A pallet jack is one of the most common pieces of material handling equipment in Australian warehouses, workshops, and distribution centres — yet choosing the wrong one can cost you in operator injuries, damaged floors, or equipment that can't handle the loads you're moving. This guide covers every type of pallet jack, how to read capacity ratings, what the fork dimensions mean for CHEP and Loscam pallet compatibility, and — because it's the most-searched question in this category — whether you actually need a licence to operate one in Australia.
What Is a Pallet Jack?
A pallet jack — also called a pallet truck, hand pallet truck, or pump truck — is a wheeled trolley designed to lift and move palletised loads across flat surfaces. It works on a simple hydraulic principle: pumping the handle raises the forks off the floor, lifting the pallet clear of the ground so the load can be wheeled from one position to another. When the handle is repositioned to the lower setting, a controlled release valve lets the forks descend slowly.
The name "pallet jack" is North American in origin but has become the dominant search term in Australia. "Pallet truck" is the traditional UK and Australian trade term and appears on most Australian product labels. They describe the same piece of equipment — this guide uses both interchangeably.
A standard manual pallet jack raises the forks 85–200 mm off the ground — enough to clear the timber runners on a standard CHEP or Loscam pallet, but not enough to lift a load to shelf height. For racking-height lifts, you need a walkie stacker or forklift, which are separate equipment categories covered later in this guide.
How the hydraulic system works
Every manual pallet jack uses the same basic mechanism. A small hydraulic cylinder sits inside the handle housing. Each pump stroke draws hydraulic fluid from a reservoir and forces it into the cylinder, which pushes the linkage arms upward and raises the forks. The pump ratio means a few full strokes raises the forks from minimum to maximum height — typically 3–5 pumps on a standard unit. A release valve in the handle allows controlled lowering; releasing the load quickly is not possible by design, which is a safety feature.
Electric pallet jacks replace the pump handle with an electric motor and battery. The operator uses a tiller control — a thumb button or lever — to raise and lower the forks and engage the drive motor. The hydraulic cylinder is still present; the motor drives it electrically rather than manually.
Types of Pallet Jacks
There are six primary pallet jack types in the Australian market. Choosing correctly depends on your load weight, travel distance, floor conditions, and how frequently the unit is used each day.
1. Manual (Hand) Pallet Jack
The standard manual pallet jack is the most widely used unit in Australian warehouses, retail stockrooms, and workshops. It requires no power source and has minimal maintenance requirements — the hydraulic seal and wheels are the only components that wear. Standard capacity is 2,500 kg, which covers the vast majority of palletised loads. Heavy-duty models rated to 3,000 kg and 5,000 kg are available for bulk materials and dense goods.
Manual jacks suit applications where loads are moved infrequently or over short distances — typically up to 30–40 metres per trip. Beyond that distance, operator fatigue becomes significant, particularly with loads over 1,500 kg. For longer runs, an electric pedestrian jack is the more appropriate choice.
Typical applications: retail stockrooms, loading docks, small warehouses, food manufacturing, short-run pallet positioning.
Standard AU specs: 2,500 kg SWL, 685 mm fork width, 1,150 mm fork length, 85–200 mm lift height.
2. Electric Pedestrian Pallet Jack
An electric pedestrian pallet jack — often called a walkie pallet truck or EPJ — uses a battery-powered motor to drive the unit and raise the forks. The operator walks alongside and steers using a tiller arm. Electric pedestrian jacks typically carry the same 2,500–3,000 kg capacity as manual units but eliminate the physical effort of pushing loaded pallets over longer distances.
The practical benefit over a manual jack is most pronounced in high-frequency operations — warehouses where a picker is moving pallets every few minutes throughout a shift. Reduced operator fatigue translates directly to fewer musculoskeletal injuries, which SafeWork Australia identifies as the leading cause of workplace injury in transport and warehousing.
Battery types vary between models. Lead-acid batteries are the lower upfront cost option but require 8+ hours to charge and need regular fluid top-ups. Lithium-ion batteries cost more initially but charge in 2–3 hours, tolerate opportunity charging (partial top-ups during breaks), and have a longer service life.
Typical applications: medium to large warehouses, distribution centres, supermarket DCs, frequent pallet movement over 30+ metre distances.
Standard AU specs: 1,500–3,000 kg SWL, 685 mm fork width, 8–48V battery depending on model.
