Pallet trucks are among the most widely used industrial trucks for internal transport. Whether in a warehouse, workshop, or outdoor use – almost nothing can be done without a pallet truck. However, not all pallet trucks are the same. Differences in design, weight, and function determine which type is suitable for which application. In this guide, you'll learn everything you need to know about pallet trucks: what types there are , what to consider when buying or using them, and how the various models differ in detail.
Why the pallet truck weight matters
The dead weight of a pallet truck affects not only its handling, but also its load-bearing capacity, maneuverability, and transport – especially when using ramps, loading trucks, or in mobile applications. Devices with additional technology such as scissor lifts or scales weigh more and require correspondingly more effort or more powerful drives .
Overview: Types of pallet trucks and their average weight
| Type | Average weight | Load capacity | Description |
|---|---|---|---|
Hand pallet truck (standard) |
approx. 65 kg | approx. 2,000–2,500 kg | Compact classic for ground-level pallet transport on almost all surfaces. |
Scissor lift truck |
approx. 120 kg | approx. 1,000–1,500 kg | Ergonomically height adjustable up to 800 mm – also ideal as a mobile workstation. |
Weighing pallet truck |
approx. 110–115 kg | approx. 1,500–2,000 kg | With integrated scale for weighing and transport in one step – optionally with printer. |
Electric pallet truck (compact) |
from 85 kg | approx. 1,200–1,500 kg | Lightweight design like the “Agile” – electrically driven and lifted with minimal dead weight. |
Electric pallet truck (standard) |
approx. 200 kg | approx. 1,600–2,000 kg | Fully-fledged devices with battery, electric motor and control – ideal for medium distances. |
High lift truck (manual/electric) |
approx. 260–300 kg | approx. 1,000–1,600 kg | For lifting heights up to 3,000 mm – perfect for loading and unloading in shelving systems. |
All-terrain pallet truck |
approx. 220–240 kg | approx. 1,000–1,500 kg | Robust construction with coarse-tread wheels for unpaved surfaces such as gravel and grass. |
Which pallet trucks are suitable for which surfaces?
Choosing the right pallet truck depends heavily on the location and surface . Here's an overview:
| Forklift type | Suitable substrates | Typical areas of application |
|---|---|---|
Hand pallet truck |
Asphalt, concrete, industrial flooring, tiles | Warehouses, ramps, transporters, platforms |
Weighing pallet truck |
Industrial floors, tiles, loading ramps | Goods receipt, picking |
Scissor lift truck |
Smooth industrial floor | Assembly, packaging, workplaces |
High lift truck |
Concrete, asphalt, ramp (electric only) | Shelf operation, loading and unloading |
All-terrain pallet truck |
Gravel, meadow, cobblestones | Outdoor storage, construction site, exhibition stand construction |
What components does a pallet truck consist of?
A pallet truck has a simple design – but that's precisely what makes it so robust and reliable. Here are the most important components you should know:
1. Drawbar with steering handle
Used for pulling, steering, and controlling. The integrated lever controls the hydraulics for lifting, lowering, and driving.
2. Drawbar mounting screw
Securely attaches the drawbar to the hydraulic block. Important for safe power transmission when steering and pumping.
3. Forks / Chassis
Solid steel construction for load transport. The two tines extend under the pallet. The hydraulic unit is located at the rear.
4. Hydraulic unit
The core of the lifting function: Through a pumping movement, it generates the necessary pressure to lift the load.
5. Steering wheels
Two wheels for steering the pallet truck. Usually with a rubber or PU coating for smooth handling on smooth surfaces.
6. Steering wheel fork
Connects the steering wheels to the frame and allows them to rotate.
7. Bearing bridge / support plate
Stabilizes the connection between the hydraulic unit and the fork frame. Important for even load distribution.
8. Push rod
Transfers the pumping force from the drawbar to the hydraulics. Without it, there is no lifting function.
9. Control rod
Connects the lowering mechanism to the valve control in the hydraulic unit.
10. Return spring
Ensures that levers and rods return to their original position after operation.
11. Coupling for valve control
Controls the “lift”, “neutral” or “lower” function via a lever.
12. Load rollers
Mounted under the tines – they carry the weight of the pallet and roll over the ground.
13. Reach fork with roller holder
Connects fork and load roller mechanism – crucial for lifting stability and freedom of movement.
Electric or specialized pallet trucks have additional components, such as:
- Battery and charging unit (for electric pallet trucks)
- Weighing unit (for pallet truck scales)
- Scissor mechanism (for scissor lift trucks)
What you should pay attention to when using it
- Check load capacity: Never overload – the maximum load capacity is clearly marked.
- Pay attention to the center of gravity: Especially on ramps, the load distribution can shift dangerously.
- Don't forget maintenance: Regular inspection is crucial for safety and longevity, especially with electric or hydraulic versions.
- Choose suitable wheels: Polyurethane wheels are recommended for hard floors, while rubber or pneumatic tires are better for uneven surfaces.
Which hydraulic oil does your pallet truck need?
To ensure your pallet truck lifts and lowers reliably and runs smoothly over the long term, it needs the right hydraulic oil. In most cases, HLP 46 is used – a high-quality hydraulic fluid with good lubricating properties, reliable corrosion protection, and ideal viscosity for normal operating temperatures.
HLP 32 – VG 10 is suitable for more sensitive applications such as cold storage or deep-freeze storage areas . This oil remains fluid even at subzero temperatures and prevents loss of performance or damage caused by viscous hydraulic fluid. In the food industry, the use of food-safe specialty oil is mandatory – look for NSF-H1 certified lubricants.
A typical hand pallet truck requires approximately 500 to 600 ml of hydraulic oil . If lifting performance decreases, unusual noises occur, or the truck is used for extended periods, the oil level should be checked. Abrasion, leaks, and dirt can impair functionality. Therefore, check the oil annually—and if in doubt, change it sooner . This ensures that your truck remains efficient and safe at all times.
Conclusion: The right pallet truck saves time, energy and money
Pallet trucks aren't one-size-fits-all products – they must be tailored to your application. Considering the weight, design, and surface conditions not only ensures greater efficiency but also greater safety in operation. Whether you need a compact hand pallet truck or a professional all-terrain vehicle – at BIBERGER, we provide independent, targeted advice to ensure your transport runs smoothly.
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