Manual pallet trucks are simple yet efficient material handling tools operated by human force, designed for transporting palletized loads at ground level. They are commonly used in warehouses, supermarkets, factories, and small-scale logistics operations. Due to their structure, they are easy to maneuver and require no motor or electrical components.

Historical Development

The development of pallet truck technology dates back to the early 20th century, paralleling the rise in industrial production. Palletized load handling systems emerged in the first quarter of the 1900s to reduce loading and unloading times. The invention of hydraulic pallet trucks enabled operators to lift loads with less effort. Over time, these systems were enhanced with electric motors to create battery-powered models capable of transporting heavier loads over longer distances.

Areas of Use

Pallet trucks are used in various industries, responding to different operational needs:

• Warehouses and logistics centers: For loading, unloading, and stock movements.
• Production facilities: For transporting raw materials to workstations.
• Markets and retail chains: For shelf stocking and product shipment.
• Cold storage units: For transporting food products under controlled conditions.
• Educational and public institutions: For moving materials in libraries, laboratories, or archives.

These tools ensure safer and more ergonomic handling of palletized loads. Their maneuverability in narrow spaces makes them advantageous compared to larger equipment, such as forklifts.

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Technical Specifications and Safety Principles

Pallet trucks are classified into two main categories: manual and battery-powered. According to the information provided by Toyota Forklifts, the technical specifications of standard manual pallet trucks are generally as follows:

• Lifting capacity: 2–2.5 tons
• Lifting height: Approximately 200 mm
• Fork length: 800–1150 mm
• Material: High-strength steel
• Wheels: Polyurethane, nylon, or rubber-based
• Control handle: Manual steering and lifting (some models have foot pedal options)

To ensure safe use, operators must observe the following rules:

• The load must be placed on the forks in a balanced manner.
• The pallet truck must not be overloaded.
• It should not be used on sloped surfaces.
• Care should be taken in areas with heavy pedestrian traffic.
• It should not be used as a jack or for transporting people.
• It should not be used on rough surfaces; it must be operated on flat and non-slippery floors.
• It must be parked properly in the designated area after use.

According to Bursa Uludağ University’s Pallet Truck Operating Instructions document, this equipment should only be operated by trained personnel within the scope of occupational health and safety. The use of CE-certified shoes and gloves is also mandatory.

Evaluation from the Perspective of Occupational Health and Safety

Possible hazards during pallet truck use include loss of control, falling loads, slippery surface accidents, and untrained usage. To minimize these risks:

• Regular maintenance and periodic checks must be conducted.
• Use by untrained personnel should be prohibited.
• Faulty equipment should be immediately sent for servicing.
• The conformity of the pallet truck to CE standards must be verified.