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A compact electric truck combining horizontal transport with mast-assisted pallet stacking, suited to moderate rack heights and tight aisles.
Definition
A powered stacker sits between a low-lift pallet truck and a counterbalance forklift. A mast, lift cylinder and hydraulic system allow rack loading, while support legs commonly replace a heavy counterweight. This makes the truck lighter and narrower, but usually limits load and lift capability. It suits smaller warehouses with moderate rack heights and pallet weights.
Pallet Trucks, Stackers and Forklifts
Pallet trucks provide low lift for transport. Stackers add a mast for rack loading, generally with legs that must fit beneath pallets or racking. Counterbalance trucks eliminate front legs and offer wider access and greater capacity, at the cost of weight, length and aisle space. Match rack height and pallets before checking clearance and payload.
Support-Leg and Counterbalance Designs
Support legs carry load directly to the floor and keep the truck compact. Closed rack bases, obstructed pallet undersides or items that must be straddled can prevent access. Counterbalance stackers remove this obstruction but become heavier, longer and more expensive. Recheck leg compatibility whenever pallets or racks change.
Mast and Lift System
Single-, two- and three-stage masts trade collapsed height against maximum lift. Free lift raises forks without increasing overall mast height, useful in containers or low spaces. Unequal chain tension, worn rollers and failed cylinder seals can cause tilt, vibration or unintended lowering and need regular inspection.
Operating Safety
Raised loads increase the centre of gravity. Travel with forks low; align at the rack before lifting. Avoid travelling or turning with elevated loads. Check the capacity chart for actual load centre and height, fully engage the pallet and confirm people are clear when visibility is obstructed.
Selection and Use
Measure top storage height, doorways, ceilings, minimum aisles and turning areas. Verify capacity for the heaviest pallet at its real load centre. Battery duty and support-leg compatibility often determine usable productivity. Recording lift cycles, height distribution and operating time can improve later fleet and storage planning.
Frequently Asked Questions
When should I choose a stacker instead of a forklift?
For moderate heights and loads in tight aisles, provided support legs fit the pallets and racks. Counterbalance forklifts offer broader access and capability but need more space.
What is a common stacker accident?
Overturning while travelling or turning with a raised load. Keep loads low during travel and respect the actual capacity chart rather than only the maximum nameplate rating.
Related Terms
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This glossary covers general industry concepts for technical reference and knowledge sharing. It contains no proprietary information from any specific manufacturer. For equipment specifications and operating procedures, always refer to the OEM documentation.