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Pallet jack features including adjustable pallet jacks

A pallet jack looks simple at first glance. Two forks a set of wheels and a handle. In practice there are many small design choices that decide how safe comfortable and productive the truck feels on your floor.

A pallet jack looks simple at first glance. Two forks a set of wheels and a handle. In practice there are many small design choices that decide how safe comfortable and productive the truck feels on your floor.

This guide explains the main pallet jack features from basic construction through safety options and special designs. It pays special attention to adjustable pallet jacks which let you change fork width for different pallet sizes.

Main parts of a pallet jack

Most manual pallet jacks share the same basic layout.

The powerhead at the handle end holds the hydraulic pump steering wheels and control linkage. The drawbar or tiller connects the powerhead to the operator.

Two steel forks run under the pallet. At the tips you find small load wheels that carry most of the weight when the pallet is raised.

Between the forks a linkage and piston form the hydraulic system. When the operator pumps the handle this system raises the forks a short distance off the floor so the pallet can roll.

Small design differences in these parts give you different features and performance.

Core performance features

When you read a pallet jack spec sheet the numbers tell you how the truck behaves with real loads. The key ones are load capacity fork dimensions lift range and steering geometry.

Load capacity

Capacity is the maximum safe load the pallet jack can carry on level ground. Common manual pallet jacks are rated around 2 000 to 2 500 kilograms which covers most standard palletised loads in retail and light manufacturing.

High capacity models go higher. Some stainless steel and heavy duty units reach 3 000 kilograms or more. Always compare the capacity with your heaviest pallet not just the average weight.

The rating assumes the load centre sits at a standard distance from the fork heels. If your pallets carry tall or uneven loads real stability may be lower than the printed figure.

Fork length and width

Fork length controls how far the forks extend under the pallet. Standard hand pallet jacks often have fork lengths around 1 150 millimetres for euro pallets. Shorter forks around 910 or 1 000 millimetres help in tight vans and small storerooms. Longer forks can carry two pallets at once for some layouts.

Fork width and the distance between forks must match your pallet design. A typical euro pallet needs an overall fork width around 540 millimetres. North American stringer pallets and many block pallets use wider settings around 685 millimetres.

If you handle unusual pallets or many different sizes an adjustable pallet jack can be the right feature. You change the distance between forks rather than buying several fixed width trucks.

Lift height and quick lift function

Manual pallet jacks raise loads only a short distance. On many models minimum fork height is around 75 to 85 millimetres with a maximum height around 190 to 200 millimetres. That is enough to clear floor bumps and dock plates but not to stack pallets in racking.

Some models add a quick lift feature. When the load is light the first few pump strokes raise the forks faster. This saves time in order picking and shipping when you handle many light pallets or empty skids.

High lift or scissor pallet jacks are a different category. They raise pallets to working height around 800 millimetres so staff can work from the pallet without bending.

Steering angle and turning circle

The steer wheels at the powerhead usually turn through a wide arc. Many trucks offer around 200 degrees of steering which lets the operator turn in narrow aisles and spin the truck under a pallet that sits close to a wall.

The turning circle depends on fork length and truck design. Shorter trucks turn tighter but may not support long pallets well. When planning a purchase measure your narrowest aisle and check it against the stated turning radius.

Wheels and tyre material

Pallet jack wheels carry high point loads so material choice matters. Common options are

You can often choose between single and tandem load wheels. Tandem wheels share weight better on poor floors and ease entry into pallets but add cost and a little length at the fork tips.

Handle and pump controls

Most manual pallet jacks use a three position control in the handle. One position raises the forks when you pump. One position holds height. One position lowers the forks in a controlled way.

A well designed handle has an ergonomic shape a comfortable grip and smooth return spring. Some models use rubber or plastic coated handles to reduce cold transfer in chill stores and give better grip.

Quality pumps include controlled lowering valves so the forks descend at a predictable speed and overload valves that relieve pressure if someone tries to lift too heavy a load.

Ergonomic and safety features

Small details in design have a big effect on strain and accident risk over many shifts.

Ergonomic design

Key ergonomic features include

Some manual pallet jacks offer adjustable fork height to deal with low or worn pallets. This feature lets you fine tune the minimum fork height so forks slide under damaged skids more easily.

Safety valves and controlled lowering

Overload valves protect the pump and frame if someone attempts to lift beyond the rated capacity. They limit internal pressure and keep the truck from raising the load further.

Flow control valves manage how fast the forks drop when you move the control to the lower position. This protects both the load and the floor and helps avoid sudden drops that could injure feet or cause goods to fall.

Brakes and parking features

Basic hand pallet jacks usually rely on careful use rather than full service brakes. Even so some designs offer parking brakes on steer wheels which help on gentle slopes and in trucks.

On powered pallet jacks braking systems are more involved. Electric units typically combine electric braking with mechanical parking brakes. Features such as automatic slowing in tight turns and cut off when the handle is in an extreme position add protection for operators and bystanders.