3. Ride-On Electric Pallet Truck
A ride-on electric pallet truck — sometimes called a walkie-rider or rider pallet truck — has a small platform at the rear where the operator stands while driving. This configuration suits very long travel distances within large warehouse floors where walking pace becomes a productivity constraint. Ride-on units are faster than pedestrian models and dramatically reduce operator fatigue on runs of 50+ metres.
Ride-on pallet trucks fall into a grey area regarding licensing. Units that operate at pedestrian speed (under 10 km/h) generally do not require a High Risk Work Licence in most Australian states. Units capable of higher speeds may be classified differently depending on your state WHS regulator. Check with SafeWork NSW, WorkSafe Victoria, or your relevant authority if your specific model is in question.
Typical applications: large distribution centres, cold store facilities, long-aisle warehouses, order picking operations.
4. High-Lift Pallet Jack
A high-lift pallet jack — also called a pallet positioner or scissor lift pallet truck — raises the forks significantly higher than a standard unit, typically to 800 mm or 900 mm lift height. This is not enough to load into racking (that requires a stacker or forklift), but it is useful for ergonomic work: bringing the pallet up to a comfortable working height to avoid repeated bending when picking or packing at floor level.
High-lift units are popular in order fulfilment, assembly operations, and anywhere operators are working directly on the pallet for extended periods. Manual high-lift models use a scissors mechanism driven by the pump handle; electric versions use a motor-driven mast or scissors.
Typical applications: order picking, packing stations, assembly lines, ergonomic lifting to reduce manual handling risk.
Standard AU specs: 1,000–2,000 kg SWL, lift height 500–900 mm depending on model.
5. Scissor Lift Pallet Jack
Similar to a high-lift jack in concept, a scissor lift pallet jack uses a scissors linkage mechanism to raise the entire platform (not just the forks) to an ergonomic working height. The key difference is that the load platform can be positioned at table height — 800–900 mm — making it effectively a mobile work table for the pallet.
These units are common in manufacturing and assembly environments where heavy components are pulled from pallets repeatedly throughout a shift. The alternative — bending to floor height hundreds of times per day — is a documented cause of lower back injury under SafeWork Australia's hazardous manual tasks guidelines.
Typical applications: manufacturing assembly, component picking from bulk pallets, ergonomic workstation positioning.
6. Narrow-Width Pallet Jack
Standard pallet jacks have a fork width of 685 mm — the industry standard for CHEP and Loscam pallets in Australia. Narrow-width units are available with fork widths of 450 mm and 550 mm to suit narrower pallets, skids, and display units used in retail and hospitality.
Narrow jacks are also used in tight aisle configurations where a standard 685 mm fork width won't fit, and in some cold store environments where Euro pallets (800 × 1,200 mm) are used in preference to the Australian hardwood pallet format. Check your pallet dimensions before ordering — a 450 mm jack cannot safely carry a standard CHEP pallet.
Typical applications: retail display movement, tight aisles, Euro pallet handling, small skid movement in workshops.
Walkie Stacker vs Pallet Jack: What's the Difference?
A pallet jack lifts a load 85–200 mm off the ground — enough to transport it, but not enough to load it into racking. A walkie stacker adds a mast to the equation, lifting the load to racking height — typically 2,000–5,500 mm depending on the model. If you need to stack pallets, you need a stacker. If you only need to move them, a pallet jack is sufficient.
Walkie stackers are pedestrian-operated (the operator walks alongside) and — like electric pedestrian pallet jacks — do not require a High Risk Work Licence in Australia. The distinction matters: a sit-down counterbalance forklift does require a licence. Many businesses use walkie stackers specifically to avoid the licensing and supervision requirements attached to forklifts.
Walkie stacker types in the Australian market
Four main configurations are common in Australia:
Straddle stacker — the most common type in Australia. Uses two outrigger legs that straddle the pallet from outside. This distributes the load weight through the legs rather than relying on counterbalance, which makes the unit stable and relatively compact. The trade-off is that the straddle legs require the pallet to be sitting on the floor, not on the bottom shelf of a rack — you can't pick a pallet that's sitting directly on a rack beam. Suited to pallets on the floor or stored in drive-in or block-stacking configurations.
Reach stacker — similar in appearance to a straddle stacker but fitted with a pantographic scissor mast that allows the forks to extend forward independently of the unit body. This lets the operator reach into racking to place or retrieve pallets without driving the entire machine into the aisle. Reach stackers are the preferred option where pallets must be stored in standard adjustable beam racking (the most common rack type in Australian warehouses).
