What are the different types of pallet trucks?

1. Manual Pallet Trucks (The Standard Jack)

The manual pallet truck is the workhorse of small warehouses and retail backrooms.1 It relies entirely on human power for both lifting and propulsion.2

Engineering and Mechanism

Manual trucks operate via a hydraulic pump handle.3 To lift the load, the operator pumps the handle up and down, forcing oil into the cylinder and raising the forks.4 To lower the load, a small lever (the "drop valve") on the handle is squeezed, releasing the hydraulic pressure.5

Key Specifications:

Capacity: Typically ranges from 2,000kg to 3,000kg.

Wheels: Usually made of Polyurethane (for quiet operation on smooth floors) or Nylon (for lower rolling resistance on heavy loads).

Steer Angle: Often features a 180° to 210° turning radius for tight spaces.

Best Use Cases:

Short-distance horizontal transport.

Low-volume loading docks.6

Environments where noise and fumes must be avoided.

2. Electric Pallet Trucks (Power Jacks)

As throughput increases, manual effort becomes a bottleneck. Electric pallet trucks (EPTs) use battery power to handle the heavy lifting and movement.7

Powered Pallet Trucks (Walkies)

The "Walkie" is the most common electric variant. The operator walks behind or alongside the truck while controlling speed and lift via a tiller arm.8

Productivity: Eliminates physical strain, allowing for faster travel speeds (usually up to 6 km/h).

Safety Features: Includes an "emergency belly button" on the tiller that reverses the truck's direction if it contacts the operator.

Rider Pallet Trucks

For massive distribution centers, "Ride-on" trucks allow the operator to stand on a fold-down platform or sit in a dedicated compartment.9

Long Distances: Designed for transporting goods across facilities that span hundreds of thousands of square feet.

High Speed: Can reach speeds of 10–12 km/h.

3. Specialized Pallet Trucks for Harsh Environments

Standard steel trucks will succumb to rust or chemical degradation in specific industries. Specialized materials are required for longevity.

The Stainless Steel Advantage

In food processing, hygiene is paramount. Stainless steel pallet trucks are designed to withstand "washdown" procedures involving high-pressure water and caustic cleaning agents.10 They feature sealed bearings and food-grade grease to prevent contamination.

4. Weigh Scale Pallet Trucks

Efficiency in logistics often requires knowing the weight of a load before it hits the shipping lane.11 A weigh scale pallet truck integrates a weighing system directly into the forks.12

How it Works

The forks are equipped with load cells—transducers that convert the force of the load into an electrical signal.13 An integrated LCD screen provides the weight readout, often with an accuracy of +/- 0.1% of the applied load.

Advantages:

Time-Saving: Eliminates the need to travel to a stationary floor scale.

Revenue Protection: Ensures outgoing shipments match the weight declared on the Bill of Lading.

5. High-Lift Pallet Trucks (Scissor Lifts)

Standard pallet trucks only lift a few inches off the ground.14 High-lift variants, or scissor lift pallet trucks, can raise loads up to 800mm.15

Ergonomic Benefits

These are primarily used as work positioners. By raising a pallet to waist height, workers can load or unload boxes without bending over, significantly reducing the risk of musculoskeletal injuries.

Safety Note: Once raised above a certain height, stabilizing legs deploy automatically to prevent the truck from moving or tipping.

6. Rough Terrain Pallet Trucks

Standard trucks require a flat, finished concrete floor. For construction sites, garden centers, or gravel yards, a rough terrain truck is necessary.

Design Differences:

Large Pneumatic Tires: These absorb shocks and provide traction on uneven soil or gravel.

Wide Straddle Legs: Provides a wider center of gravity to prevent tipping on slopes.

Lightweight Frame: Often built with heavy-duty tubular steel to handle the torsion of uneven ground.

7. Low-Profile and Extra-Long Trucks

Standard pallets have a standard entry height, but international shipping often involves "low-profile" pallets or crates that sit closer to the ground.

Low-Profile Trucks: Feature a lowered fork height of just 35mm to 50mm (compared to the standard 85mm).

Extra-Long/Short: Fork lengths can be customized. Extra-long forks (up to 2400mm) can carry two pallets at once, while short forks are used for navigating the cramped "side-loading" aisles of delivery trucks.

Summary of Selection Criteria

When choosing a pallet truck, engineers and warehouse managers should utilize the following matrix:

Floor Surface: Is it smooth concrete (Standard), gravel (Rough Terrain), or wet (Stainless)?

Travel Distance: Is it under 30 meters (Manual) or over 100 meters (Rider Electric)?

Load Weight: Does it exceed the 2,500kg limit of a standard manual jack?

Special Requirements: Do you need to weigh the load or use it as a workbench (High-Lift)?

Conclusion

The evolution of the pallet truck reflects the broader trends in the supply chain: a push for higher speed, better ergonomics, and greater data integration. From the simple manual jack to the high-speed electric rider, understanding these nuances ensures that your material handling operation remains both safe and profitable.