Pallet Jacks: Manual & Electric

Pallet jacks move loads in every warehouse, store and loading dock. They look simple, but loaded jacks weigh thousands of pounds. Crushed feet, workers pinned against racks, and back injuries from manual jacks are common.

• Warehouses
• Retail
• Delivery drivers

Types

• Manual pallet jack: pumped up by hand and pushed or pulled.
• Electric walkie: powered drive; the operator walks with it.
• Electric rider: the operator stands on a platform.

Electric pallet jacks are powered industrial trucks under OSHA. Operators must be trained and evaluated, just like forklift operators. See Forklifts.

Common injuries

• Feet run over by the wheels or crushed under the load
• Being pinned between the jack and a rack, wall or truck
• Back and shoulder strain pulling heavy manual loads
• Loads falling off when going over bumps, dock plates or ramps
• Runaway jacks on ramps and trailer floors
• Riders’ feet or legs outside the platform hitting racks

Safe operation

• Wear safety-toe shoes.
• Know the capacity and don’t overload. Center the forks fully under the pallet.
• Walk beside or ahead of electric walkies, holding the handle to the side, with a clear escape path. Never ride a walkie.
• Use the reverse safety switch (belly button) on electric jacks, and make sure it works.
• Manual jacks: push when you can see ahead; it’s easier on your back. Start and stop slowly.
• Ramps: go slowly and keep the load under control. Avoid ramps steeper than the maker allows.
• Dock plates and trailers: check the trailer is secured and the plate is in place before rolling on. See Forklifts in Trailers.
• Lower the forks and park out of aisles when done.

Check before use

• Wheels and rollers turn freely and aren’t damaged
• Forks not bent or cracked
• Hydraulics lift and hold; no leaks
• Electric: horn, brakes, belly button switch and controls work; battery charged
• Handle returns properly and brakes engage

Last updated: October 2, 2026