Counterbalance stacker — uses counterbalance weight at the rear rather than outrigger legs at the front. This means no straddle legs protruding in front of the forks, which allows it to operate in narrower aisles and pick standard pallets directly from rack beams at floor level — a task straddle stackers cannot perform. The counterbalance configuration also allows it to handle larger pallet sizes without modification. Counterbalance walkie stackers are the most versatile but typically the most expensive pedestrian stacking option.
Standard (single-mast) stacker — uses legs that sit directly under the forks. This allows two pallets to be lifted simultaneously — one on each fork — which makes them efficient for environments requiring both transportation and stacking of full pallets in quick succession. Less common in general warehousing but used in specific manufacturing and DC applications.
Pallet Jack Capacity: How Much Weight Can It Actually Lift?
Pallet jack capacity ratings are straightforward in principle but have real-world conditions attached that affect what the unit will safely handle in your environment.
Standard Australian capacity ratings
| Unit type | Standard capacity | Heavy-duty capacity | Notes |
|---|---|---|---|
| Manual pallet jack | 2,500 kg | 3,000–5,000 kg | 5,000 kg units are specialist items |
| Electric pedestrian | 1,500–2,000 kg | 2,500–3,000 kg | Capacity varies significantly by brand/model |
| High-lift jack | 1,000 kg | 2,000 kg | Capacity reduces at maximum lift height |
| Walkie stacker | 1,000–1,600 kg | 2,000–2,500 kg | Lift height affects rated capacity |
What degrades real-world capacity
The rated capacity is measured under ideal conditions — load centred on the forks, level floor, new hydraulic seals. In practice, several factors reduce what a pallet jack can safely carry:
Load centre distance: Capacity ratings assume the centre of gravity of the load sits 600 mm from the heel of the fork. Loads that extend further forward — long pipes, oversized machinery skids — effectively reduce the rated capacity. A 2,500 kg jack may handle only 1,800 kg safely with a load centred at 900 mm.
Floor condition: Moving a loaded jack across cracked concrete, grating, or expansion joints creates dynamic shock loads that exceed static capacity ratings. Reduce speed and use appropriate wheels for rough surfaces.
Ramp gradients: Most manual pallet jacks are rated for level surfaces only. Operating on ramps significantly increases the effort required and can exceed the hydraulic cylinder's ability to hold the load — particularly during lowering. Electric jacks with motorised travel are a safer option on ramp gradients, but check the manufacturer's rated gradient (typically 5–8%).
Hydraulic seal wear: An ageing hydraulic seal allows fluid bypass, meaning the forks slowly sink under load. A jack that drops even under a static load has a compromised seal and must be serviced before further use.
Fork Dimensions and Australian Pallet Compatibility
Fork dimensions are critical in the Australian market because the two dominant pallet pools — CHEP and Loscam — have specific entry dimensions that the pallet jack's fork width must clear.
Australian standard pallet dimensions
The Australian standard hardwood pallet — as used by CHEP, Loscam, and most domestic pallet pools — is 1,165 mm × 1,165 mm. This is different from the European standard (1,200 × 800 mm) and the North American standard (1,219 × 1,016 mm). If your competitor's guide gives dimensions in inches, it was written for a US audience and may not apply to your operation.
| Pallet type | Dimensions (mm) | Recommended fork width | Notes |
|---|---|---|---|
| CHEP hardwood (AU) | 1,165 × 1,165 | 685 mm | AU standard — 685 mm is specifically designed for this |
| Loscam hardwood (AU) | 1,165 × 1,165 | 685 mm | Same dimensions as CHEP |
| Euro pallet | 1,200 × 800 | 520–550 mm | Used by some importers and pharmaceutical supply chains |
| Quarter pallet / display | 580 × 580 | 450 mm | Retail display units — requires narrow jack |
Fork length
Standard Australian pallet jacks have a fork length of 1,150 mm — designed to pass fully through the 1,165 mm pallet. Short-fork variants at 900 mm are available for confined spaces and shorter skids. Never use a fork length shorter than the pallet depth — the load will be unsupported at the front and unstable in transit.
Adjustable-width forks
Some electric pallet jack models feature adjustable fork tines with a width range of 360–690 mm. This is useful in operations that regularly handle both standard Australian pallets and Euro format pallets, eliminating the need for two units. Adjustable-width models are more expensive but justify the cost in mixed-pallet environments.
