An all terrain forklift is a counterbalance forklift with large pneumatic tyres and extra ground clearance, built to lift on gravel, mud and unsealed yards instead of concrete floors. It's also called a rough terrain forklift or an off road forklift, and all three names mean the same machine. Many models add switchable 4WD and a differential lock for soft or loose ground. All terrain doesn't mean any terrain, though: the slope limits in the operator manual and the load chart still apply.
All terrain forklift vs warehouse forklift
An all terrain forklift and a warehouse forklift share the same layout, with a mast at the front and a counterweight at the back. The differences are in the tyres, chassis and drive. The table uses Hangcha rough terrain figures against a typical indoor counterbalance forklift.
| All terrain forklift (Hangcha) | Warehouse counterbalance forklift | |
|---|---|---|
| Tyres | Large deep-tread pneumatic tyres, solid tyres optional | Usually smaller solid or press-on tyres for concrete |
| Ground clearance | About 235-290 mm (1.5-3.5 t), 370-424 mm (5-10 t) | Low, built for flat floors |
| Drive | 2WD, or switchable 2WD/4WD with a differential lock | Two-wheel drive |
| Laden gradeability | Up to 32% (2WD diesel), up to 60% (4WD diesel), up to 63% (lithium) | Usually lower, built for docks and ramps |
| Turning radius | About 2,900 mm (2WD) to 3,300 mm (4WD) on 2.5-3.5 t models | Tighter, built for aisles |
| Power | Diesel or high-voltage lithium | Electric, or LPG with good ventilation |
| Where it works | Building sites, yards, farms, unsealed ground | Warehouses, docks, sealed yards |
| Licence | LF high risk work licence | LF high risk work licence |
An all terrain forklift trades tight turning for grip, clearance and climbing ability. On a smooth warehouse floor it's the wrong tool: it turns wider, and diesel versions produce exhaust.
How a rough terrain forklift handles rough ground
A rough terrain forklift copes with rough ground through its tyres, clearance, steer axle and drivetrain.
Tyres and ground clearance
Hangcha rough terrain forklifts run large deep-tread pneumatic tyres as standard. The 1.5-3.5 t models use 12-16.5 or 14-17.5 front tyres, and the 10 t model uses 17.5-25. Solid tyres are an option for puncture-prone sites.
Ground clearance is about 235-290 mm on the 1.5-3.5 t models and 370-424 mm on the 5-10 t models. That clearance lets the chassis pass over ruts and rubble that would ground a warehouse truck.
Oscillating steer axle and drivetrain
An oscillating steer axle lets either rear wheel ride up over a rock or rut while the truck and load stay level. On 4WD models, a switch selects 2WD or 4WD. A differential lock stops power escaping to one spinning wheel. Drive goes through a hydraulic torque converter transmission with three forward gears and a top speed of about 23-28 km/h.
Mast, tilt and load centre
The standard mast is 3.0 m, with options up to 6.0 m (5 m on the 7 t and 10 t models). On the 1.5-3.5 t models, masts up to 4.7 m tilt 10 degrees forward and 12 degrees back. Taller masts are limited to 6 degrees each way.
Capacity is rated at a 500 mm load centre on models up to 3.5 t and 600 mm on the 5-10 t models. A long or bulky load moves the load centre out and cuts what the machine can lift.
2WD or 4WD rough terrain forklift?
Choose a 2WD rough terrain forklift for firm, dry, compacted yards and site roads, and 4WD for mud, sand, loose gravel or steeper unsealed ground. 4WD adds drive to the rear wheels, so the machine keeps traction when the front wheels start to slip.
The climbing figures show the gap. On Hangcha 2.5-3.5 t diesel models, laden gradeability is about 22-32% on the Hangcha rough terrain forklift 2WD 2.5-3.5 t, and up to 60% with 4WD.
4WD has trade-offs. The turning radius grows from about 2,900 mm to 3,300 mm on the 2.5-3.5 t models, and there's more driveline to maintain. The weight penalty is small: the 4WD version weighs only about 100-220 kg more. In the larger sizes, the 5 t and 7 t come in 2WD or 4WD, and the 10 t is 4WD only.
A 4WD machine usually costs more than the same model in 2WD, so don't pay for it if your ground is firm all year. For current price ranges, see this guide to how much an all terrain forklift costs.
Diesel or lithium all terrain forklift?
A diesel all terrain forklift suits sites with no power for charging, while a lithium model suits sites that can charge on site and want no exhaust.
