Purpose

To outline the procedures for preventing, identifying, and responding to a pinch or crush injury caused by the operation of a pallet jack.

NB: No one is to use a pallet jack PRIOR TO RECEIVING TRAINING AND A DEMO SESSION.

Scope

This SOP applies to all employees operating pallet jacks in the workplace.

Responsibilities

• Operators: Ensure safe use of pallet jacks and immediate reporting of any incidents. Incidents are to be reported to First Aiders, Health & Safety Reps and Human Resources.
• Supervisors/Managers: Enforce compliance, provide training, and respond appropriately to incidents.
• Safety Officer: Conduct investigations and update risk assessments.

Pre-start checks:

1. Inspect the pallet jack for any physical damage, especially on the forks and the hydraulic pump.
2. Check the wheels to ensure they are intact, secure and roll freely without any obstructions.
3. Examine the handle for secure attachment and test the control lever for lifting, lowering and neutral operation.
4. Wear appropriate PPE: steel-toe shoes, gloves, and high-visibility clothing
5. Look over the hydraulic oil reservoir to ensure it’s not leaking and has sufficient oil.
6. Ensure the path is clear of obstructions and personnel.
7. Confirm there is no debris in the path of travel and that the work area is clear.

 Safe Operating Procedure:

1. Never place hands or feet under the forks.
2. Keep hands and feet clear of moving parts.
3. Do not overload the pallet jack beyond its rated capacity.
4. Use proper body positioning — push rather than pull when possible.
5. Move slowly in tight spaces to avoid crushing against walls, racks, or corners.
6. Communicate clearly with nearby workers.
7. Place the pallet jack’s forks fully into the pallet, ensuring they’re centred, and the pallet is balanced.
8. Pump the handle to raise the pallet off the ground, checking that the lift mechanism operates smoothly and the pallet is stable.
9. Push the pallet jack handle forward to the neutral position before moving.
10. Pull or push the pallet jack at a controlled pace, keeping the path ahead in clear view and avoiding sudden stops or sharp turns.
11. Use the control lever to carefully lower the pallet once destination is reached and before removing the forks from the pallet.

Emergency Reponses:

• Stop the pallet jack immediately.
• Do not attempt to move the injured person unless in immediate danger.
• Call for first aid Team.
• Notify a supervisor or manager right away.
• Request for emergency services (hospital) to be called in. 

While Waiting for Help:

• Keep the injured area stable and elevated if possible.
• Apply ice (if appropriate) to reduce swelling.
• Reassure the injured person and monitor for shock

Incident Reporting & Investigation:

• Complete an Incident Report Form within 24 hours by reporting it to your Health and Safety Reps, Human Resources, and your Manager.
• Supervisor to conduct a preliminary investigation.
• Safety officer to perform a root cause analysis.
• Document all findings and update any relevant risk assessments or SOPs.

Post Operation procedure:

1. Upon completion of work, ensure the forks of the pallet jack are fully lowered to the ground.
2. Conduct a final inspection of the pallet jack, looking for any damage or excessive wear incurred during operations.
3. Clean the forks and wheels of the pallet jack to remove any debris that could impede function.
4. Store the pallet jack in its designated area so it does not hinder traffic or pose a safety hazard.
5. Report any operational issues or defects noticed during the post-use inspection to the supervisor or maintenance team for further action.

Operating Manual

A detailed Operating Manual for the Pallet Jack is available and must be referenced by all operators. Familiarity with the manual’s instructions is a mandatory part of complying with this SOP.

Training & Review

• All staff must undergo pallet jack safety training annually.
• Review this SOP every 12 months or following any incident