Do You Need a Licence to Operate a Pallet Jack in Australia?
This is the most-searched question in this category, and the answer depends on the type of equipment — not just the brand or size.
Manual pallet jack
No licence required. A manual pallet jack is a non-powered, non-motorised trolley. There is no licensing requirement under any Australian state or territory WHS regulation. Employers should still provide basic operator instruction — correct technique for pushing, steering, and loading — as manual handling is a documented source of musculoskeletal injury, but no formal certification is required.
Electric pedestrian pallet jack
No High Risk Work Licence required. Electric pedestrian pallet jacks are classified as pedestrian-operated equipment, not as forklifts, under Australian WHS regulations. This classification is consistent across all states and territories. No HRW licence is required to operate them.
However, WHS obligations still apply to employers. Under the Work Health and Safety Act, businesses must:
— Ensure the equipment is safe and properly maintained
— Provide adequate training and instruction before authorising use
— Maintain competency records and records of authorised operators
— Implement safe operating procedures for electric-powered material handling equipment
In practice, most employers use a simple operator induction that covers start-up procedure, tiller controls, speed limits, load limits, and daily inspection — typically 1–2 hours. Records of this induction should be kept in the employee training file.
Walkie stacker (pedestrian)
No High Risk Work Licence required for pedestrian-operated walkie stackers. The same classification as electric pallet jacks applies — they are pedestrian equipment, not forklifts. Training and competency records are still required under WHS obligations.
Some walkie stacker training providers offer a formal competency assessment (the Crown Walkie Pallet Truck Operator Training is one commonly cited example), but this is not a regulatory requirement — it is simply good practice that also provides liability documentation for employers.
Counterbalance forklift
High Risk Work Licence required. Sit-down counterbalance forklifts — including reach trucks with an enclosed cabin or standing cab — require a Class LF (Forklift) High Risk Work Licence in all Australian states. This involves formal training and assessment with a licensed trainer and is issued by the relevant state regulator. If you are operating this class of equipment without an HRW licence, you are in breach of WHS legislation regardless of how brief or infrequent the operation is.
Manual vs Electric Pallet Jack: How to Choose
The choice between manual and electric is rarely about preference — it comes down to measurable operational criteria. Run through the following decision factors before purchasing.
| Factor | Manual jack suits you if… | Electric jack suits you if… |
|---|---|---|
| Daily pallet moves | Under 20 per operator per day | 20+ moves, or continuous use |
| Travel distance per move | Under 30 metres | 30 metres or more |
| Load weight | Typically under 1,000 kg | Regularly 1,000 kg or more |
| Operator profile | Occasional use, varied staff | Dedicated operator, daily shifts |
| Floor surface | Smooth concrete, level | Long smooth runs, slight gradients |
| Upfront budget | Under $700 — manual is the option | $2,000+ available; ROI via productivity |
| WHS injury risk | Low-volume operations tolerable | High-frequency use — electric reduces MSD risk |
| Maintenance resource | Minimal — seals and wheels only | Battery management, scheduled service needed |
The injury cost calculation
If you are operating manual pallet jacks at high frequency, the cost of a single musculoskeletal injury — lost time, WorkCover claims, replacement labour, retraining — typically exceeds the purchase price of an electric pedestrian unit. In operations where manual jacks are used continuously for full shifts, the business case for electric is almost always positive when injury costs are factored in. This is the primary driver behind the widespread adoption of electric pedestrian jacks in distribution centre environments.
Pallet Jack Wheel Types
Wheels are the most overlooked specification when purchasing a pallet jack, and the wrong wheel type damages floors, reduces service life, and creates operator safety hazards on contaminated surfaces.
| Wheel type | Best for | Avoid if |
|---|---|---|
| Nylon | Hard smooth floors, dry environments, general warehouse use. Low cost, durable, long service life. | Epoxy or coated floors — nylon can chip surface. Wet areas — low traction. Sensitive floors. |
| Polyurethane (PU) | Epoxy and resin-coated floors, food facilities. Softer contact — protects floor surface. Good traction. | High-grit or abrasive surfaces — PU wears faster. Higher cost than nylon. Not for outdoor use. |
| Stainless steel | Wet, washdown, food processing, corrosive environments. Fully corrosion resistant. Hygienic surfaces. | Epoxy floors — stainless will mark surfaces. Much higher cost — justified only in wet/food environments. |
| Rubber | Uneven surfaces, outdoor use, timber floors. Absorbs shock. Good traction on varied surfaces. | Oils and solvents degrade rubber quickly. Not for food environments. Higher rolling resistance. |
Tandem vs single load wheels: Standard manual pallet jacks use a single load wheel at the tip of each fork. Tandem load wheels — two wheels per fork tip — distribute the load over a larger contact area, reducing floor pressure and improving stability on slightly uneven surfaces. Tandem wheel configurations are recommended for loads over 2,000 kg and for facilities with older concrete floors where cracking is a concern.
