A manual pallet jack, often referred to as a pump truck, is a common piece of warehouse equipment designed for moving heavy, palletized loads short distances. This wheeled trolley uses a hydraulic system to lift and lower goods. Understanding the correct operational steps for lifting a pallet is a foundational skill for maintaining a secure and efficient working environment. This guide focuses on the proper technique required to safely raise a load using this mechanical device.
Essential Safety Practices
Before attempting to lift any load, operators must confirm the equipment and the surrounding area are ready for use. Inspect the pallet jack’s wheels and frame to ensure they are free of debris and damage that could impede smooth operation. Visually check the load to verify it is stable, properly stacked, and securely wrapped before any movement occurs.
The maximum weight capacity, typically stamped onto the jack’s frame, must be observed to prevent mechanical failure or injury. Never attempt to lift a load that exceeds this rated capacity, as it places undue stress on the hydraulic components and structure. Confirm that the floor surface is level, dry, and clear of obstructions that could cause the jack to tip or become uncontrollable.
Preparing the Load and Positioning the Forks
Proper preparation begins with setting the jack’s control lever to the neutral position, which often requires a half-pull on the handle trigger. This setting disengages the hydraulic pump, allowing the forks to move freely without engaging the lift mechanism. Approach the pallet squarely, ensuring the jack is aligned straight with the openings, known as stringers, on the pallet’s side.
The operator needs to push the forks completely through the pallet until the back of the jack contacts the load or the far side of the pallet. Full insertion ensures the entire weight of the load is distributed evenly across the length of the forks. The weight should be centered between the two forks, as an off-center load can cause instability and make steering difficult once the pallet is raised.
Step-by-Step Guide to Raising the Pallet
The process of elevating the pallet begins by placing the control lever into the “up” or “lift” position, which engages the hydraulic pump mechanism. This position is achieved by pushing the control lever on the handle completely down and holding it in place. Once the lever is set, the operator can begin the pumping action by pulling the handle back and pushing it forward in a full, smooth stroke.
A consistent, rhythmic stroke motion applies pressure to the hydraulic fluid, which then forces the lift cylinder to extend and raise the forks. For a standard load, five to ten full strokes of the handle are required to reach the necessary lifting height. The goal is not to lift the pallet high, but rather to elevate it just enough to fully clear the floor.
The ideal clearance height is one to two inches above the ground, allowing the pallet to roll freely without dragging or catching on minor imperfections in the floor surface. Pumping past this small clearance height is unnecessary and places extra strain on the equipment. Operators should visually confirm that the pallet base is fully suspended before proceeding.
Moving the Load and Safely Lowering the Forks
With the pallet successfully raised, the operator can now move the load to its destination, usually by pulling the jack rather than pushing it for improved control and visibility. Maintain a steady, moderate pace, especially when navigating turns or uneven surfaces, to prevent the load from shifting or falling off the forks. Sudden stops or rapid changes in direction should be avoided while the load is in motion.
Once the destination is reached, the final step involves carefully lowering the pallet back down onto the floor surface. To initiate the descent, the control lever must be moved to the “down” position, which releases the hydraulic pressure in a controlled manner. This action is achieved by pulling the trigger mechanism on the handle fully up toward the operator.
Controlling the descent is important to prevent damage to the pallet, the goods, or the floor. The operator should release the hydraulic pressure slowly, allowing the forks to settle gradually rather than dropping rapidly. A slow, controlled lowering ensures the load remains stable until the forks are completely resting on the floor and the hydraulic pressure is fully relieved.
Troubleshooting Common Lifting Issues
If the pallet jack fails to raise the load despite the operator pumping the handle, a few simple checks can resolve the problem quickly. First, verify that the control lever is fully and correctly positioned in the “up” or “lift” setting, as a partially engaged lever may prevent the pump from building sufficient pressure.
If the lever position is confirmed, the issue may be an overloaded pallet. The operator must confirm the weight does not exceed the jack’s rated capacity; if it does, the load must be reduced before lifting can occur.
Another common reason for lifting failure is a low level of hydraulic fluid within the pump housing. While complex repairs are reserved for maintenance staff, a low fluid level prevents the necessary pressure from being generated, requiring a top-off to restore full lifting capability.