Pallet trucks (or pallet jacks) are essential tools for material handling, but improper use can lead to accidents, injuries, or product damage. According to OSHA, over 20% of warehouse injuries involve improper equipment operation. To protect your team and maintain productivity, follow these safety guidelines when using pallet trucks.
1. Pre-Operation Checks: Start with Inspection
Before using a pallet truck, conduct a thorough inspection:
Hydraulic System: Check for leaks, and ensure the lift mechanism operates smoothly.
Wheels and Forks: Look for cracks, debris, or wear on wheels. Forks should be straight and undamaged.
Load Capacity: Confirm the truck’s maximum capacity (marked on the label) matches your load weight.
Never use a damaged pallet truck—report issues immediately for repairs.
2. Proper Loading Techniques
Center the Load: Position the pallet evenly on the forks to avoid tipping.
Avoid Overloading: Exceeding the weight limit destabilizes the truck and strains components.
Secure Unstable Loads: Use straps or shrink wrap for irregularly shaped or loose items.
3. Safe Operating Practices
For Manual Pallet Trucks:
Push, Don’t Pull: Pushing provides better control and reduces back strain.
Keep Forks Low: Transport loads with forks 2–5 cm (1–2 inches) off the ground to maintain stability.
Watch for Obstacles: Clear pathways of debris, cords, or wet spots that could cause slips or jolts.
4. Navigating Hazards
Slopes and Ramps:
Always descend slopes backward (manual trucks) or follow manufacturer guidelines (electric models).
Never turn on a ramp—position the truck straight before ascending/descending.
Uneven Surfaces: Use pallet trucks with pneumatic tires for outdoor or rough terrain.
5. Parking and Storage
Lower Forks Fully: After unloading, lower forks to the ground to prevent tripping hazards.
Park in Designated Areas: Keep aisles and emergency exits clear.
6. Training and Maintenance
Train All Operators: Ensure staff understand how to use the specific pallet truck model, including load limits and emergency protocols.
Schedule Regular Maintenance: Lubricate wheels, inspect hydraulics, and replace worn parts promptly.
Post Safety Reminders: Display checklists and warning signs near storage areas.
Common Mistakes to Avoid
Riding the Pallet Truck: Never stand on the forks or use it as a personnel transporter.
Ignoring Weight Distribution: Uneven loads can tip sideways, causing injuries.
Rushing Operations: Hurrying increases the risk of collisions or drops.
Final Thoughts
Safe pallet truck operation hinges on proper training, equipment maintenance, and adherence to protocols. By prioritizing safety, you not only protect your team but also extend the lifespan of your equipment and reduce downtime.
