Pallet Jack Types
Pallet jacks also called pallet trucks come in many types. Each type is tuned for certain loads environments and levels of use. When you choose the right type you protect people reduce damage and keep pallets flowing smoothly through your building.
Pallet jacks also called pallet trucks come in many types. Each type is tuned for certain loads environments and levels of use. When you choose the right type you protect people reduce damage and keep pallets flowing smoothly through your building.
This guide walks through pallet jack families in detail. It covers how each type is built where it works best and what tradeoffs to keep in mind.
How pallet jacks are built
Most pallet jacks share a few core parts.
A steel frame with two forks carries the pallet. Fork length and the distance between forks vary with pallet standard and purpose.
At the front of the forks sit small load wheels. At the rear a steer axle carries larger steer wheels connected to the handle or tiller. This layout lets the operator lift the pallet then steer around tight corners.
A compact hydraulic unit raises and lowers the forks. On manual trucks a hand pump in the handle builds pressure and cylinders push the forks down relative to the wheels so the load rises. On electric units an electric motor drives the pump and controls in the tiller manage lift and lower functions.
Frame capacity and wheel choice set the basic limits of the truck. Heavy frames and strong hydraulics carry more weight but increase cost and rolling resistance. Wheel material must match floor type noise limits and temperature.
From this base manufacturers create many types tuned for specific jobs.
Manual pallet jacks in depth
Manual pallet jacks are the basic workhorses of many warehouses and workshops. They rely on human effort for travel and a simple hydraulic pump for lift.
Standard manual pallet jacks
A standard manual pallet jack covers most everyday pallet moves on good concrete floors.
Common features include
- Capacity around 2 000 to 2 500 kilograms
- Fork length near 1 150 millimetres to suit euro pallets
- Overall fork width around 520 millimetres for euro pallets or about 685 millimetres for larger pallets
- Polyurethane steer and load wheels that balance low rolling resistance with quiet running
They suit short routes docks trailers and back rooms where many people share equipment and loads are moderate.
Low profile manual pallet jacks
Low profile pallet jacks have reduced fork entry height so they can enter pallets with low openings thin bottom deck boards or heavy wear.
Typical minimum fork height can drop from roughly 85 millimetres for a standard truck to around 51 millimetres or less on some models. This matters in import export work recycling and sites with mixed non standard pallets.
The lower fork section can be more vulnerable to impact so low profile trucks should not be used to ram loads or strike dock edges.
Short and ultra short pallet jacks
Short fork manual pallet jacks use fork lengths in the range of 600 to 900 millimetres. Ultra short versions go even shorter.
They are meant for
- Small trucks vans and tail lift deliveries
- Cold rooms and small stores with tight aisles
- Turning pallets in narrow service corridors
Short forks reduce turning radius but they must still support the pallet well enough. For large pallets this can mean lifting from the side rather than fully lengthwise and may reduce stability at high loads.
Long and extra long pallet jacks
Long fork pallet jacks extend fork length beyond the standard range to about 1 800 or 2 000 millimetres and sometimes further.
They can
- Carry two pallets at once when the load and route allow it
- Support long crates and machinery skids
- Reduce trips in production lines where pallets queue nose to tail
Long trucks need wider turning space and careful training because the long forks can swing through a bigger arc and create collision risk near racks or walls. Floor strength and dock design must support the longer load path.
High capacity manual pallet jacks
High capacity manual pallet jacks serve dense loads such as stone tiles metal coils and beverages.
They may offer capacities of 3 000 kilograms 5 000 kilograms or higher. Frames are heavier and wheels and axles are larger. Hydraulic units use bigger pistons and stronger seals.
Pulling these loads by hand takes significant effort. In many sites high capacity manual trucks are used sparingly or as backup where an electric pallet jack or forklift normally handles the worst loads.
Low temperature and cold store manual pallet jacks
Cold rooms and freezers demand special materials. Low temperature manual pallet jacks use
- Hydraulic oil that stays fluid at low temperature
- Seals and hoses that remain flexible
- Greases that resist water and do not harden in the cold
- Wheels that keep grip on damp cold floors
These trucks often have stainless axles or coated components to stand up to condensation and frequent cleaning.
