{"id":24389,"date":"2021-02-01T03:40:00","date_gmt":"2021-01-31T14:40:00","guid":{"rendered":"https:\/\/www.drivingtests.co.nz\/resources\/?p=24389"},"modified":"2026-06-24T14:59:39","modified_gmt":"2026-06-24T01:59:39","slug":"types-of-pallet-jack-accidents","status":"publish","type":"post","link":"https:\/\/www.drivingtests.co.nz\/resources\/types-of-pallet-jack-accidents\/","title":{"rendered":"Types of pallet jack accidents, with examples"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">There are five main types of pallet jack operation that causes damage or injuries to freight or operators: <\/p>\n\n\n\n<ol class=\"wp-block-list\">\n<li>Tipping<\/li>\n\n\n\n<li>Speed<\/li>\n\n\n\n<li>Vehicle impact<\/li>\n\n\n\n<li>Reckless driving<\/li>\n\n\n\n<li>Manual handling<\/li>\n<\/ol>\n\n\n\n<p class=\"wp-block-paragraph\">The risks can be reduced by ensuring your team has had <a href=\"https:\/\/www.drivingtests.co.nz\/course\/walkie-stacker-electric-pallet-jack-training\/\">electric pallet jack training<\/a> and <a href=\"https:\/\/www.drivingtests.co.nz\/course\/manual-handling-back-injury-prevention-training\/\">manual handling training<\/a>.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Incidents caused by tipping<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">A pallet jack has a stability triangle, just like a forklift. If the centre of gravity moves outside the stability triangle, either the pallet jack will start to tip, the goods will fall off, or both. The causes include:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Unbalanced load on the forks, e.g. the operator places too much weight on one side of the load without knowing where the centre of gravity is<\/li>\n\n\n\n<li>A balanced load is disturbed by a change in direction or an unexpected force, for example, going over a weatherstrip, gutter or pothole, getting a wheel caught in a grate, etc. See also incidents involved with speed, reckless driving or vehicle impact<\/li>\n\n\n\n<li>A live load &#8211; one which can move independently of its container, such as a liquid load in a chemical container &#8211; sloshes around and moves the centre of gravity outside the stability triangle<\/li>\n\n\n\n<li>The load is too heavy for the rated capacity of the pallet jack or walkie at the height it&#8217;s being used<\/li>\n\n\n\n<li>A load is incorrectly stacked on the forks and all or part of it falls off<\/li>\n\n\n\n<li>The operator jumps off or falls off a ride-on walkie into the path of the falling machine or freight<\/li>\n\n\n\n<li>A load can also be inadvertently tipped and knocked off a stack when operating at height with a high lift pallet truck or <a href=\"https:\/\/www.drivingtests.co.nz\/resources\/forklift-abbreviations-acronyms\/\">HLPT<\/a><\/li>\n\n\n\n<li>A manual pallet jack runs off a dock or tail lift and the operator keeps hold rather than letting go (<a href=\"https:\/\/www.drivingtests.co.nz\/course\/tail-lift-training\/\">tail lift training<\/a> is important to avoid these kinds of incidents).<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Incidents caused by excess speed<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Even a manual pallet jack can be capable of carrying 2500kg. The operator must manage the speed of the pallet jack as it takes energy to stop or turn it.  <\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Turning too quickly creates too much centrifugal force &#8211; the pallet jack could skid and stop abruptly or could tip over<\/li>\n\n\n\n<li>Impossible to stop in time, e.g. operator misjudges stopping distance or a pedestrian walks out in front of the walkie<\/li>\n\n\n\n<li>As manual pallet jacks and some electric pallet jacks don&#8217;t have backwards tilt, stopping abruptly can cause the load to come off the forks.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Incidents caused by impacts<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">An electric pallet jack plus load can weigh over three tonnes, meaning impacts can cause a lot of damage, particularly where that inertia is concentrated in the tips of the forks.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Pedestrians can walk into the forks, which are a trip hazard at ground level, and a bodily hazard if left raised<\/li>\n\n\n\n<li>The pallet jack is driven into a pedestrian or the operator, which can cause crush injuries<\/li>\n\n\n\n<li>Pedestrians trip over a charging cable.