How to Choose the Right Pallet Jack: Decision Guide
Use this framework to shortlist the right unit before approaching a supplier.
Step 1 — Confirm your maximum load weight. Weigh your heaviest pallet if you do not have data on it. Add 10–15% margin for load variation. This determines your minimum SWL requirement.
Step 2 — Measure your standard pallet. Confirm whether you are running CHEP/Loscam (685 mm fork width), Euro (550 mm), or display quarter pallets (450 mm). If you run mixed pallets, consider an adjustable-width model or specify separate units for each format.
Step 3 — Measure your typical travel distance. Walk your longest regular pallet run with a measuring wheel or count steps. Under 30 metres: manual. 30–80 metres: electric pedestrian. Over 80 metres regularly: electric pedestrian or ride-on.
Step 4 — Assess your floor condition. Smooth sealed concrete: nylon or PU wheels. Epoxy coating: PU mandatory. Wet or washdown areas: stainless or PU. Rough/outdoor: rubber. This determines your wheel specification.
Step 5 — Confirm lift height requirement. Floor transport only: standard pallet jack (85–200 mm lift). Ergonomic work positioning: high-lift or scissor lift jack. Racking height: walkie stacker or forklift.
Step 6 — Assess frequency of use. Occasional (a few times per day): manual is appropriate. Frequent (every 10–15 minutes through a shift): electric. Continuous (multiple operators, full-shift operation): electric with lithium battery for opportunity charging.
Industry-specific considerations
Food and pharmaceutical: Stainless steel frame and polyurethane or stainless wheel options. Sealed bearings to prevent contamination. Some applications require full stainless steel construction to meet HACCP requirements. Confirm food-grade specification with the supplier.
Cold store: Low-temperature grease in hydraulic seals and bearings — standard mineral-based fluids thicken at -18°C and below. Electric battery performance drops significantly in sub-zero temperatures; lithium-ion performs better than lead-acid in cold conditions. Confirm cold-store rating with the supplier.
Chemical storage: Standard painted steel frames are not suitable for corrosive environments. Stainless steel or galvanised construction required for acid or solvent storage areas. Check compatibility of wheel and seal materials with specific chemicals present.
Outdoor use: Standard pallet jacks are designed for indoor use on smooth surfaces. Outdoor use on uneven ground, gravel, or through dock doors introduces moisture and debris. Rubber wheels, sealed wheel bearings, and a painted or galvanised frame are minimum requirements for regular outdoor exposure.
Pallet Jack Safety and WHS Obligations
Under the Work Health and Safety Act (Commonwealth and state equivalents), businesses are required to ensure pallet jacks are safe, properly maintained, and operated by trained personnel. Specific obligations include:
Pre-start inspection
Every pallet jack — manual or electric — should be inspected before each shift by the operator. The inspection takes under two minutes and should cover:
— Forks: check for cracks, bends, or visible damage at the heel weld
— Wheels: check for flat spots, cracking, or embedded debris
— Hydraulics: test the lift and lower function with no load — confirm the forks hold position and do not creep down
— Horn and controls (electric): confirm all controls operate correctly
— Battery level (electric): confirm sufficient charge for the shift
— Frame: check for visible damage, loose pins, or bent tines
Defective equipment must be tagged out of service immediately. Do not use a pallet jack with a slow hydraulic leak, damaged fork, or compromised wheel — the failure mode for hydraulic-related incidents is load drop, which is a serious injury risk.