Spark resistant and explosion protected manual pallet jacks
In some chemical and paint plants and in areas with flammable vapours or dusts companies use pallet jacks with spark resistant features.
Frames may use bronze or other non ferrous material for key contact points. Wheels and forks are designed to reduce the risk of sparks when they strike small obstacles. These units are specialised and must be matched to the hazard classification of the area and local rules. Suppliers usually provide documentation and consultative support for these cases.
Electric pallet jacks bring powered drive and lift to pallet handling. They reduce physical effort and speed up work in busy facilities. Learn more about automated pallet jacks and their benefits.
They use electric drive motors often with electric lift as well. Battery power can be lead acid or lithium depending on design and duty cycle.
Walkie electric pallet jacks
Before selecting a pallet jack review the work environment load types and operator preferences. Match the truck type to the job rather than choosing based on price alone. Consider renting equipment before making a purchase decision.
Typical features
- Capacity from about 1 600 to 2 700 kilograms
- Travel speeds higher than manual trucks yet still limited for safety
- Electric lift with simple push button control
- Regenerative or electromagnetic braking systems
Walkies work well in docks short to medium aisles and mixed workplaces where people walk and ride equipment in the same areas.
Walkie pallet jacks with fold down platforms
Some walkie pallet jacks add a small fold down platform at the rear. The operator can ride on short hops then fold the platform up for tight spaces.
They suit cross docks and retail distribution where routes vary between tight pedestrian aisles and longer clear stretches.
Rider and center controlled pallet trucks
Rider pallet trucks put the operator fully on board. Stand on end rider trucks are common for fast horizontal moves. Center controlled models put the operator in the middle behind a console for long runs in big facilities.
These units often handle
- Store order pallets in grocery and retail distribution
- Pallet shuttles between long staging lanes and docks
- Heavy traffic in cross dock and hub terminals
They move quickly so they demand well marked aisles good floor maintenance and strong training around turning clearances and stopping distances.
Li ion and advanced battery options
Modern electric pallet jacks increasingly use lithium ion batteries. Benefits can include
- Fast opportunity charging during breaks
- More cycles before replacement compared with many lead acid packs
- Flat voltage curve over much of the discharge cycle
Battery change systems vary. Small walkies often use simple drop in packs while larger riders may use slide out or side entry batteries and dedicated change equipment. Charging infrastructure and ventilation must match the chemistry used.
High lift and scissor pallet jacks
High lift pallet jacks and scissor pallet jacks combine limited travel with lifting to work height.
Manual high lift pallet jacks
Manual high lift units look like pallet jacks with a taller scissor frame. The operator pumps the handle to raise the fork platform up to around 800 or 1 000 millimetres.
They are used as
- Work positioners at packing benches
- Loading aids for light assembly lines
- Adjustable stands for inspection and rework
As the load rises stabiliser legs often touch the floor to keep the unit steady. Once the legs are down the truck should not be moved with a person on board or with the load raised.
Electric high lift pallet jacks
Electric high lift variants use an electric pump for lift while travel is usually manual and limited to low height.
They suit higher frequency work where constant pumping would tire operators. They still must respect capacity and stability limits and are usually kept in fixed work areas rather than used for general transport.
Rough terrain and all terrain pallet jacks
Rough terrain pallet jacks serve builders yards farms nurseries and outdoor storage areas where floors are not smooth.
Key features
- Large pneumatic or foam filled tyres to roll over stones and cracks
- Higher ground clearance than warehouse pallet jacks
- Wider stance and stronger frames to cope with uneven support
- Often adjustable fork spacing for different pallets and crates
Some models are purely manual and best for moderate loads on fairly level ground. Others add engine or electric power so they can climb grades and handle heavy pallets over longer distances.
Rough terrain trucks do not replace rough terrain forklifts for very heavy loads or steep ground but they are useful for short last metre moves in tight spaces and low roofed areas where forklifts cannot operate easily.
Stainless steel and galvanised pallet jacks
Where hygiene or corrosion risk dominates stainless and galvanised pallet jacks are common.
