Manual Pallet Jack Safety

1. ManualPallet Jack Safety Robert A. Wachter UC Davis EH&S

2. Electric Pallet Jacks • 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

3. 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.

4. 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

5. 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 footcrushed 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.

6. Pallet Jack SafetyInjury 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

7. Pallet Jack Safety RulesSafe 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!

8. Pallet Jack Safety RulesPPE 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

9. Pallet Jack Safety RulesForks • 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.

10. Pallet Jack Safety Rules Push or Pull • 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

11. Pallet Jack Safety RulesInclines/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

12. Pallet Jack Safety RulesParking • 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

13. Pallet Jack Safety RulesHandling 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

14. Pallet Jack Safety RulesPallets • Store pallets in a dry place • Inspect the pallet for loose or rotting sections • Make sure the pallet is in good 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

15. Pallet Jack Safety RulesInspections 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

16. 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.

17. 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

18. 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

19. 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.

20. Short Quiz Safe Use of Hand Pallet Trucks Name____________________________________ True or False? 1. Push the load. T or F 2. Enter or exit a truck at an angle. T or F 3. Pallet trucks do not have brakes. T or F 4. Keep the forks 1-2 inches above the ground. T or F 5. Keep yourself uphill when going up or down any incline. T or F

21. Answers 1. F 2. F 3. T 4. F 5. T