While electric pallet jacks are essential for improving efficiency in warehouses and logistics hubs, they also pose safety risks when not used correctly. From minor sprains to serious crush incidents, injuries caused by improper handling of pallet jacks can lead to lost time, costly claims, and long-term harm. This article highlights the most frequent accidents involving electric pallet movers and offers expert guidance on how to keep your team safe.

Top Causes of Electric Pallet Jack Injuries

Whether you’re using a compact pallet jack electric or a heavy-duty powered pallet truck, certain types of injuries are more likely to occur. Here are the most common:

1. Overexertion & Strains

Improper lifting or pushing of loads that exceed capacity can lead to back, shoulder, and wrist strains. Operators should always let the electric power jack do the work.

2. Foot & Hand Crush Injuries

Hands and feet can become trapped between the pallet truck and fixed objects, especially in tight warehouse aisles. This can result in broken bones or serious lacerations.

3. Load Collapse Accidents

If goods are not properly stacked on the forks, or the maximum rated weight is exceeded, items can fall—posing a risk to operators and nearby personnel.

4. Slips, Trips, and Falls

Wet floors, poorly maintained pallet jack wheels, or cluttered paths can cause the operator to slip or trip while maneuvering the truck pallet.

Best Practices to Prevent Pallet Truck Accidents

Mitigating risks starts with awareness and consistency. Whether you're using an entry-level pallete jack or a feature-rich electric pallet lifter, follow these proven safety measures:

Operator Training
All staff using electric pallet jacks should undergo hands-on training that covers safe driving, loading limits, and emergency handling. Annual refreshers are encouraged.
Wear the Right PPE
Outfit warehouse employees with reflective vests, gloves, and steel-toed boots. These provide extra protection when handling or walking near electric pallet trucks.
Keep Equipment Maintained
Schedule regular inspections of all pallet truck parts, especially the brakes, battery, and wheels. Clean the equipment often to prevent operational malfunctions.
Communicate in Busy Zones
Use warehouse signals or audible horns to notify co-workers when a pallet jack electric is in motion. This reduces the chance of collisions.
Organize Your Layout
Ensure wide, clear aisles and install dock lighting where needed. A neat environment prevents trip hazards and improves the maneuverability of electric pallet jack for sale units.

Is Certification Needed to Operate a Pallet Jack?

Absolutely. In Canada and the U.S., formal training is required to operate an electrical pallet jack. Certification typically includes safe operation techniques, load handling, and environmental hazard recognition. Training is essential for both new hires and experienced operators transitioning to lithium-ion or upgraded power pallet truck models.

Modern Safety Features Worth Investing In

If you’re currently evaluating new equipment, look for features designed to enhance operator safety and control:

Emergency Stop Button
Allows instant shutdown in dangerous situations.
Turtle Walk Mode
Limits movement speed for tight or congested spaces.
Stability Wheels & Fork Guards
These help prevent side tilts and protect against pallet slide-outs.

Explore models like the Raelon 3300lbs Lithium Electric Pallet Jack or the 4400lbs Heavy-Duty Pallet Truck, both offering ergonomic design and premium safety features.

Get a Safer, Smarter Pallet Jack

If you're ready to upgrade your fleet with modern, safety-first designs, Raelon’s lineup of electric pallet jacks for sale is built to protect your team while boosting efficiency. Our jacks combine power, control, and stability—ideal for warehouses, retail backrooms, and logistics centers.

Browse all pallet trucks including models with lithium batteries, fast-charging systems, and enhanced pallet truck wheels for indoor and outdoor use.