What is a Pallet Jack?

 

A pallet jack is a piece of wheeled material handling equipment designed to lift a pallet, loaded or unloaded, a few inches off the floor to move it across a flat floor or other surface. It is also called a pallet truck, pump truck, or hand truck depending on the region and industry.

 

To load, the two fork arms slide into openings on a pallet. The forks lift the pallet just enough to clear the floor, and the operator rolls the load to its destination on specially-engineered wheels.

 

Keeping loads close to the ground keeps the load’s center of gravity close to the ground to reduce tip-over risk, and the limited lift height is why pallet jacks can be operated without the certification requirements that apply to forklifts.

 

Standard Pallet Jack Dimensions and Capacity

 

 

Pallet Jack vs. Forklift: What is the Difference?

 

A pallet jack moves pallets across a floor at the same low level. Lift height maxes out at 7” to 8”, and it cannot lift pallets onto racks or elevate loads above waist height.

 

A forklift raises pallets to racking heights of 20-feet or more and requires 8’ to 12’ of aisle clearance to operate safely.

 

For moving pallets from a receiving dock to a staging area, or from storage to a production line, a pallet jack is faster, cheaper, takes up less space, and requires less clearance. For placing pallets on elevated racks or lifting loads to significant heights, a forklift is the right tool.

 

Types of Pallet Jacks

 

Manual Pallet Jack

 

Hydraulic and operator-powered. The operator pumps a lever, typically integrated into the control handle, to raise the forks. With the pallet raised, the load can be pushed or pulled to its destination. No battery, no motor, no charging required.

 

• Unit weight: 150 to 190 lbs.
• Best for smaller facilities, retail stockrooms, and operations where pallets move occasionally rather than continuously throughout a shift.

 

Powered (Electric) Pallet Jack

 

A battery-driven motor handles both lifting and movement. The operator walks behind the unit and controls the speed & direction from the control handle. Larger ride-on models feature a standing platform for the driver.

 

• Unit weight with battery: 750 to 1,500 lbs.
• Best for high-volume distribution centers, multi-shift operations, and heavy loads moved repeatedly across a full shift.

 

All-Terrain Pallet Jack

 

A specialty type of pallet jacks built for uneven surfaces such as loading dock plates, outdoor pavement, and floors with gaps or cracks. Not the right tool for standard smooth-floor warehouse use.

 

For a full side-by-side buying comparison, see the Manual vs. Powered Pallet Jacks guide.

 

How a Manual Pallet Jack Works

 

Utilizes a hydraulic cylinder for the lifting mechanism. Each pump stroke pushes fluid from a reservoir into the cylinder which extends a piston and drives a set of linkage arms downward. As the linkage presses toward the floor, the forks rise.

 

Step-by-Step Operation:

 

1. Roll the jack to the pallet and steer the forks into the fork pockets until the forks fully engaged in the pallet.
2. Pump the handle. Typically, 3 to 7 strokes bring the forks to full height, but heavier loads may need more.
3. Push or pull the unit to the destination. Two larger caster wheels at the handle end are used to steer, with two load wheels at the fork tips to carry the weight.
4. At the destination, squeeze or move the release control. This bleeds hydraulic pressure and lowers the forks at a controlled rate.

 

The hydraulic system is sealed. Under normal use, you should not need to add or change fluid. Fluid pooling under the unit or visible on the cylinder body means a seal is leaking.

 

How a Powered Pallet Jack Works

 

Even though the fork-and-linkage geometry is the same as a manual jack, a powered jack utilizes a battery to drive the electric motor and operate the hydraulic pump instead of doing it by hand. A drive motor handles movement instead of the operator pushing.

 

Operation:

 

Lifting:

 

1. Press the lift button.
2. The electric pump raises the forks to full height.
3. Press the lower button when at the load destination.

 

Travel:

 

An electric motor connected to the rear wheel assembly drives the unit forward and reverse. A throttle on the handle controls speed. Pedestrian models top out at 3 to 4 mph. Rider models reach 5 to 7 mph.