Operator training
While no formal licence is required for manual or electric pedestrian pallet jacks, employers must be able to demonstrate that operators have been trained in correct use. Training should cover:
— Safe load limits and how to identify overloading
— Correct approach angle to pallets
— How to check pallet integrity before lifting (a damaged pallet can collapse under load)
— Safe travel speed and turning procedure
— Parking and storage procedure (forks lowered to floor, not left raised)
— Emergency stop procedure (electric units)
Maintenance schedule
Manual pallet jacks require minimal maintenance but should be serviced at regular intervals:
— Monthly: lubricate the steering axle, check wheel condition, inspect hydraulic seals for leakage
— 6-monthly: hydraulic fluid level check, complete mechanical inspection, fork integrity check
— Annually: full hydraulic service, seal replacement if required, load test to rated SWL
Electric pedestrian jacks require additional attention to the battery system — electrolyte levels for lead-acid batteries, connection checks, and periodic capacity testing. Lithium-ion systems require less ongoing maintenance but should be inspected for connection integrity and casing damage as part of the monthly check.
Pallet Jack Prices in Australia
Prices below are indicative as at 2026 and reflect standard commercial-grade units from reputable suppliers. Cheap imported units at significantly lower price points are available but typically carry shorter warranties, non-standard spare parts, and in some cases do not meet Australian WHS equipment standards. For any unit used in a workplace, purchase from a supplier who can confirm compliance with AS 3000 where applicable and provide local spare parts and service.
| Unit type | Entry price (AUD) | Mid-range (AUD) | What you get for more |
|---|---|---|---|
| Manual pallet jack (2,500 kg) | $300–$450 | $450–$700 | Better hydraulic quality, PU wheels, longer warranty |
| Manual pallet jack (3,000–5,000 kg) | $600–$900 | $900–$1,500 | Tandem wheels, heavier frame, stainless options |
| High-lift pallet jack | $800–$1,200 | $1,200–$2,500 | Higher lift height, electric lift option |
| Electric pedestrian pallet jack | $2,000–$3,500 | $3,500–$8,000 | Lithium battery, brand warranty, service network |
| Walkie stacker (straddle) | $3,000–$6,000 | $6,000–$12,000 | Higher lift, better mast, reach or counterbalance type |
| Walkie stacker (counterbalance) | $8,000–$12,000 | $12,000–$20,000+ | Full counterbalance, can pick from racking |
For businesses purchasing a first pallet jack, the 2,500 kg standard manual unit at $400–$600 covers the majority of general warehouse and workshop applications. Upgrade to electric when operational frequency or operator injury risk justifies the cost — and factor in the Australian distributor's service network, not just the unit price.
AIMS Industrial stocks a range of material handling equipment including manual and electric pallet jacks for Australian warehouse and workshop applications. Browse the rigging and lifting range for current stock and specifications.
For related workshop tooling, see our guides on types of spanners and drill bit types — commonly needed for maintenance tasks in warehouse environments.
Frequently Asked Questions
What is the difference between a pallet jack and a pallet truck?
There is no functional difference — they describe the same piece of equipment. "Pallet jack" is the North American term that has become the dominant Australian search term. "Pallet truck" or "hand pallet truck" is the traditional UK and Australian trade terminology and still appears on most Australian product labels. Both terms are used interchangeably in Australian warehousing and are accepted on product documentation, WHS records, and purchase orders.
Do you need a licence to operate an electric pallet jack in Australia?
No. Electric pedestrian pallet jacks are classified as pedestrian-operated equipment under Australian WHS regulations and do not require a High Risk Work Licence (HRW). This applies consistently across all states and territories. Employers are still required to ensure operators have received adequate training and to maintain competency records — but no formal licence is issued or required. Forklifts (sit-down counterbalance and reach trucks) are a different category and do require a Class LF HRW Licence.
What is the standard pallet jack capacity in Australia?
The standard capacity for a manual pallet jack in Australia is 2,500 kg (Safe Working Load). This covers the vast majority of standard palletised loads in general warehousing and distribution. Heavy-duty models rated to 3,000 kg, 4,000 kg, and 5,000 kg are available for bulk materials, steel coils, and dense industrial goods. Always confirm load weight before selecting a unit — rated capacity applies at the standard load centre of 600 mm from the fork heel.
What fork width do I need for CHEP and Loscam pallets?
The standard fork width for CHEP and Loscam pallets in Australia is 685 mm. This dimension is specifically designed to suit the 1,165 mm × 1,165 mm Australian hardwood pallet used by both pallet pool operators. A 550 mm narrow-fork unit will technically enter a CHEP pallet but provides insufficient support width for safe operation. Do not use a 450 mm Euro-width jack on standard Australian pallets.
How far can a manual pallet jack travel with a load?
