all Terrain Pallet Jack

An all terrain pallet jack sometimes called a rough terrain pallet truck is built to move pallets over ground where a standard warehouse pallet jack struggles. Instead of small hard wheels and a low frame it uses larger tyres more ground clearance and a stronger chassis so it can roll on gravel compacted soil outdoor yards and unfinished floors.

This guide explains what all terrain pallet jacks are how they differ from standard pallet trucks where they work best and which features to focus on when you choose one.

What an all terrain pallet jack is

A typical warehouse pallet jack is designed for smooth concrete floors. It has small load wheels under the forks and medium steer wheels in the powerhead. Entry height is low and the frame sits close to the ground. On rough ground these small wheels fall into holes and cracks and the low frame can bottom out.

An all terrain pallet jack solves this with a different layout.

Many models use a tubular steel frame with three large wheels or four wheels in total. Two big front wheels carry most of the load with pneumatic or deep tread tyres. At the rear a steer assembly with one or two wheels lets the operator guide the pallet truck. Forks sit higher above the ground than on a standard pallet jack but still low enough to slide under most pallets.

Manual all terrain pallet jacks usually lift loads with a hand pumped hydraulic unit just like a warehouse pallet jack. Capacities commonly sit around 1 200 to 2 000 kilograms with some heavy duty models reaching about 2 500 kilograms depending on fork length and design.

Some manufacturers offer powered all terrain pallet trucks which add a drive motor and in some cases engine power. These machines keep the basic fork layout but use powered traction for long runs or steep grades with typical rated loads around 900 to 1 800 kilograms.

All terrain pallet jack versus standard pallet jack

Choosing between an all terrain pallet jack and a standard pallet jack comes down to the surface you work on plus the weight and volume of your loads.

A standard pallet jack works best on

Smooth level warehouse floors
Loading docks with good dock plates
Trucks and trailers with flat timber or steel decks

An all terrain pallet jack earns its keep when you face

Gravel mud compacted soil and crushed stone
Block paving and rough outdoor concrete
Unfinished warehouse floors and construction sites
Outdoor storage yards farms nurseries and builders yards

On these surfaces the large pneumatic or deep tread tyres roll over small holes and debris and protect both load and frame from harsh impacts. The tradeoff is higher weight and a higher minimum fork height compared with a low profile warehouse pallet jack.

Key design features of all terrain pallet jacks

When you look at spec sheets for rough ground pallet trucks several design features repeat. Understanding these helps you match a model to your work.

Frame and forks

All terrain pallet jacks use a welded steel frame often tubular to keep weight reasonable while resisting twisting forces. The frame wraps around the wheel assemblies and supports the forks.

Forks are shorter on some rough terrain models than on standard pallet jacks. For example many units use fork lengths around 800 to 900 millimetres while others offer longer forks near 1 000 to 1 200 millimetres depending on application.

Several products use adjustable fork spacing. On these models forks slide on cross tubes or support beams so you can narrow or widen the distance between forks for different pallet sizes and crates. This lets one truck fit both narrow and standard pallets.

Fork height range usually starts a little higher than on a low profile warehouse pallet jack. Minimum fork height on many rough terrain trucks is around 50 to 80 millimetres with maximum raised height around 200 to 240 millimetres which is enough to clear uneven ground and small ridges.

Wheels and tyres

The wheels are the heart of an all terrain pallet jack. Common setups include

Large front load wheels with pneumatic tyres that absorb shocks and roll over stones and gaps
Deep groove or rough terrain rubber tyres for trucks that must work both indoors and outside
Sealed bearings to keep out dust mud and moisture for longer life outdoors

Tyre diameter is far larger than on a standard pallet jack. Big wheels reduce rolling resistance on rough ground and lower the risk of digging into soft surfaces. The tradeoff is a taller chassis so you must check clearance with low pallets and doorways.

Pressure maintenance is critical with pneumatic tyres. Underinflated tyres increase rolling resistance and make steering heavy. Overinflated tyres reduce grip and ride comfort.

Steering and manoeuvrability

All terrain pallet jacks must turn around obstacles on sites where space is often tight. Most use a central steer wheel assembly at the rear with a long tiller handle. A wide steering arc lets the operator make tight turns and maintain good control in yards and on sites.

Because the whole frame sits higher the centre of gravity is also higher than a standard pallet jack. This makes smooth steering and careful speed control important on side slopes and ramps.

Manual and powered drive

Manual all terrain pallet jacks rely on the operator to push or pull. They suit relatively flat yards and moderate distances where loads are heavy but not extreme.

Powered all terrain pallet trucks use either electric motors or small petrol engines to drive the wheels. These units can carry heavy loads and climb steeper grades than manual models.

Powered drive reduces strain over long distances and on ramps but adds cost weight and maintenance. It also brings extra safety considerations such as engine exhaust outdoors and charging or refuelling arrangements.

Brakes and control features

Many manual rough terrain pallet trucks include simple braking systems that act on the steer wheels. These help hold the truck on gentle slopes during loading or when parked. Hand operated release triggers give controlled lowering of the forks so loads do not drop suddenly on uneven ground.

