How Can I Move a Dead Electric Pallet Jack Safely?

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You’re wheeling a heavily-laden electric pallet jack through the warehouse when suddenly the motor cuts out and the unit grinds to a halt. You try the controls but nothing happens – the battery is completely dead. Now you face a tricky situation: how can you safely move this large, heavy pallet jack out of a busy thoroughfare without power assistance?

This stressful scenario confronts many warehouse operators at some point. Immobilised electric pallet jacks present significant manual handling hazards and can cause workflow disruptions. Simply dragging a 1000 lb electric pallet jack by hand risks injury, and can be incredibly difficult, while leaving it stranded could obstruct traffic.

So what’s the safe way out when your electric pallet jack loses power? This guide covers techniques for cautiously relocating dead electric pallet jacks without power assistance. We’ll outline preparation steps, review equipment choices (such as forklifts), suggest manual handling postures and highlight key safety factors when pushing, towing or carrying heavy electric pallet jacks. Follow these tips to keep your goods and people moving even with a dead lift truck.

Initial Response Steps Once an Electric Pallet Jack Stops Working

Before physically attempting to move the stricken electric pallet jack, you should:

  1. Move it to an area clear of active traffic to create a safe workspace and prevent obstructions.
  2. Lower the forks fully and neutralise the parking brake if it’s still functional to stabilise the unit.
  3. Shut off and isolate the jack’s power source if possible according to manufacturer guidelines to prevent sudden activation during relocation.
  4. Inspect for any faults or damage that could further complicate moving the unit like punctured wheels or twisted components.
  5. Use appropriate PPE (personal protection equipment) including safety gloves to protect your hands when gripping components later.

How to Move a Dead Electric Pallet Jack Safely

Technique 1: Pushing the Electric Pallet Jack Manually 

With the lift truck stabilised, you can attempt pushing or steering it like a typical non-powered pallet jack across shorter distances under 50 metres to the intended maintenance area.

  • Position the pallet jack to utilise gravity – gently steer it down steeper but controlled grades in the destination direction when possible.
  • Push pallet jacks cautiously on flat floors using the correct manual handling posture – keep your back straight and use your leg muscles to bear the weight.
  • Take care to retain steering control when building momentum and wear appropriate footwear with slip resistance. 
  • Stop regularly to check your route for obstacles and reposition your hands for the best grip.

Technique 2: Towing the Electric Pallet Jack 

For longer relocation distances or handling detained pallet jacks with gross weights exceeding 500 kg, a tow strap offers a safer manual handling option.

  • Use a designated tow strap with ratings at least 4x the pallet jack’s gross weight. Attach the strap to the designated tie-down points as outlined in the operating manual.
  • Connect the tow strap to a suitably rated tugger train, forklift or even robust 4×4 vehicle via its tow hitch. Make sure to maintain adequate slack during pulls.
  • Ensure the towing machine has traction aids like weight over its drive wheels. Appoint a trained spotter to relay directions.
  • Pull the pallet jack slowly in a straight line where possible. Go around corners gradually, taking care not to over-articulate the strap.
  • Stop regularly to allow the belt slack to settle and inspect the route forward.

Technique 3: Lifting and Transporting the Pallet Jack 

In situations lacking towing vehicles and where pushing proves unfeasible, you can elevate and carry the electric pallet jack on another platform.

  • A small flatbed trolley is suitable for lightweight pallet jacks under 250 kg. Secure the pallet jack using ratchet tie-downs.
  • For heavier models, use a pallet jack, forklift or improvised lifting beam to raise then transport the pallet jack on its forks or a sling.
  • Position the lifting machine directly in front and centre of the electric pallet jack to evenly elevate it. Strapping it down prevents it from shifting around.  
  • Travel slowly with extreme care to avoid upending the load, and lower it gently. Use tag lines for steering if your visibility is obstructed.

Safety Reminders When Relocating Dead Electric Pallet Jacks

Regardless of your chosen relocation method, exercising caution and preparation is vital:

  • Never rush the process or take risky shortcuts that compromise stability just to save time. 
  • Carefully inspect your planned travel paths and look out for potential obstructions before shifting the pallet jack.
  • Use properly rated equipment. Improvising with under-strength trolleys or slings risks catastrophic failure and damage.
  • Adhere to safe manual handling limits and get assistance to move heavier electric pallet jacks exceeding your individual lifting thresholds.  
  • Ensure personnel tasked with moving dead pallet jacks have appropriate training in towing, lifting, signalling and equipment use.  

Forklift Preventative Maintenance 

Ultimately, the best method for avoiding unplanned electric pallet jack stoppages is diligent preventative maintenance:

  • Follow the manufacturer’s recommended service intervals, including checking fluid levels, changing filters, inspecting tyres, testing brakes, etc.
  • Periodically service batteries and recharge them overnight to avoid failures mid-shift.
  • Respond promptly to any mechanical or electrical faults flagged by operators.

By combining cautious operating techniques, appropriate equipment, spotters when necessary and proactive upkeep, you can manually move even heavy 500kg+ electric pallet jacks in emergencies without undue risk.

However, avoiding those scenarios through attentive maintenance is the safest long-term approach for maximising uptime.

Discover Our Range of Electric and Manual Pallet Jacks

At TAG Forklift Trucks, we maintain a sizable fleet of dependable electric and manual pallet jacks available for competitive hire or purchase. Our qualified technicians can also service your existing equipment to extend its reliability long-term.

For expert advice tailored to your specific operational requirements and site conditions, contact us today at 0161 848 0555.