There is no fixed distance limit for a manual pallet jack — it is limited by operator fatigue, not the machine. In practice, manual jacks are suitable for runs of up to 30–40 metres with loads of 1,000 kg or more. Beyond that distance, the sustained push force required for a fully loaded standard pallet (typically 12–18 kg of sustained push force at 2,000+ kg) becomes a manual handling hazard under SafeWork Australia's hazardous manual tasks guidelines. For regular runs over 30 metres, an electric pedestrian unit significantly reduces injury risk.
What is a walkie stacker and when do I need one instead of a pallet jack?
A walkie stacker is a pedestrian-operated lift truck with a mast that raises the load to racking height — typically 2,000–5,500 mm. A pallet jack only raises the load 85–200 mm off the ground. If you need to place pallets into racking, onto shelving, or stack them more than one high, you need a walkie stacker. If you only need to move pallets between locations on the floor, a pallet jack is sufficient and significantly cheaper. No High Risk Work Licence is required for pedestrian walkie stackers in Australia.
How long does an electric pallet jack battery last?
Battery life depends on the chemistry and usage pattern. Lead-acid batteries in electric pedestrian pallet jacks typically provide 6–8 hours of operation on a full charge and require 8–10 hours to fully recharge — effectively one charge per shift. Lithium-ion batteries provide similar operating time but charge in 2–3 hours and tolerate opportunity charging (partial top-ups during breaks) without reducing battery lifespan. Lead-acid battery packs typically last 3–5 years with correct maintenance. Lithium-ion packs typically last 5–8 years. The higher upfront cost of lithium is generally recovered in service life and reduced downtime within 3–4 years of operation.
What wheels should I choose for rough or outdoor surfaces?
For rough or uneven surfaces, rubber wheels provide the best shock absorption and traction across varied floor conditions. For outdoor use where moisture and debris are a factor, rubber wheels with sealed bearings are the recommended option. Nylon wheels suit smooth dry concrete but become unsafe on wet or grit-contaminated surfaces. Polyurethane wheels are the preferred option for sealed indoor floors (epoxy, resin-coated) where floor protection is a priority. Stainless steel wheels are specified for washdown and food processing environments where corrosion resistance is required.
What is a high-lift pallet jack used for?
A high-lift pallet jack raises the load to a working height of 500–900 mm above the floor — significantly higher than a standard jack's 85–200 mm range, but below racking height. The primary application is ergonomic positioning: bringing the pallet to a comfortable working height for picking, packing, or assembly tasks, eliminating repeated bending to floor level. High-lift jacks are common in order fulfilment operations, manufacturing assembly lines, and any environment where operators work directly on a pallet for extended periods. They do not replace a stacker for racking-height lifts.
How much does a pallet jack cost in Australia?
Standard 2,500 kg manual pallet jacks cost $300–$700 depending on quality and wheel specification. Heavy-duty manual units (3,000–5,000 kg) range from $600 to $1,500. Electric pedestrian jacks range from $2,000 for entry-level lead-acid models to $8,000+ for quality brand units with lithium batteries and local service networks. Walkie stackers start at $3,000 for basic straddle models and reach $20,000+ for full counterbalance units with high-mast capability. All prices are indicative and vary with model specifications, brand, and supplier.
What is the difference between a pallet jack and a forklift?
A pallet jack moves pallets horizontally across a floor — it lifts only enough to clear the pallet boards (85–200 mm). A forklift lifts pallets to full racking height (commonly 4,000–8,000 mm or higher), operates at speed, and can operate across uneven or outdoor surfaces depending on specification. Forklifts require a Class LF High Risk Work Licence in all Australian states. Pedestrian pallet jacks do not. Forklifts cost $30,000–$80,000+ new; pallet jacks cost $300–$8,000. The right choice depends entirely on whether you need to stack or just transport — and if you need both, a walkie stacker is often the most cost-effective middle option.
How often should a pallet jack be serviced?
Manual pallet jacks should receive a basic monthly inspection (wheels, hydraulic seals, lubrication), a 6-monthly hydraulic service, and an annual full inspection and load test. The most common service item is hydraulic seal replacement — a seal that allows the forks to slowly creep down under load must be replaced before further use. Electric pedestrian jacks add battery system servicing to this schedule — lead-acid batteries require monthly electrolyte checks; lithium systems need periodic connection and capacity checks. Both unit types should be inspected by the operator before each shift as a minimum WHS compliance measure.
For Australian-compliant PPE and workplace safety equipment, see AIMS Safety.
