
can safely support the load
 Ensure no leakage from the previous or current
load has weakened the structure of the pallet
 Stabilize the load on the pallet
 Interlocked stacking, plastic wrap, or straps
Pallet Jack Safety Rules
Inspections
Make a quick inspection
• Inspect pallet jack in general for good working
condition
• Check brakes, steering, controls, forks, hoists
and warning devices
• Look for water, oil, or other liquids on the floor
• Observe the wheels; ensure they are not worn out
and have no cracks
• This will prevent poor handling and reduce the risk of
an unstable load
• Report any problems to your supervisor
Pallet Jack Safety: Fork Operation
 Use both forks for lifting a load
 Never use one fork to lift a load
 Ensure the stability of the load
 Maintain good balance, center the forks

evenly under the load

 Maintain a clearance of about 1 inch

between the floor and the pallet

 The load is more stable if it is kept close to

the floor.
Pallet Jack Safety: Actuating lever
 Safe handling requires skill
 Raise the forks by pushing the actuating lever down and

pumping the handle

 Use both hands when jacking up a manual pallet jack to

prevent muscle strain

 The only time the handle is down is to jack the pallet
 Put the actuating lever in a neutral or middle position to

move the load.

◦ This position disengages the lifting mechanism and frees
the handle from hydraulic resistance, but keeps the forks
raised
 When the lever is released, it will automatically return to the
neutral position
Pallet Jack Safety: Safe Maneuvering
 Use the neutral position when moving loads, this reduces
operator fatigue
 Push if you safely can, but pulling allows for increased

maneuverability and better control of the load

 If pulling the pallet jack, make sure it is in the neutral

position to reduce fatigue

 Do not turn the handle too fast, can cause the load to shift.
 Watch for clearances on both sides of the aisle
 Operate at controllable speeds, hand pallet trucks do not

have brakes, allow plenty of room to stop

 Do not carry riders on the hand pallet truck
 Be aware of other people and forklifts in the vicinity
Pallet Jack Safety: Loading docks
 Always be alert on loading docks. Stay away
from the edge of the dock.
 If you are loading or unloading a truck at a

dock, enter or exit the truck squarely

 Park the pallet truck out of traffic areas in a

safe, level place with the forks lowered.

 The handle should be left in the up position

to eliminate tripping hazards.