Safe Use of Pallet Jacks

Overview

Pallet jacks are essential material handling tools that enable workers to move heavy loads safely and efficiently. However, improper use causes crush injuries, struck-by incidents, and strains. Understanding proper operation prevents these preventable injuries. Whether you use a manual hand pallet jack or a powered electric model, the fundamental safety principles remain the same.

Why This Is Important

Pallet jacks seem simple but create serious hazards when misused. Loads can tip and crush feet or legs. Workers’ fingers get pinched in mechanisms. Poor technique causes back and shoulder strains. Following proper procedures eliminates these risks while making material movement easier and more efficient. Taking time to inspect equipment, position loads correctly, and use proper techniques prevents injuries that could sideline you for weeks or months. The few extra seconds spent working safely are time well invested.

Common pallet jack incidents include foot and ankle crush injuries from dropped loads, hand and finger injuries from pinch points in the handle mechanism, and musculoskeletal strains from pulling heavy loads with poor body mechanics. Many of these injuries happen when workers rush, skip pre-use inspections, or attempt to move overloaded or unstable pallets. Every one of these incidents is preventable with proper training and consistent safe work practices.

Best Practices & Safety Tips

• Inspect pallet jacks before each use—check wheels, forks, hydraulic cylinders, and controls for damage or defects.
• Verify load weight is within the pallet jack capacity rating—overloading causes equipment failure and tipping.
• Ensure loads are stable, evenly distributed, and properly stacked before attempting to move pallets.
• Position forks completely under pallets with loads centered between the forks to prevent tipping during movement.
• Pump the handle slowly and smoothly to raise loads—jerky movements destabilize loads and stress equipment.
• Keep hands and feet clear of pallet jack mechanisms and moving parts to prevent pinch point injuries.
• Pull pallet jacks rather than pushing to maintain visibility and control during movement.
• Navigate corners slowly and deliberately to prevent loads from tipping or shifting unexpectedly.
• Lower forks completely before traveling across uneven surfaces, ramps, or dock plates.
• Never ride on pallet jacks or allow others to ride—they are designed only for moving materials, not transporting people.

Additional Safety Measures

Working on Ramps and Dock Plates

• When going down a ramp, position yourself on the downhill side and let the pallet jack go ahead of you so you can control the speed.
• When going up a ramp, push the pallet jack ahead of you rather than pulling, to prevent the load from rolling back toward you.
• Ensure dock plates and bridge plates are rated for the combined weight of the pallet jack, the load, and the operator.
• Check that dock plates are properly secured and free of debris, oil, or moisture before crossing.

Housekeeping and Environment

• Keep floors clean, dry, and free of debris in areas where pallet jacks are used to prevent wheels from catching or sliding.
• Ensure travel paths are wide enough for safe passage and free of obstructions, protruding objects, and pedestrian traffic.
• Store pallet jacks in designated areas with forks lowered completely to prevent tripping hazards.
• In cold storage or wet environments, be especially cautious of reduced traction and slower equipment response times.

Action Items

• Inspect all pallet jacks currently in use and tag any with damaged wheels, leaking hydraulics, or malfunctioning controls for repair or replacement
• Verify that load capacity ratings are clearly marked on every pallet jack and that workers know how to find and apply those ratings
• Review travel routes for hazards such as uneven surfaces, tight corners, ramps, and congested pedestrian areas
• Ensure all pallet jack operators have received proper training and understand safe operating procedures
• Establish a routine maintenance schedule for all pallet jacks to keep equipment in reliable working condition

Takeaway: Pallet jacks are valuable material handling tools that work safely when operated properly. By inspecting equipment before each use, respecting load limits, using proper technique on flat surfaces and ramps, and keeping work areas clean and clear, we prevent crush injuries, strains, and other preventable incidents. If a pallet jack is damaged or a load looks unstable, stop and address the problem before proceeding.