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The dimensions of pallet trucks and stackers affect where they can be used. They also determine how easily the vehicles can manoeuvre and how safely they can transport loads. Before choosing a model, consider several key measurements. This guide explains the most important pallet truck dimensions and how they affect manoeuvrability, handling and employee safety.
Why are pallet truck and stacker dimensions important?
The dimensions of a pallet truck or stacker determine which areas of a warehouse it can navigate. They also affect how quickly and safely you can store or retrieve goods. The vehicle’s width and length determine the aisle width required for safe operation. Its weight affects the floor’s load-bearing capacity and the point loading on the warehouse floor.
Pallet trucks and stackers – some quick definitions
Pallet trucks and stackers are two different types of material handling vehicles. Their dimensions and areas of use therefore differ.
A pallet truck is used to lift, transport and lower pallets and other underrideable goods clear of the ground. Both manual and electric models are available, as well as special application models.
Unlike pallet trucks, stackers can transport loads both horizontally and vertically. Depending on the model, they can also be used to load and unload lorries. Some stackers are suitable for storing and retrieving goods from warehouse racking.
Stackers are available with various mast types. These vary in their rated load capacities and maximum lifting heights. Unlike counterbalance forklifts, stackers do not require a counterweight. Instead, they pick up the load within the wheelbase.
Pallet truck width and length – key factors for manoeuvrability and material handling
Width and length are important pallet truck dimensions. They affect how easily pallet trucks and stackers can manoeuvre. They also determine the aisle width required for safe operation and the loads the vehicles can handle.
Fork carriage width
Standard pallet truck dimensions vary depending on the model and its intended application. Measure the width of a pallet truck or stacker at two points: the front structure and the forks. As a general rule, a narrower vehicle is easier to turn and manoeuvre. However, the right width also depends on the loads and pallets you need to transport.
On manual pallet trucks, the fork carriage width usually matches the overall width. On electric pallet trucks and stackers, the front structure usually determines the overall width. These are general guidelines rather than fixed rules. The exact dimensions depend on the vehicle type, particularly in the case of electric hand pallet trucks, manual hydraulic stackers and special designs.
The fork carriage width also largely determines which loads can be handled. A standard pallet truck fork carriage is usually between 520 mm and 540 mm wide. This width is suitable for transporting standardised Euro pallets.
However, there are also pallet trucks whose dimensions in width deviate from standard fork carriage widths:
- Extra-narrow fork carriage widths of 380 mm to 450 mm enable handling of piece goods such as cartons or boxes, display pallets, half pallets and quarter pallets (CHEP pallets)
- Extra-wide fork carriage widths of 670 mm to 685 mm enable picking up oversized pallets or handling Euro pallets crossways.
Stackers with standard fork carriage width are also suitable for handling standardised Euro pallets. Wide-track stackers are available for transporting pallets crossways or handling special pallet sizes.
The length of pallet trucks and stackers
Measure the length of a pallet truck or stacker at the front structure and the forks. The overall vehicle length consists of the front structure length plus the fork length. Together, the vehicle’s length and width influence its turning circle.
Fork length also affects which loads the vehicle can handle. The standard fork length for pallet trucks and stackers is 1,150 mm. This is suitable for transporting Euro pallets.
- Short forks measuring 800–1,000 mm are suitable for cartons, boxes, display pallets, half pallets and quarter pallets, including CHEP pallets.
- Extra-long forks measuring 1,207–2,100 mm can be useful for oversized pallets. They can also be used to pick up several pallets at once or transport pallets crossways.
Stacker dimensions: Height and overhead clearance
Stacker dimensions determine where the vehicle can be used. Height is particularly important in areas with restricted ceiling clearance. When choosing a model, consider both its lowered height and its maximum lift height.
The mast assembly is usually the highest point on a stacker. The vehicle’s height with the mast retracted is called the lowered height. This measurement varies according to the mast type and equipment. The lowered height and lift height are related. With a single-stage mast, the maximum lift height is lower than the lowered height. With a multi-stage mast, the vehicle can achieve a significantly higher lift height than its lowered height.
