Powered pallet jacks

Scope

Powered pallet jacks are a type of powered industrial truck used to move pallets. Pallet jacks are battery powered and are one of two designs: either walk-behind or ride-on.

There are different types of pallet jacks as well; such low lift or high lift. The controls for different designs may vary.

Regulatory citations

• 29 CFR 1910.178 — Powered industrial trucks

Key definitions

• Motorized hand truck: OSHA’s term for a powered pallet jack (see “pallet jack” definition).
• Pallet jack: A type of powered industrial truck used to move materials from one place to another. They do not typically raise the material very high.
• Powered industrial truck: Fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines, excluding compressed air or nonflammable compressed gas-operated industrial trucks, farm vehicles, and to vehicles intended primarily for earth moving or over-the-road hauling.
• Walkie: A common industry term for powered pallet jack (see “pallet jack” definition) that can only be operated by a walking operator.
• Walkie-rider: A type of pallet jack that can be operated by a walking operator on the ground, or by a riding operator who stands on a built-in platform.

Summary of requirements

OSHA requires employers to:

• Evaluate the workplace for motorized pallet jacks. OSHA’s PIT standard covers all types of powered pallet jacks and similar equipment. The key is “powered”; manually operated lifts are not covered.
• Train all operators. All PIT operators must undergo a rigorous training that includes a combination of formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator’s performance in the workplace. See 1910.178(l) for the full training requirements, which, among other things, include a specific list of topics, some of which may be truck- and workplace specific.
• Re-evaluate operators at least once every three years. Document this evaluation.
• Provide refresher training when operators are observed driving unsafely, involved in an incident or near miss, or are assigned a different type of equipment.
• Allow only qualified persons to train operators. Persons wishing to train forklift operators must have the “knowledge, training, and experience” to train operators and evaluate their competence. The OSHA standard does not further define this requirement or set any specific certifications.
• Ensure equipment is inspected at least daily. Where pallet jacks are used on a round-the-clock basis, they must be examined after each shift. OSHA does not require these inspections be documented; however, many companies keep a set number of inspections (e.g., “the most recent 2-month period”) as a way to prove to OSHA the inspections are being conducted.
• Remove unsafe equipment from service immediately.
• Only allow employees to operate correctly-classified equipment in hazardous atmospheres — to prevent explosion hazards. See 29 CFR 1910.178 Table N-1.
• Set and enforce operating rules. Refer to the manufacturer’s safety instructions for procedures such as operating on ramps, function of controls, maintenance, etc.
• Provide designated areas for battery charging/changing operations. This includes provisions for adequate ventilation, protection of the charging equipment, spill cleanup, and an eyewash/shower if workers could be exposed to the batteries’ dangerous substances (e.g., they open the caps).
• Obtain the manufacturer’s prior written approval before making modifications that would impact safety and capacity, such as adding a man basket.