 

Stopping:

 

Every powered pallet jack has a dead man's witch in the handle, which means the drive motor runs only while the operator holds it. When the switch is released, the unit stops immediately. This is the unit's primary braking mechanism.

 

Battery Options:

 

 

Runtime varies based on load weight, travel distance, operating conditions, and battery capacity.

 

How to Maintain a Manual Pallet Jack

 

Daily Pre-Checks

 

1. Inspect the forks

 

Both forks should sit at the same height with no visible bends, cracks, or weld damage where they meet the frame. One fork sitting noticeably higher than the other may indicate a bent fork, damaged linkage, or hydraulic problem. Remove the jack from service until it is inspected.

 

2. Check all four wheels

 

Inspect the two load wheels at the fork tips and the two caster wheels at the handle end. Look for flat spots, cracking, or missing chunks. A wheel with flat-spots produces increases impacts during movement and stresses the fork frame & welded joints with every load cycle.

 

3. Test the lift

 

Pump the handle to confirm the forks rise smoothly. Lower with the release valve and confirm descent is even and controlled.

 

4. Check for hydraulic drift

 

Raise the forks to full height. Release the handle. Watch the forks for 30 seconds. If they descend slowly on their own, a hydraulic seal is losing pressure. A jack that drops a load during a move is a hazard. Do not use it until the seal is replaced.

 

Monthly Maintenance

 

• Lubricate the handle pivot-point, steer axle, and linkage arm pins with light grease or machine oil.
• Check and tighten the handle stop bolt. This bolt limits handle travel toward the forks. Vibrations can cause it to back it out over time and creates a pinch point.
• Check load wheel axle bolts for tightness. Lift each wheel and feel for lateral wobble.
• Wipe down the exterior of the hydraulic cylinder shaft. Grime pulled into the seal during operation accelerates seal wear.

 

Annual Maintenance

 

• Check hydraulic fluid level with forks fully lowered. Top off with manufacturer-specified fluid, typically ISO 32 or ISO 46 mineral oil. Trace the source of any fluid loss before returning the unit to service.
• Inspect cylinder and linkage seals for weeping.
• Evaluate wheels for replacement. Flat-spotted or reduced-diameter wheels should be replaced regardless of calendar schedule.
• Verify all labels, capacity markings, and safety information remain legible.

 

How to Maintain a Powered Pallet Jack

 

Daily Pre-Checks

 

1. Check battery state of charge

 

Start each shift at 80% charge or above. Regularly starting below 50% causes deep discharge, which shortens battery life faster than most other operating habits.

 

2. Inspect battery terminals

 

White or greenish buildup is corrosion. Follow the manufacturer's procedures and use appropriate PPE when cleaning battery terminals. Corroded terminals can cause bad contacts, reduced power output, and generate heat during charging & use.

 

3. Inspect the drive wheel

 

The rear wheel controls all propulsion and braking. Check for flat spots, tears, and missing pieces. Damaged wheels reduce traction, steering performance, and braking effectiveness, increasing the risk of losing control of the load.

 

4. Test travel controls and braking

 

Roll forward slowly on a clear stretch of floor, then release the switch. The unit should stop immediately. If it coasts, the switch is not functioning. Pull the unit from service.

 

5. Test the lift

 

Activate lift and raise the forks fully. Movement should be smooth and prompt. A sluggish lift points to low charge or a failing pump motor.

 

Monthly Maintenance

 

• Lead-acid batteries: Check electrolyte level in each cell after charging. Add distilled water, not tap water, to the marked fill line. Never add water before charging.
• Test braking at low speed with a load on the forks. Verify the truck stops smoothly and consistently in accordance with the manufacturer's specifications.
• Inspect the charger connector for heat discoloration, melted plastic, or bent pins. A damaged connector is a fire risk during charging.
• Lubricate the steering column pivot, axle pins, and hydraulic linkage points with light grease.

