Module 7 of 85–7 minutes

Equipment, Aids and Tools for Warehousing and Freight

Pallet jacks, trolleys, roll cages, conveyors, lift tables, vacuum lifters, dock levellers, tail lifts and step platforms — pre-use checks, defect reporting and the limits of PPE.

Last reviewed September 2026 · Part of Manual Handling Training for Warehouse and Logistics Workers

Key learning points

Recognise the common manual handling aids used in warehouses, docks and delivery vehicles
Understand that every aid requires training and some require a licence
Perform appropriate pre-use checks and report defects
Know why gloves and safety boots are the least effective control
Understand that this course is not a forklift or high-risk work licence

Common equipment

Manual pallet jack: Moves palletised loads short distances on level floors; no brakes, so load, floor and slope limits matter
Electric pallet jack and walkie stacker: Powered movement and braking for heavier loads, longer hauls and ramps; training and site authorisation required, and stackers may need a licence depending on type
Hand trolley and sack truck: Cartons, bags and small appliances; two-wheel for stairs and kerbs, four-wheel platform trolleys for volume
Roll cage: Wheeled cage for store and parcel deliveries; keep loads low and within the line, doors clipped, brakes on where fitted
Conveyors and ball tables: Move cartons without carrying; telescopic boom conveyors extend into containers and trailers, ball tables let you slide and turn cartons at packing
Scissor lift tables and pallet levellers: Bring the load to a constant waist height as a pallet is built or broken down; spring levellers rotate so the pick is always at the front
Vacuum tube lifters and hoists: Lift sacks, drums, tyres and repetitive cartons with a suction pad or hook; the operator guides, the machine takes the weight
Dock levellers and dock plates: Bridge the gap and height difference between dock and trailer; a missing or lifted plate is a sudden-force and fall hazard
Tail lifts: Lower cages and pallets from a truck or van to the ground; require level parking, load stops and a trained operator
Step ladders and order-picking platforms: Bring your shoulders level with high stock; never replaced by climbing racking or standing on a pallet on the forks
Forklifts, reach trucks and order pickers: Mechanical aids operated by people holding the relevant high-risk work licence and site authorisation; they take the heavy lifts out of hands entirely

This course is not a forklift licence

Operating a forklift or an order-picking forklift requires a high-risk work licence issued by your state or territory regulator, plus site-specific training and authorisation. This course does not provide that, and it does not teach you to operate any equipment. Powered pallet jacks, tail lifts, vacuum lifters and conveyors must be learned in your workplace, on the actual equipment, with competent supervision, before you use them.

Rules that apply to all equipment

Only use equipment you are trained and authorised to use, and hold the licence where one is required
Check it before every use — wheels and castors, handle and pump, brakes and controls, battery, guards, forks and load stops
Stay within the rated capacity marked on the equipment; if the plate is missing, ask
Follow the manufacturer's instructions and your workplace procedures
Use the aid the procedure specifies for that task — a sack truck is not a substitute for a lifter and a pallet jack is not a substitute for a forklift
Tag out and report faulty equipment immediately; do not leave it for the next shift to find
Do not improvise, modify or overload equipment, and do not remove guards or bypass interlocks
Park it where it cannot roll, trip or block an exit

Pre-use checks

Manual pallet jack: Forks lift and lower smoothly and hold under load; wheels turn freely with no flat spots or wrapped strapping; handle returns to neutral
Electric pallet jack: Battery charged, horn works, belly button reverse switch stops and reverses the unit, brake holds on a slope, forks lift, no hydraulic leaks
Hand trolley and sack truck: Tyres inflated or solid wheels intact, nose plate not bent, handles and straps secure
Roll cage: Castors spin and swivel, brakes hold, sides and doors latch, base not bent, no protruding wire
Conveyor: Emergency stops work and are reachable, guards in place, rollers turn, boom extends and retracts under control
Scissor lift table: Rises and lowers under control, holds at height, no leaks, rated load visible, area under it clear
Tail lift: Platform level and free of debris, controls function, load stops or ramp operate, warning lights on, van parked level with the handbrake on
Step platform: Feet and wheels lock, treads secure, handrail firm, rated for you plus the load

Gloves and boots: the least effective control

Gloves improve grip on slick, frosted or sharp-edged loads and protect against cuts and strapping; they do nothing to reduce the weight or the reach
Safety boots protect your feet from a dropped carton or a pallet jack wheel; they do not change the lift
Thick freezer gloves reduce dexterity, so allow for a weaker grip in cold rooms
Back belts are not recommended as a manual handling control; they do not reduce the load on the spine and can encourage heavier lifts
PPE sits at the bottom of the hierarchy — wear it, and still expect the higher controls to be in place

Practical scenario

Scenario: the soft brake

The electric pallet jack you use for ramp work has started to roll a little before the brake bites. It still stops, and it is the only one available at the start of the shift.

Is it acceptable to keep using it carefully?

Reveal the explanation

No. A brake that has started to fade on equipment used on ramps is a serious fault, and intermittent faults get worse. Take it out of service according to your workplace process, tag it, report it and use an alternative your supervisor approves — which may mean the forklift moves the ramp loads until it is repaired. The half hour lost is the cheapest outcome available.

Practical scenario

Scenario: the carton on the third beam

A single carton is sitting on the third beam level of the racking, above head height. The step platform is at the other end of the aisle and the forklift driver is on a break. A colleague suggests climbing the first two beams to reach it.

What should you do?

Reveal the explanation

Do not climb the racking. Racking is not designed to be climbed, a fall from the second beam onto concrete is a serious injury, and you would be lifting an unknown load at full reach with nothing under your feet. Walk to the step platform and bring it back, or wait for the forklift. If a step platform is never near the picks that need it, raise that — the fix is more platforms or better slotting, not climbing.

Knowledge check

These questions are for your own learning. They are not part of the final assessment.

1. You have been shown a walkie stacker informally by a colleague but have not been trained or authorised on it. The supervisor is busy. What should you do?

2. Which is an appropriate pre-use check on an electric pallet jack?

3. Why are gloves and safety boots considered the least effective control for manual task risk?

4. Does completing this course allow you to operate a forklift?