How to Use a Pallet Jack Correctly: Operating Guide for Xilin Manual and Electric Models

To use a pallet jack correctly: lower the forks, slide them fully into the pallet, pump or press to lift the pallet 25-50 mm off the floor, walk at a steady pace toward the destination, then release the lowering lever to set the pallet down gently before withdrawing the forks. This guide covers the exact steps for low-lift manual jacks and high-lift or electric stacker models, plus the 25 mm clearance rule and the speed limits most operators miss.

Quick-reference operating steps

• Low-lift manual pallet jack: lower forks, insert into pallet, pump handle to lift, walk to destination, press release lever to lower, withdraw forks.
• High-lift or electric stacker: lift forks with foot pedal or control button, raise to required height, move to position, lower with button or lever.
• Safety reminders: inspect the jack before every shift, never exceed the rated capacity, only travel on flat floors, and always lift and lower slowly.

The pallet jack is a standard tool in warehouses and production facilities. Mastering it takes only a few sessions, but each step must be done in the right sequence to keep goods, equipment, and operators safe.

1. How to use a low-lift manual pallet jack

A low-lift pallet jack, also called a pallet hand truck, is the most widely used type in warehouses. The operating sequence is straightforward, but the correct safety procedure must be followed each time to prevent product damage and equipment wear.

• Pre-use inspection:
  • Check the entire jack for visible damage, leaks, or worn wheels.
  • Confirm the load weight does not exceed the rated capacity marked on the unit.
• Insert forks into the pallet: push the jack squarely into the pallet entry until the fork tips reach the far inside edge of the pallet. Both forks must be fully seated.
• Lift the load: set the handle selector to the lift position, then pump the handle up and down to raise the forks until the pallet clears the floor.
• Move the load:
  • Push from behind the handle, keeping your back straight to avoid strain.
  • Walk at a steady pace equivalent to a normal walking speed.
  • At corners, swing wide to keep the load balanced and avoid catching the fork tips.
  • Avoid ramps where possible; if a ramp is unavoidable, get a second operator to help control the load.
• Lower the load: at the destination, press or squeeze the release lever to lower the forks slowly and evenly until the pallet rests on the floor. Withdraw the forks completely before moving the jack away.

2. How to use a high-lift manual jack or electric stacker

High-lift manual jacks and electric stackers are used to place loads onto racking or stack pallets one on top of another.

• Step 1 - Lower forks and insert into pallet: the same entry procedure as for a low-lift jack - forks fully seated, pallet square on both forks.
• Step 2 - Raise forks to the required height:
  • High-lift manual jack: continue pumping the handle or operate the foot pedal until the forks reach the required height.
  • Electric stacker: use the raise/lower button on the tiller handle to control fork height precisely.
• Step 3 - Move and lower: travel carefully to the target position. Use the release lever or control button to lower the forks smoothly onto the racking beam or floor before withdrawing.

3. Safety rules every operator must follow

Field observations across more than 200 customer warehouses show that most pallet jack incidents come down to the same handful of errors. Keep these points in front of every new operator:

• Keep hands and feet clear of the forks: never position any part of your body under the forks while lifting or lowering.
• Keep the load balanced: distribute goods evenly across the pallet before lifting. An off-center load shifts the center of gravity and can tip during cornering.
• Maintain clear sightlines: do not stack loads so high that your view ahead is blocked.
• One operator per jack: do not use a single fork to lift a load, and do not allow a second person to ride on the jack or the pallet.
• Keep posture neutral: head up, spine straight throughout operation to avoid cumulative musculoskeletal strain.

The 25 mm clearance rule - the mistake 80% of operators make

Standard guides say

The 4-5-6 rule: maximum travel speed by load

Most operating guides tell you to “move slowly” but never quantify it. Travel speed must drop as the load gets heavier, because a fully loaded pallet jack carries far more momentum and needs a longer distance to stop. ICD field technicians use a simple 4-5-6 rule, tied to the rated capacity of the jack, to keep stopping distances inside one metre.

The reason is inertia. A 2-tonne pallet stopped suddenly at 6 km/h generates around 2,300 N of force - more than the roughly 1,500 N that a standard hand brake can hold. Slowing to 4 km/h under heavy load keeps that force within the brake’s capacity and prevents the load from sliding forward off the forks.

Routine maintenance that keeps a pallet jack working

A pallet jack is mechanically simple, but skipping basic upkeep is the fastest way to lose lift performance. Two issues account for most service calls ICD receives: hydraulic oil that drops below level, and wheels that wear unevenly and cause the unit to pull to one side. Run the short checks below at the intervals shown to avoid both.

• Daily: wipe the forks, check that the load wheels and steer wheels turn freely, and confirm the lift, neutral, and lower handle positions all engage cleanly.
• Weekly: inspect the hydraulic unit for oil seepage around the ram. A jack that needs several pumps to lift, or that slowly sinks under load, usually signals low oil or a worn seal.
• Monthly: top up hydraulic oil to the marked level and apply grease to the pivot points and wheel bearings. Replace polyurethane wheels once the tread shows flat spots, since worn wheels raise rolling resistance and strain the operator.

ICD Vietnam distributes Xilin (Ningbo Ruyi) hand pallet trucks and electric stackers from 500 kg to 10 tonnes, all backed by a 2-year manufacturer warranty and same-region spare-part support. For help choosing the right capacity or arranging service, browse the full range of forklift models or call our team on 0983 797 186.