Stainless pallet jacks
Stainless pallet jacks use stainless grades for frames forks axles and many fittings. They are designed so that
- Surfaces are smooth and easy to wash
- Water and food residues do not collect in hidden pockets
- Corrosion from salt and cleaning chemicals is reduced
They are found in meat and dairy plants fish processing lines bakery production and pharmaceutical packing and clean support areas.
Galvanised pallet jacks
Galvanised pallet jacks coat steel frames and components in a thick zinc layer. This offers strong corrosion resistance at a cost below full stainless construction.
They see use in chilled stores outdoor loading zones and chemical storage where occasional splashes or wet conditions would shorten the life of standard painted trucks.
Weighing pallet jacks and scale trucks
Weighing pallet jacks combine a pallet jack frame with an integrated scale system.
Key points
- Load cells under the forks or frame sense weight as soon as the pallet rises clear of the floor
- A digital display shows weight to a stated resolution and accuracy band
- Some models add printers data logging or wireless connection to warehouse systems
Applications include goods receiving where staff verify supplier weights batching stations in production and shipping zones where pallet weights feed freight documents. Where legal for trade use is needed the scale system must carry relevant approvals and be maintained within calibration rules.
Special and adjustable pallet jack designs
Real operations often have loads that do not fit standard pallets. Manufacturers offer many special designs to match these needs.
Narrow and wide body pallet jacks
Narrow pallet jacks work in tight aisles and between closely spaced pallets. Wide body trucks suit broad custom pallets containers and stillages. Matching frame width to load footprint improves stability and reduces the chance of striking racking or goods.
Reel and coil pallet jacks
Reel and coil pallet jacks use cradle shaped forks or frames that hold rolls and coils along their axis. They support cable drums paper reels and similar cylindrical loads. The cradle keeps the load centred and prevents it from rolling off during travel.
Drum handling pallet jacks
Drum pallet jacks include clamps hooks or cradles to handle steel and plastic drums. Some lift drums vertically on pallets while others can tilt or rotate them for emptying. They reduce the need for manual drum tipping and lower the risk of spills.
Order picking pallet jacks and platform trucks
Order picking pallet jacks carry one or more pallets or cages as a mobile base for pickers. They may include platforms for operators to ride and controls optimised for frequent starting stopping and steering in picking aisles.
Platform pallet trucks with short fixed platforms serve similar needs for bulkier loads and roll cages.
Adjustable fork pallet jacks
Adjustable fork pallet jacks allow the operator to change fork spacing to fit different pallets. This is helpful in facilities that handle euro pallets block pallets special display pallets and custom skids with one fleet of trucks.
Adjustment can be manual with sliding forks and locking pins or in some advanced designs semi automatic with guides and simple locking systems.
Automated pallet jacks and pallet moving robots
Automated pallet jacks combine a powered pallet jack base with navigation sensors and control systems. They move pallets between defined points with little or no human steering.
Common uses
- Horizontal transfers in large warehouses and factories
- Feeding and clearing conveyor infeed and outfeed points
- Linking distant zones where manual travel time is high
They rely on fleet control software maps and safety scanners to work around people and other vehicles. Planning and standardisation of pallet types routes and rules are important before deployment.
How to choose between pallet jack types
Most operations benefit from a small family of pallet jack types chosen to match real work rather than a single catch all design.
Key points to review
- Typical and maximum pallet weight and centre of gravity
- Pallet standards in use and any non standard loads such as drums reels and cages
- Floor quality including slopes thresholds cold rooms and outdoor yards
- Travel distances and how many pallet moves each shift
- Hygiene needs washdown routines and exposure to chemicals or salt
- Available power supply and space for charging or parking equipment
- Future plans for automation or layout change
Manual pallet jacks handle light and varied work. Electric pallet jacks cover high volume and heavier weights. High lift and weighing types support specific stations. Rough terrain stainless low profile and special form trucks solve focused problems where standard designs struggle. Automated pallet jacks become attractive once flows are stable and repetitive.
Review choices with operators safety specialists and suppliers. The best mix is the one that lets people move pallets safely with the least effort while fitting the limits of your building and budget.