 

Annual Service

 

• Test battery capacity with a discharge tester. A battery below 80% of rated capacity should be scheduled for replacement.
• Brush-type DC motors: Inspect motor brushes. Brushes under 25% of original length need replacement before they damage the commutator.
• Inspect the wiring harness for chafe marks, heat damage, and loose terminals. Have a technician check the control board for logged fault codes.

 

Full Maintenance Schedule At-A-Glance

 

 

When to Pull a Pallet Jack from Service Immediately

 

Tag the handle with a do-not-use sign and remove the unit from the floor if any of the following apply:

 

• Forks are bent, cracked, or sitting at uneven heights
• Forks drift downward on their own when raised
• Any wheel is missing, cracked through, or severely flat-spotted
• Releasing the dead man's switch does not stop the drive motor on a powered unit
• Hydraulic fluid is leaking onto the floor
• Battery terminals show active sparking or melted material around the contacts

 

An unlabeled damaged unit in a busy facility can get used by the next operator who needs one, leading to damage, injury, unexpected down time, and compromised productivity.

 

Frequently Asked Questions

 

What is the difference between a pallet jack and a pallet truck?

 

None. The two names refer to the same piece of equipment. "Pallet jack" is the common term in the United States. "Pallet truck" is standard in the UK and parts of Europe.

 

What is the weight capacity of a standard pallet jack?

 

Most manual pallet jacks are rated for 4,000- to 5,500-pounds. Most powered models handle 4,500- to 6,000-pounds. The rated capacity is stamped on an identification plate on the unit. Repeated use above the rated capacity can gradually bend forks over time, often without obvious visible damage until the fork is significantly weakened.

 

Do you need a certification to operate a pallet jack?

 

Manual pallet jacks do not require formal certification. Powered pallet jacks do. OSHA standard 29 CFR 1910.178 requires operators of powered industrial trucks, which includes powered pallet jacks, to complete formal training and evaluation before operating the equipment.

 

How long does a pallet jack last?

 

A manual pallet jack with regular maintenance typically lasts 5 to 7 years. A powered pallet jack in a well-maintained operation typically lasts 7 to 10 years. Battery life is the most common limiting factor on powered units. Lead-acid batteries usually need replacement every 3 to 5 years depending on charge cycle frequency and whether they have been regularly deep-discharged.

 

What is a dead man's switch on a pallet jack?

 

A dead man's switch is a safety component found on the handle of a powered pallet jack that must be held continuously to keep the drive motor running, and releasing it immediately cuts power to the motor and stops the unit. It is the primary braking mechanism on most pedestrian-operated powered jacks.

 

What causes a pallet jack to not lift?

 

On a manual jack, the most common cause is low hydraulic fluid from a leaking seal. Air in the hydraulic system is another cause, which can be purged by pumping the handle repeatedly with no load and utilizing the release valve. On a powered jack, a hesitant or non-functional lift usually points to low battery charge or a failing hydraulic pump motor.

 

Can a pallet jack be used on a ramp?

 

Manual pallet jacks are not rated for ramp use due to safety concerns. They handle very shallow grades on smooth surfaces but steeper inclines create load rollback risk. Powered models vary by specification. Check the specifications for your specific model before using it on any incline. Some are rated for grades from 5- to 10-percent.

 

How do you maintain a pallet jack?

 

Inspect forks and wheels, test lift and lower, run the lowering drift test on manual units, check battery charge and dead man's switch on powered units before every shift. Lubricate pivot and linkage points, water lead-acid battery cells, test the brake on powered units monthly. Check hydraulic fluid & seals, and test battery capacity on powered units annually. The full schedule is in the table above.

 

The information contained in this article is for informational, educational, and promotional purposes only and is based on information available as of the initial date of publication. It is the reader’s responsibility to ensure compliance with all applicable laws, rules, codes and regulations. If there is any question or doubt in regard to any element contained in this article, please consult a licensed professional. Under no circumstances will Global Industrial be liable for any loss or damage caused by your reliance on this article.