Protection for operators and goods

Rounded fork tips closed fork designs and smooth welds reduce the chance of pallets catching and splitting. Some stainless steel pallet jacks use fully closed forks to reduce zones where dirt and bacteria can stick.

Hand guards and adequate distance between handle and chassis keep hands clear in tight turns. Good ground clearance at the fork tips reduces the risk of snagging floor joints at speed.

Special pallet jack feature options

Beyond the basic hand pallet truck many specialised versions offer extra functions. Common feature families include low profile pallet jacks high lift designs pallet jacks with scales and corrosion resistant models for harsh environments.

Low profile pallet jacks

Low profile pallet jacks use thinner forks to reach under pallets with very low entry height. Some models start as low as around 51 millimetres. They are helpful when you work with low pallets or some imported skids that sit closer to the floor than standard designs.

Because the frame is thinner capacity can be lower than a standard truck so always check ratings.

High lift and scissor pallet jacks

High lift pallet jacks use a scissor mechanism to raise pallets to bench height. They combine short transport moves with ergonomic work positioning for packing assembly and repair tasks.

Many high lift models include stabiliser legs that touch the floor when the forks pass a set height. At that point the truck no longer rolls and behaves more like a fixed lift table which protects stability at height.

Pallet jacks with built in scales

Weighing pallet jacks combine a manual or electric pallet truck with a scale system in the forks and a display on the handle. Typical models handle up to around 2 000 kilograms while showing weights in small steps such as 0.1 or 0.5 kilogram.

These feature sets are useful when you must record shipping weights check incoming goods or mix materials by weight without sending pallets to a separate scale. They save time but cost more than a standard truck and need battery power for the display.

Stainless steel and corrosion resistant models

Stainless steel pallet jacks are built for food processing chemical plants clean rooms and other aggressive or hygienic environments. Frames forks axles and fasteners often use stainless steels such as AISI 304 with smooth surfaces and closed sections.

These features allow frequent washdowns and resist rust. Nylon or stainless steel bearings and bushings avoid corrosion where standard carbon steel parts would fail quickly. Capacity can match or slightly trail that of similar painted steel models depending on design.

Silent and low noise pallet jacks

Some pallet jacks are designed to run quietly in retail and residential delivery work. They combine softer wheel materials good shock absorption and tight dimensional control so wheels and joints do not rattle over joints and thresholds.

Low noise certification schemes in some regions require maximum rolling noise below a set decibel level over test surfaces. These trucks reduce disturbance during night deliveries and early morning store work.

Adjustable pallet jacks in detail

Adjustable pallet jacks are a special group where the distance between forks can be changed to fit different pallet sizes. Instead of two fixed forks welded to the frame these trucks use sliding or repositionable forks linked by adjustable rods or cross members.

How adjustable pallet jacks work

On many designs each fork slides along a support frame. Adjustable connecting rods and guide beams keep forks parallel. A locking system usually pins forks at set positions to prevent movement under load.

Typical adjustable manual pallet jacks offer ranges such as

In inch based markets an adjustable pallet jack might cover fork widths from about 530 millimetres up to around 685 millimetres which corresponds roughly to 21 to 27 inch width for narrow through standard pallets.

Capacity on adjustable pallet jacks often sits around 2 000 to 2 500 kilograms similar to many standard pallet trucks though some ranges reach 3 000 kilograms.

Where adjustable pallet jacks help most

Adjustable pallet jacks are valuable when you

By setting a narrow fork spacing you can collect small pallets or special skids without tilting them. By widening the forks you still support standard euro or block pallets correctly.

Limitations and tradeoffs

An adjustable pallet jack has more moving parts than a simple fixed width truck. This usually makes it heavier and more expensive. Sliding fork arrangements also need regular cleaning and lubrication especially in dusty or corrosive environments.

Some adjustable designs limit how close forks can get to their outer range because of fixed front supports. This can restrict use with very wide pallets or long loads.

For operations with only one or two pallet sizes standard fixed width pallet jacks are often cheaper and simpler to maintain. Adjustable models shine in mixed fleets and specialist industries where pallet sizes vary daily.

Choosing pallet jack features for your operation

When you choose features think about your environment equipment mix and long term plans rather than just the next month of work.

For simple back room and light warehouse work a standard manual pallet jack with 2 000 or 2 500 kilogram capacity standard fork length and good polyurethane wheels is often enough.

In food processing or pharma look for stainless steel trucks with closed forks smooth welds and corrosion resistant bearings. Combine this with appropriate wheel materials that handle both washdowns and any chemicals on the floor.

Where operators move many pallets per shift or work on ramps consider electric pallet jacks with strong drive motors controlled lowering and solid braking features. Match fork length to your trailers and dock layout.

If you support many pallet sizes or run a rental store adjustable pallet jacks can reduce the number of different models you need. Make sure the adjustment range covers your smallest and largest pallets and that staff learn how to set and lock the forks correctly before use.

For specialist work such as order checking blending and shipping weight control pallet jacks with built in scales can save repeated trips to static scales and tighten inventory control.

Checklist when comparing pallet jack specifications

When you review spec sheets from different brands focus on these items.

References