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Incidents caused by reckless driving<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Operators sometimes take risks and use machinery in ways in which it shouldn&#8217;t be used:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>The operator rides on a pallet jack which isn&#8217;t intended to be ridden on<\/li>\n\n\n\n<li>A passenger rides on the forks or some other place where people should not be carried<\/li>\n\n\n\n<li>The operator puts a limb in a place it shouldn&#8217;t be, e.g. the mast mechanism<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Manual handling<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The operator often has to manually lift items on and off the pallet jack, and <a href=\"https:\/\/www.drivingtests.co.nz\/resources\/walkie-and-pallet-jack-operator-injuries-and-how-to-prevent-them\/\">manual handling injuries<\/a> are common in warehouses:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Poor bending and lifting technique<\/li>\n\n\n\n<li>Trying to lift objects from a high rack without using steps<\/li>\n\n\n\n<li>Lifting an object that&#8217;s too heavy for one person<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Other potential dangers<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Operators should avoid any type of mechanical or electrical fix of a pallet jack unless they are fully trained in how to repair them. Injuries can occur.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Examples of accidents resulting in injury or death<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">You can find more of these accidents <a href=\"https:\/\/www.osha.gov\/pls\/imis\/AccidentSearch.search?p_logger=1&amp;acc_description=&amp;acc_Abstract=&amp;acc_keyword=pallet+jack&amp;sic=&amp;naics=&amp;Office=All&amp;officetype=All&amp;endmonth=06&amp;endday=20&amp;endyear=2002&amp;startmonth=06&amp;startday=20&amp;startyear=2020&amp;InspNr=\">here<\/a>, some of which can be managed by <a href=\"https:\/\/www.drivingtests.co.nz\/course\/first-aid\/\">first aid training<\/a>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Employee was struck in the head by a falling pallet jack battery and is killed through blunt force trauma. The employee was trying to dislodge the pallet truck battery. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Employee fell backwards off a semitrailer while loading it at Avalon Transportation. The pallet jack rolled backwards off the semitrailer, landing on his torso and crushing him to death.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Employee fractured his leg in two places while riding on a pallet jack. He jumped off and his leg was caught between racking and the pallet jack.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Employee in Aldi, UK, <a href=\"https:\/\/www.ioshmagazine.com\/update-aldi-fined-ps1m-after-substituting-shadowing-pallet-truck-training\">fractured all toes on one foot<\/a>, losing two to surgical amputation and his foot having to be restructured using pins. Aldi was fined \u00a31m.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Tecomet was <a href=\"https:\/\/www.fork-lift-training.co.uk\/accidents\/accidents2019\/11-serious-injuries-from-pallet-truck-accident.html\">fined over \u00a3275,000<\/a> when a machine fell off a pallet jack and amputated an employee&#8217;s finger. The machine did not have channels to be lifted by the pallet jack and the operator had not been trained in its operation.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>There are five main types of pallet jack operation that causes damage or injuries to freight or operators: The risks can be reduced by ensuring your team has had electric pallet jack training and manual handling training. Incidents caused by<span class=\"ellipsis\">&hellip;<\/span><\/p>\n<div class=\"read-more\"><a href=\"https:\/\/www.drivingtests.co.nz\/resources\/types-of-pallet-jack-accidents\/\">Read more &#8250;<\/a><\/div>\n<p><!-- end of .read-more --><\/p>\n","protected":false},"author":1,"featured_media":24390,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"om_disable_all_campaigns":false,"footnotes":""},"categories":[370],"tags":[87],"class_list":["post-24389","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-walkie-pallet-jack","tag-safety"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Types of pallet jack accidents, with examples - DT Vehicle and Workplace Training Resources<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.drivingtests.co.nz\/resources\/types-of-pallet-jack-accidents\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Types of pallet jack accidents, with examples - DT Vehicle and Workplace Training Resources\" \/>\n<meta property=\"og:description\" content=\"There are five main types of pallet jack operation that causes damage or injuries to freight or operators: The risks can be reduced by ensuring your team has had electric pallet jack training and manual handling training. 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