The Hangcha high-voltage lithium rough terrain forklift comes in 2.5-3.5 t, in 2WD or 4WD. It runs a 317 V, 150 Ah battery of about 46.4 kWh that charges fully in about 1.5 hours. It's rated up to 63% laden gradeability, and its high-voltage components are rated IP67 (the rating covers those parts, not the whole machine).
Electric models cost more to buy but less to fuel and service. Hangcha claims energy costs up to 90% lower than diesel, but real savings depend on your hours, shifts and power prices.
One of these lithium machines works at Kimbriki Environmental Enterprises, a waste and resource recovery site at Terrey Hills in Sydney, which bought it through DJJ Equipment. The site handles about 280,000 tonnes of waste a year and runs seven days a week. Dust got into the seat harness connection, so DJJ fitted a dedicated harness connection socket at no charge. Kimbriki agreed to be named only after the first service.
Where rough terrain forklifts are used
Rough terrain forklifts are used on building sites, timber and building supply yards, landscape supply yards, farms, and waste and recycling sites. On these sites pallets and bundles sit on gravel, dirt or broken concrete, where a warehouse truck would bog or bottom out.
They're the wrong choice for a warehouse with smooth floors and racking, where a standard counterbalance forklift turns tighter and fits narrower aisles. If your yard is sealed and the work often moves inside, a counterbalance forklift on pneumatic tyres may be enough. Several forklift manufacturers build rough terrain ranges, and we sell Hangcha's.
All terrain forklift vs telehandler
An all terrain forklift lifts straight up on a mast, while a telehandler lifts and reaches forward on a telescopic boom. The boom lets a telehandler place loads over a trench, onto scaffolding or into the middle of a truck deck.
That reach has a cost. Capacity falls as the boom extends, which is why telehandlers use a load moment indicator.
A rough terrain forklift is usually simpler, more compact and cheaper. It's the better pick when loads only go up and down close to the machine, and a telehandler is better when you regularly reach over something.
Slopes, load charts and tip-over risk
Slopes and load height are where rough terrain forklifts get into trouble. A gradeability figure is a drivetrain test result, not a safe working slope. The safe slope limit is in the operator manual for your model, so check it before the machine goes near a bank.
Capacity also drops as the forks go higher and the mast tilts forward. Take our example of a Hangcha 3.5 t rough terrain forklift. It lifts 2,900 kg at 3.2 m with the mast vertical, 1,890 kg tilted forward and 1,320 kg at 4.5 m tilted forward.
Hangcha also publishes a separate rough terrain rating under ISO 22915-13, which is lower again. A 1.8 t model is rated 900 kg at 6.0 m on firm ground, but only 800 kg on the rough terrain test. Side shift costs capacity too: on the 2.5-3.5 t lithium model, an integral side shifter takes off about 200 kg and an external one about 300 kg.
Safe Work Australia guidance for forklifts on slopes and uneven ground comes down to a few habits:
- Keep the combined centre of gravity of truck and load inside the stability triangle formed by the two front wheels and the rear axle pivot. Overloading, sharp turns at speed and a raised load push it outside.
- Drive forwards up a slope and reverse down it when loaded, so the load stays on the uphill side.
- Never turn on a slope or drive across it.
- Travel with the forks as low as practical.
- Wear the seatbelt whenever one is fitted, because it keeps you in the seat if the machine tips.
Hangcha rough terrain forklifts come with an overhead guard that protects the operator from falling objects, and an enclosed cab is an option. Never drill, weld or modify the guard.
Do you need a licence for an all terrain forklift?
Yes, anyone operating an all terrain forklift in Australia needs a high risk work licence in class LF, because the machine has a mast and an elevating load carriage. Training is through a Registered Training Organisation, and your state or territory regulator issues the licence. A trainee may operate only while enrolled in the course and directly supervised by a licence holder.
Telehandler licensing is different and varies by state. In NSW, a telehandler fitted with forks or a bucket doesn't need a high risk work licence, but the business must train its operators. In Victoria, non-slewing telehandlers rated over 3 t have needed a high risk work licence since 1 July 2024. Fitting a jib, hook or work platform can bring in a crane or WP licence. Check the current rules with your state regulator, such as SafeWork NSW, WorkSafe Queensland or WorkSafe WA.
An all terrain forklift is the right machine when your loads sit on ground a warehouse truck can't handle. DJJ sells Hangcha rough terrain forklifts from 1.5 to 10 t from Silverwater NSW, Meadowbrook QLD and Bayswater WA, and hires selected models subject to availability. Tell us the load weight, lift height, ground and hours a day you run, and our team will recommend options to buy or hire. Call 1800 355 388.
