How Do Pallet Jacks Work? (Plus How to Use One)

How Do Pallet Jacks Work?

A pallet jack works by sliding a pair of forks into the openings of a pallet, then using a hydraulic pump — worked by hand on a manual unit, or by an electric motor on a powered one — to raise the forks just high enough to lift the pallet clear of the floor. Once the load is up, the operator steers the jack to its destination and lowers the forks back down by releasing that same hydraulic pressure. It's a simple mechanism, but it's also the single most-used piece of equipment on most warehouse floors, which makes understanding it — and using it correctly — worth more attention than it usually gets.

Below, we break down the hydraulics behind a pallet jack, walk through how to use one step by step, and compare manual, walkie electric, and rider electric models using real specs from Iron Line's own lineup.

How a Pallet Jack Works: The Hydraulics Explained

Forks. The two flat steel arms that slide into the pallet's openings. On most pallet jacks, the forks sit just under 3" off the ground when fully lowered, which is why pallets need enough clearance underneath to accept them.

Hydraulic cylinder and pump. A sealed cylinder filled with hydraulic fluid sits between the forks. On a manual jack, pumping the handle up and down drives a small piston that forces fluid into the cylinder, and that pressure is what raises the forks. On an electric jack — like Iron Line's lithium-powered models — a small electric pump does that same job at the push of a button, no pumping required.

Control handle/lever. A single handle-mounted lever typically controls three positions: raise, neutral (for towing), and lower. Lowering works by slowly releasing the hydraulic pressure rather than reversing the pump, which is why it's a controlled descent rather than a drop.

Steer and load wheels. Large steering wheels at the handle end carry the jack's own weight and set direction; smaller load wheels near the fork tips carry the pallet's weight once it's lifted. On walkie and rider electric models, a separate drive motor — similar in principle to the drive motor we cover in how electric forklifts work — also propels the unit instead of relying on the operator to push or pull it.

How to Use a Pallet Jack, Step by Step

1. Inspect before you load. Check that the forks aren't bent or cracked, the wheels roll freely, and — on an electric unit — the battery has a usable charge.

2. Square up to the pallet. Align the forks with the pallet's openings and push them in fully, so the load sits as far back on the forks as possible rather than hanging off the tips.

3. Raise the load. Pump the handle (manual) or hold the raise control (electric) until the forks lift the pallet roughly 1-2 inches off the floor — just enough to clear it, not maximum height.

4. Move with the load low and controlled. On a manual jack, pull rather than push whenever possible so you can see your path and react quickly; on a walkie electric, walk alongside the control handle at a controlled walking pace, especially around corners and blind spots.

5. Lower slowly. Move the control lever to the lower position and ease the forks down — the valve releases hydraulic pressure gradually, so the load settles rather than drops.

6. Withdraw and clear. Back the forks out of the pallet once they're fully lowered and the load is resting on the floor, then park the jack somewhere it won't block an aisle or exit.

Manual vs. Walkie Electric vs. Rider Electric

"Pallet jack" actually covers three distinct categories of equipment, and the right one depends on load, distance, and volume:

	Manual (GNT G55)	Walkie Electric (EKKO EPC18LI)	Rider Electric (GNT G66P-LI)
Lifting	Hand pump	Electric pump (lithium-ion)	Electric pump (lithium-ion)
Travel	Operator pushes/pulls	Electric drive, operator walks alongside	Electric drive, operator rides a fold-down platform
Load capacity	5,500 lb	4,000 lb	6,600 lb
Best for	Short, occasional moves	Frequent moves, less fatigue	Heavier loads, longer runs
Price (Iron Line)	$414	$2,548	$13,948

If your team is moving the same loads a handful of times a shift over short distances, a manual jack is usually all you need. Once you're covering real distance repeatedly, or lifting at or near a manual jack's capacity, the reduced operator fatigue of an electric model — walkie or rider — tends to pay for itself quickly. For a deeper look at how that compares to a full forklift rather than another pallet jack, see pallet jack vs. forklift.

Pallet Jack Safety and Training

Manual pallet jacks aren't powered industrial trucks. Because they have no motor, manual pallet jacks fall outside OSHA's 29 CFR 1910.178 powered industrial truck standard — but they still fall under OSHA's General Duty Clause, meaning employers still need to provide basic training on safe lifting, pushing, and load limits.

Electric pallet jacks are powered industrial trucks. Walkie and rider electric models are classified as Class III electric motor hand or hand/rider trucks under the OSHA/ANSI powered industrial truck system, which means operators need the same kind of formal training and evaluation required for an electric forklift before running one unsupervised.

Never ride a jack that isn't built for it. A manual or walkie pallet jack has no platform and isn't designed to carry an operator — riding on the forks or chassis is a common cause of tip-overs. Only a rider model like the G66P-LI, with its fold-down platform, is built for the operator to stand on while traveling.

Stay within the rated capacity. Every pallet jack has a load capacity printed on its data plate — 5,500 lb on the G55, 4,000 lb on the EPC18LI, 6,600 lb on the G66P-LI. Overloading a hydraulic jack doesn't just risk a dropped load; it stresses the hydraulic seals and can cause a sudden, uncontrolled drop.

Real Pallet Jacks, Real Specs

GNT G55

5,500 lb / Manual

$414

EKKO EPC18LI

4,000 lb / Walkie Electric

$2,548

GNT G66P-LI

6,600 lb / Rider Electric

$13,948

View all Pallet Jacks → | Pallet Stackers → | Electric Forklifts → | All Material Handling Equipment →

Frequently Asked Questions

Q: What makes the forks go up on a pallet jack?

A: A hydraulic cylinder between the forks. On a manual jack, pumping the handle drives fluid into the cylinder under pressure, which raises the forks; on an electric jack, a small electric pump does the same job at the push of a button.

Q: How do you lower a pallet jack's forks?

A: By moving the control lever to the lower position, which slowly releases the hydraulic pressure so the forks settle down in a controlled descent rather than dropping suddenly.

Q: Is a manual pallet jack considered a powered industrial truck?

A: No. Because it has no motor, a manual pallet jack falls outside OSHA's 29 CFR 1910.178 powered industrial truck standard, though employers still owe operators basic safe-use training under OSHA's General Duty Clause. Electric pallet jacks, by contrast, are classified as Class III powered industrial trucks and do require formal operator training.

Q: How much weight can a pallet jack carry?

A: It depends on the model — Iron Line's manual GNT G55 is rated for 5,500 lb, the walkie-electric EKKO EPC18LI for 4,000 lb, and the rider-electric GNT G66P-LI for 6,600 lb. Always check the specific unit's data plate rather than assuming capacity.

Q: Can you ride on a pallet jack?

A: Only if it's built for it. A manual or walkie electric jack has no platform and isn't designed to carry an operator — riding on one is a common cause of tip-overs. A rider model like the G66P-LI has a fold-down platform specifically built for the operator to stand on.

Q: What's the difference between a walkie and a rider electric pallet jack?
A: A walkie electric jack (like the EKKO EPC18LI) has electric lift and drive, but the operator walks alongside it holding the control handle. A rider electric jack (like the GNT G66P-LI) adds a fold-down platform so the operator can stand on the unit while it travels — faster and less fatiguing over longer distances.