Powered all terrain pallet trucks may add service brakes parking brakes and speed control systems. Always review the braking description in the data sheet alongside the maximum rated grade and speed.

Where all terrain pallet jacks work best

All terrain pallet jacks fill the gap between simple warehouse pallet jacks and full rough terrain forklifts. They shine when loads are heavy enough to need a pallet truck but not so heavy or high that you need a forklift.

Common environments include

Builders yards and construction sites with pallets of block board and bagged materials
Garden centres and nurseries where paths are gravel or paving and loads include soil plants and stone
Farms and agricultural sites with uneven yards barns and outdoor storage areas
Outdoor event sites where pallets of staging fencing or equipment must move across grass and compacted soil

Warehouses with unfinished slabs or busy yards where forklifts are not always available

In many of these locations the all terrain pallet jack is a support tool to complement forklifts. Forklifts handle long distance moves and truck loading while all terrain pallet jacks take care of short transfers into tight areas or locations with restricted headroom where a forklift mast would clash with structures.

All terrain pallet jack versus rough terrain forklift

Rough terrain forklifts are powerful vehicles with masts and large tyres that lift pallets high into storage or onto trucks. They carry much heavier loads and travel faster over rough ground than any pallet jack.

They also cost much more to buy or rent and require trained licensed operators in many regions. They need more turning space and often create more ground damage on soft surfaces because of their weight.

An all terrain pallet jack is not a full replacement for a rough terrain forklift. It is a simpler tool that fits when you need

Loads moved at ground level or small height differences
Equipment that can be towed or lifted in a small van or pickup
A lower purchase price with minimal fuel or charging needs
A solution for tight access areas where forklifts cannot reach

If you frequently lift to truck beds or high platforms and move very heavy pallets a rough terrain forklift is usually the better core tool. An all terrain pallet jack then becomes a useful supplement for final positioning and access work.

How to choose an all terrain pallet jack

When you compare models focus on practical fit for your site.

Capacity and pallet type

Start with the heaviest pallet you must move. Many rough terrain pallet trucks are rated around 1 200 to 2 000 kilograms with some heavy duty versions at 2 500 kilograms. Leave a safety margin above your heaviest expected load.

Check pallet sizes as well. Confirm that fork length and adjustable width range fit your usual pallets including any oversized skids crates or containers.

Ground conditions and grades

Look closely at your surfaces. Deep mud loose sand or large rocks may still defeat any pallet truck. For moderate gravel compacted soil and rough concrete an all terrain pallet jack usually works well.

If ramps or long slopes are part of the path pay attention to the maximum grade listed by the manufacturer. Gas or electric powered all terrain pallet trucks can often climb steeper grades with a full load than manual models. Manual units handle smaller grades and need strict procedures for pushing and braking on slopes.

Manual versus powered drive

Choose manual drive when

Distances are short
Ground is fairly level
Use is occasional or seasonal
Budget is limited and you want simple maintenance

Choose powered drive when

Loads approach the top of the capacity range
Distances are long or include ramps
Use is daily and continuous through shifts
You can support refuelling or battery charging at the site

Adjustability and transport

If you handle different pallet sizes look for adjustable fork spacing. This lets one truck cover narrow special pallets and standard block pallets without extra equipment. Adjustable forks also help position loads for stability on steep or uneven surfaces.

Think about transport too. If you move between sites you may need a truck light enough to load with a ramp or crane and short enough for your vehicle bed.

Safe use of all terrain pallet jacks

Rough ground adds risk so safe practice is vital.

Walk routes first and clear large stones scrap and other hazards where you can
Keep loads low and centred over the forks and respect the rated load centre in the manual
Take shallow angles across slopes and avoid cross slopes that risk tipping
Push uphill and guide the truck carefully downhill keeping control speed steady

Use brakes and chocks when parking on any incline
Never ride on the truck or allow passengers on the load

Read and follow the manufacturer instructions and any local safety standards that apply in your region. Many points mirror the rules for standard pallet trucks but surface conditions make good habits even more important.

Maintenance and care

Outdoor work exposes all terrain pallet jacks to water dirt and impacts. Simple maintenance extends life and protects safety.

Check tyre pressure regularly and inspect treads for cuts and embedded sharp objects
Clean mud and debris from forks frame and wheel hubs after wet shifts
Inspect welds and frame members for cracks especially near wheel mounts and fork roots
Grease pivot points and steering joints on the schedule given in the manual

Watch for hydraulic leaks and repair them quickly

Store trucks under cover when possible. Long term exposure to sun and rain can age tyres and paint and speed corrosion especially on coastal or chemical sites.

Rental versus purchase for all terrain pallet jacks

All terrain pallet jacks are more specialised than standard models so many businesses start with rental.

Rental suits

Short projects at outdoor sites
Seasonal work in builders yards or garden centres
One off civil engineering or event jobs on grass and rough ground

Purchase makes sense when

Rough ground pallets are part of daily operations
You have several yards or farms that need regular movement
You want to tune forks wheels and accessories to your exact pallet mix

Because these trucks are niche products availability can vary by region. In some areas all terrain pallet jacks are available from general equipment rental companies. In others you may need to work directly with material handling dealers who specialise in pallet trucks.