The material handling industry uses a wide array of equipment, leading to common confusion over how different machines are categorized. Both a pallet jack and a forklift share the general purpose of moving unitized loads, typically on pallets, to increase efficiency in a commercial environment. However, their physical design, power source, and intended functionality create distinct operational profiles. This article clarifies the technical classification, mechanical differences, training requirements, and specific applications for each of these tools.
Fundamental Classification: Is a Pallet Jack a Forklift?
A definitive answer depends on the specific type of equipment, as regulatory bodies group powered industrial equipment into a broad category. The Occupational Safety and Health Administration (OSHA) defines a Powered Industrial Truck (PIT) as any mobile power-propelled equipment used to lift, move, stack, or carry materials. In this context, a powered pallet jack is considered a type of forklift, specifically falling under the Class III designation for Electric Motor Hand Trucks.
A standard manual pallet jack, which relies entirely on human muscle power for propulsion, is not classified as a PIT. Traditional forklifts are engineered for high-level vertical stacking, utilizing a mast to place loads high into racking systems. Pallet jacks are primarily designed for horizontal movement, lifting the load only minimally off the ground for transport. The regulatory inclusion of powered pallet jacks highlights the safety hazards associated with their powered movement and load capacity.
Operational and Design Differences
The most noticeable distinctions between a pallet jack and a standard forklift lie in their lifting mechanism and overall physical architecture. Forklifts utilize a robust mast assembly, driven by powerful hydraulics, that allows for significant vertical travel, often capable of raising a load 30 feet or more. A pallet jack employs a simple hydraulic pump mechanism to lift the forks only a few inches from the ground, sufficient only for ground-level movement.
Stability and capacity also differ significantly. Traditional forklifts rely on a heavy counterweight integrated into the rear of the vehicle to offset the load weight, enabling them to lift several tons safely. Pallet jacks lack this counterweight, are far lighter, and typically have a maximum load capacity around 3,000 to 6,000 pounds. Pallet jacks are superior in tight spaces, offering a compact footprint and excellent maneuverability. Forklifts, being larger, necessitate wider aisles for safe operation.
Forklifts are commonly powered by internal combustion (IC) engines—using propane, gasoline, or diesel—or by heavy-duty electric batteries. Pallet jacks are either manual or use a smaller, rechargeable battery for propulsion and minimal lift. The electric power source of most powered pallet jacks makes them suitable for indoor environments where exhaust emissions are a concern.
Training and Safety Compliance
Compliance with safety standards represents one of the most practical differences between the two types of material handling equipment. Operators of traditional forklifts and all other Powered Industrial Trucks (PITs) must complete mandatory formal training and certification. This certification process involves formal instruction, practical training, and a final performance evaluation, with refresher training required at least every three years.
The requirement for formal certification extends to all powered pallet jacks because they are designated as Class III PITs, emphasizing the potential hazards they pose. Anyone operating this powered equipment must be at least 18 years of age and hold the proper certification. Conversely, a manual pallet jack does not require formal certification, though employers should still provide basic on-the-job instruction for safe use. All powered industrial trucks require mandatory daily pre-shift checks by the operator.
Types of Pallet Jacks and Powered Industrial Trucks
Manual and Powered Pallet Jacks
The most basic material handling tool is the manual pallet jack, often called a pump truck, which uses a hand-operated lever to pump the hydraulic fluid for low-level lifting. Powered pallet jacks, or walkie jacks, are battery-operated, eliminating the physical effort of pulling heavy loads over long distances. Rider jacks are a variation that allows the operator to stand on a platform, enhancing speed and reducing fatigue over very long transport runs in a large facility. These machines are characterized by their primary function of short-distance horizontal transport and limited vertical lift capability.
Counterbalance Forklifts
Counterbalance forklifts are the standard, most recognizable lift truck. They are designed with the forks positioned in the front and a heavy weight in the rear to maintain stability while lifting heavy loads. These versatile machines, often classified as Class I (electric) or Class IV/V (Internal Combustion), are the workhorses of many warehouses and distribution centers. They are suitable for both indoor and outdoor use, depending on their tire type, and are the primary tool used for stacking pallets in low to medium-height racking.
Reach Trucks and Order Pickers
Specialized equipment like reach trucks and order pickers are engineered for operations in narrow-aisle warehouses with high-density storage. Reach trucks feature a mechanism that allows the mast and forks to extend forward, enabling them to place and retrieve pallets in deep racking. Order pickers are distinct in that the operator’s platform elevates with the forks, allowing the worker to access individual items or cases from high shelves for fulfillment. Both of these Class II electric trucks prioritize vertical lift and maneuverability within confined spaces.
Telehandlers
Telescopic handlers, or telehandlers, represent the extreme end of the lift truck category, designed for rugged applications, frequently at construction sites or in agricultural settings. These machines are characterized by a telescopic boom arm that extends outward and upward, offering greater forward reach and lift height than a standard forklift. Classified as Class VII rough terrain trucks, they are built with large pneumatic tires and a robust chassis to safely navigate uneven and outdoor surfaces while handling heavy loads.
Applications: When to Use Which Tool
The decision of which tool to use is based on the required lift height, travel distance, load volume, and spatial constraints of the operation. Pallet jacks are the ideal solution for low-volume, short-distance material movement and situations where space is extremely limited. They are commonly used for unloading freight from truck trailers, staging materials in retail backrooms, or moving products over short, level distances.
Forklifts become necessary when vertical stacking or high-volume transport is involved, such as in a main warehouse or distribution center. They are required for placing inventory into high racking, handling extremely heavy loads, and moving materials across long distances or uneven terrain. Many facilities operate a combination of both, utilizing pallet jacks for quick local moves and forklifts for high-level stacking and bulk shipping tasks.