Electric Pallet Truck and Stacker Safety

Why is pallet truck safety underestimated?

Pallet truck safety is one of the least discussed subjects in warehouses. Many businesses that prepare training, certificates and check forms for forklifts see the pallet truck as a "hand cart" and let inexperienced employees use it. Yet an electric pallet truck can pull loads of over a tonne; a stacker raises this load above eye level. The risks of crushing, trapping and falling loads belong to the same family as forklifts; the only difference is that the operator is often right next to the machine rather than on it.

The legal framework is the Regulation on Health and Safety Requirements for the Use of Work Equipment. Under Annex II 2.1, self-propelled work equipment is used only by employees who have received appropriate training in its safe use; under Annex II 2.2, traffic rules and speed limits are set and enforced in the area where the equipment moves.

Pallet truck foot crushing: how does it happen and how is it prevented?

Foot crushing is a typical injury specific to this equipment and usually happens in one of three scenarios:

1. When pulling backwards. The operator walks backwards while pulling a loaded pallet truck and their foot ends up in front of the wheel or fork tip.
2. When lowering the forks. While the load is being lowered, the foot is under the fork or at the edge of the pallet.
3. Trapping. An operator reversing with an electric pallet truck is caught between the machine and a rack, wall or another pallet.

The measures are chosen according to these scenarios:

• Teach the tiller arm positions. On most electric pallet trucks the brake is applied when the tiller arm is upright or fully horizontal. The operator should try this out in practice on the first day.
• Have the emergency reverse button tested. The safety button at the end of the tiller, known as the "belly button", pushes the machine in the opposite direction when pressed while it is moving towards the operator. It should be checked that it works at the start of each shift.
• Walk beside the tiller. When pulling an electric pallet truck, the operator walks beside the tiller and slightly to one side, not in front of it; feet are kept away from the line of the wheels.
• Leave no trapping points. When reversing in front of racks, against walls and at doorways, there should be at least one step of clearance behind you. Low-speed mode is used in narrow passages.
• Provide suitable safety footwear. Toe-capped footwear reduces the severity of crushing; for choosing the class, see our article on safety footwear classes. Footwear is the last line of defence; it is not enough on its own unless walkways and manoeuvring areas are organised.

The pallet itself is also a source of foot crushing. A pallet with broken boards or protruding nails collapses under the forks or the load slides; as the operator instinctively tries to hold the load, they put a foot in front of the fork. Insert the forks fully under the pallet, check that the load is evenly distributed along the forks, and secure loads whose stretch wrap has loosened before moving them. Instead of putting a damaged pallet into the line, take it to the segregation area.

Loss of control on ramps and slopes

Ramps and slopes are where control of a pallet truck is most easily lost. Most manual pallet trucks have no brake; when a loaded manual pallet truck goes onto a slope, the only thing that can stop it is the operator's body. That is why loads are not moved on sloping surfaces with a manual pallet truck; if a slope is unavoidable, a model with a brake or powered equipment is chosen.

For electric pallet trucks, the following rules apply:

• The maximum gradient stated in the manufacturer's operating manual is not exceeded; this value is also taken into account in ramp design.
• Do not turn, park or leave a load on a ramp. The direction in which the ramp is to be used and the side on which the load is to be are written into the operating instruction according to the manual.
• A wet, icy or oily ramp is not used until it has been dried.
• Before entering a truck trailer, check that the vehicle is secured and the dock leveller is seated. Details are in our article on loading dock safety.

Stackers: raised loads and tipping over

A stacker is a pallet truck that reaches rack height. The centre of the risk is the raised load:

• Capacity falls with height. The stacker's label states the capacity, which decreases according to lift height and load centre. For a load to be placed on the top shelf, look at the value for that height.
• Pallet type matters. Stackers with front legs cannot go under every pallet. With an unsuitable pallet, the legs lift the pallet or the load sits unevenly.
• Do not travel with the load raised. The load is raised and lowered only in front of the rack with the machine stationary; the forks are in a low position while moving.
• Nobody stands under the load. Pickers working between racks are kept away from below the bay being stacked; this is a basic rule of lifting operations.
• Uneven floors cause tip-overs. The small wheels of stackers wobble in potholes, on drain covers and in cable channels. Regularly check the evenness of the floor in rack aisles.

Interaction with racks is a separate subject: uprights struck by a stacker can lead to rack collapse. For damage inspection, see our article on industrial racking safety.

Battery and charging area

The risk of battery-powered equipment continues in the charging area. Lead-acid batteries release hydrogen during charging; that is why the charging area is well ventilated, nobody smokes nearby and no spark-producing work is carried out. Acid can splash when topping up water and checking electrolyte: a face shield, chemical-resistant gloves and an eyewash nearby are needed. For lithium-ion batteries, the manufacturer's charger is used, and a battery that has been struck or has swollen is not connected for charging.

There is no separate article in the regulation for the charging area; base the arrangements on the risk assessment and the manufacturer's instructions. A layout where cables and plugs will not be crushed, separating the charging area from pedestrian routes and having a suitable fire extinguisher nearby are the basic measures.

Daily check and pallet truck periodic inspection

The start-of-shift check is the operator's job and takes no more than two minutes:

Equipment with a finding is not used and is tagged. The check logic is the same as for forklifts; you can find a sample form in our article on the forklift daily check.

The periodic inspection obligation for pallet trucks comes from Annex III. In Table 2, the pallet truck is listed in the "industrial trucks" row; unless the relevant standard sets a shorter period, the maximum interval is 1 year, and the TS EN ISO 3691 series is listed among the criteria. The table does not distinguish between manual and electric; list manual pallet trucks in your inventory too. Stackers are not named separately in the table; in practice, the safest course is to include them in the inspection plan under the same row as self-propelled industrial trucks. The inspection is carried out by an authorised person registered on EKİPNET (the Ministry's register of authorised inspectors), and the contract is set up on İSG-KATİP (the Ministry's online OHS registration system) at least one day before the inspection. For intervals, see our article on periodic inspection intervals.

Training and warehouse layout

The training required by Annex II 2.1 should be given on the machine itself: trying the tiller brake, pressing the emergency reverse button, using the direction specified in the manual on the ramp and manoeuvring at low speed in a narrow aisle. This practice can be written into the equipment-specific section of induction training. For the question of which jobs require a certificate, our article on the forklift operator certificate makes a similar assessment.

If pallet trucks and pedestrians share the same aisle, speed limits and crossing points should be addressed together with the forklift and pedestrian traffic plan. In logistics and warehousing businesses in Bursa and the surrounding provinces, equipment-based risk assessment and operator instructions are part of our OHS specialist service; you can plan annual inspections through our periodic inspection service, carried out via our solution partners, and track dates with the OHS calendar.

Frequently Asked Questions

Is a manual pallet truck subject to periodic inspection?

The pallet truck row in Annex III, Table 2 does not distinguish between manual and electric. Unless the relevant standard sets a shorter period, have it inspected at least once a year by an authorised person registered on EKİPNET.

Can anyone use an electric pallet truck?

No. Under Annex II 2.1 of the Work Equipment Regulation, self-propelled work equipment is used only by employees who have received appropriate training in its safe use. The training should be given hands-on, on the machine.

What prevents pallet truck foot crushing most?

Walking beside the tiller, leaving clearance behind when reversing, checking the tiller brake and emergency reverse button every shift, and wearing toe-capped footwear. Footwear alone is not enough.

Can you travel with the load raised on a stacker?

No. The load is raised and lowered while the machine is stationary in front of the rack. The forks are kept low while moving; a raised load increases the risk of tipping over and falling.