When checking the lowered height, make sure the stacker can move safely through all areas with restricted ceiling height. The mast must remain retracted and there must be sufficient overhead clearance. These areas may include:
- Clearance height of doors
- Clearance height of hall gates
- Clearance heights under order-picking floors or mezzanine floors
- Aisles in racking systems
- Suspended ceiling components
- Goods lifts
You must also consider initial lift when transporting a load through an area with restricted ceiling height. Initial lift is the height to which the load-handling attachment can be raised without extending the mast. This allows you to raise the load while keeping the vehicle within the available clearance. For stacking work in rooms with low ceilings, choose a mast and initial-lift configuration that provides sufficient clearance.
This is particularly relevant when loading lorries, railway wagons or containers. The standard internal height of a lorry is approximately 2,600 mm, while railway wagons typically have an internal height of around 2,000 mm. Container door heights generally range from 2,280 mm to 2,585 mm. A stacker without a suitable initial-lift function may not be suitable for these environments.
Ground clearance and initial lift
Ground clearance is the smallest distance between the vehicle floor and the ground. It must be sufficient to prevent the vehicle from touching the ground during operation. This is particularly important on uneven surfaces and at transition points between ramps and level ground. Check the ground clearance before using a pallet truck or stacker at loading bays, door thresholds or underground car park entrances and exits.
Straddle-leg-supported equipment, such as stackers, typically has a low ground clearance of approximately 25–30 mm. Depending on the model, the vehicle may therefore feature initial lift. This raises the straddle legs independently of the mast. This feature compensates for changes in ground level and can allow the vehicle to negotiate gradients of up to 16%.
The graphic shows a stacker without and with straddle-leg lift on a ramp:
When assessing ground clearance, also consider the transition between a gradient and a level surface. Calculate the transition break to determine whether the vehicle can pass over it safely:
Height difference (h) = Gradient (s)
Base of the inclined surface (l)
Manual and electric pallet trucks use initial lift to raise the load with the straddle legs. Depending on the vehicle type, they can negotiate gradients of up to approximately 20%. If you are unsure whether a stacker with initial lift is suitable for your application, test the vehicle under the relevant operating conditions.
The weight of pallet trucks and stackers
For manual pallet trucks, the stated weight usually refers to the construction weight. It may vary depending on the fork length, fork carriage width and whether the truck has single or tandem tyres.
For other pallet trucks and stackers, the technical specification usually states the vehicle weight with the battery included. The battery weight is often listed separately as well. The total weight can vary according to the fork length, mast type, lift height and battery type. Larger batteries and battery compartments can also increase the vehicle’s weight.
Both tare weight and total weight are important vehicle specifications. Total weight consists of the tare weight plus the load weight. These values help you determine which floors and surfaces are suitable for the vehicle. A pallet truck’s weight depends largely on its construction. Heavier models often have reinforced components. These may include the forks, fork carriage or mast. Such reinforcement can increase the vehicle’s residual load capacity.
FAQ for pallet truck dimensions
The dimensions of pallet trucks and stackers determine where the vehicles can be used. They affect whether the vehicles can pass through doors, navigate warehouse aisles and operate safely in confined areas. The dimensions also influence manoeuvrability and the aisle width required for transporting loads.
The dimensions of pallet trucks and stackers are broken down into the following specifications:
• Width (overall width and fork carriage width)
• Length
• Height (lowered and lift height)
• Ground clearance
• Tare weight
The turning circle, also called the turning radius, affects how easily a pallet truck can manoeuvre. This is particularly important in confined spaces such as warehouse aisles and lorries. A small turning circle allows the vehicle to turn in tight spaces, both with and without a load. The following pallet truck dimensions influence the turning circle:
• Vehicle width and length
• Distance between front and rear axle (wheelbase)
• Load dimensions
Please note: The regulations mentioned above represent only a selection of the most important legal requirements. Please refer to the listed organisations and directives for more detailed information. If in any doubt, consult experts or contact the relevant regulatory authorities.
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