top of page
Search

Pallet Jacks, Everything To Know and More!

  • Dan Cook
  • Oct 22
  • 2 min read
ree

What Is a Pallet Jack?

A pallet jack, also known as a pallet truck, is a wheeled trolley designed to lift and move pallets. It’s the most basic form of a forklift and is commonly used for short-distance transportation within warehouses, retail stores, and manufacturing facilities.


Types of Pallet Jacks

There are two main categories:


1. Manual Pallet Jacks

  • Operated by hand

  • Ideal for light-duty tasks

  • Lower upfront cost

  • Minimal maintenance


2. Electric Pallet Jacks (Powered)

  • Battery-operated with motorized lifting and driving

  • Suitable for high-volume operations

  • Reduces operator fatigue

  • Requires charging and regular maintenance


Key Features to Consider

When selecting a pallet jack, consider the following:

  • Load Capacity: Ranges from 2,000 to 5,500 lbs. Choose based on your typical pallet weight.

  • Fork Length & Width: Match your pallet dimensions for optimal maneuverability.

  • Wheel Type: Nylon, polyurethane, or rubber — each suited for different floor surfaces.

  • Ergonomics: Look for padded handles, easy-lift mechanisms, and intuitive controls.


Strategic Use in Warehouse Operations

Pallet jacks are more than just tools — they’re part of your operational strategy. Here’s how to maximize their value:

  • Zone Optimization: Use manual jacks in picking zones and electric jacks for long hauls.

  • Cross-Docking Efficiency: Electric jacks speed up trailer unloading and reduce turnaround time.

  • Safety Protocols: Train staff on proper usage to prevent injuries and product damage.


Maintenance Tips

To keep your pallet jacks in top shape:

  • Inspect wheels and forks weekly

  • Lubricate moving parts monthly

  • Check hydraulic fluid levels...and for leaks to prevent a traveling safety hazard.

  • Recharge batteries fully (for electric models)


Manual Stacker Pallet Jacks

Manual stacker pallet jacks are a step up from traditional pallet jacks, offering vertical lifting capabilities without the need for a full forklift. These units are ideal for small warehouses, retail backrooms, and operations where space or budget constraints make forklifts impractical.


Key Benefits:

  • Vertical Lift: Raise pallets to shelving or workbench height, typically up to 63 inches or more.

  • Compact Design: Fits into tighter spaces than most forklifts.

  • Cost-Effective: Lower purchase and maintenance costs compared to powered stackers or forklifts.

  • Versatile Use: Great for stacking, loading, and light-duty order picking.


Considerations:

  • Load Capacity: Usually ranges from 1,000 to 2,200 lbs.

  • Effort Required: Manual lifting via hydraulic pump and foot pedal — not ideal for high-frequency use.

  • Floor Conditions: Best used on smooth, level surfaces for stability and ease of movement.



ree

However, these manual stackers are NOT a back for when a forklift goes down. They are often required to straddle the freight to meet load capacities. Loading racks with regular lifts and jacks means not being able to come in with a stacker. Pallet jacks CAN act as backups to when forklifts go down (or all in use) for at least part of the work.




One last point, many warehouses often have at least one pallet jack with narrow forks (sometimes called a grocery jack) to deal with odd pallets that may come in.

bottom of page