Stacker trucks

High lift trucks are wheel-assisted industrial trucks that not only transport goods horizontally, but also store and retrieve them at heights of up to several metres. With classic hand pallet trucks or low-lift trucks, load carriers can only be lifted off the ground and transported horizontally. For vertical transport, stacker trucks are available with different types of masts, which offer different lifting capacities and maximum lifting heights. In contrast to forklifts, pallet stacker trucks do not need a counterweight, as the load's centre of gravity is located inside the fork structure. This makes them very manoeuvrable and allows use in warehouses with narrow working aisle widths.

2. How to choose the right high lift truck

To find the right high lift truck model for your needs, you need to determine the requirements of your working environment. The best way to create a detailed requirements profile is by answering the following questions:

• Where will the high lift truck be used most often?
• What tasks will the industrial truck perform?
• Which drive is required for the driving and lifting function?
• At what heights do goods have to be stored and retrieved?
• What is the maximum load weight to be carried?
• What fork length and width is required?
• What type of load is to be moved with the high lift truck?
• Which tyres are suitable for the surfaces that the forklift truck will travel on?
• What special features of the storage areas need to be considered?

You can also use the following selection parameters to determine which truck is right for your needs.

Use

In general, high lift trucks are ideal for indoor use. They operate emission-free and can be moved easily on flat, smooth floors. Depending on the area of use, different types of forklift trucks may be suitable, as you can see from the table below.

Drive

The drive determines the way a high lift truck can be operated during horizontal transport, vertical stacking, and retrieval:

• Manual drive: Manual forklift trucks are operated solely by the operative’s physical strength and are recommended for short transport distances. We supply high lift trucks with hydraulic cylinders and greater load capacity. With hydraulic stackers, manual pumping activates the hydraulic pump and power is transmitted by means of a hydraulic cylinder with linear movement.
• Semi-electric drive: Semi-electric high lift trucks are also more suitable for short distances, as the battery only supports the lifting work. Loads are lifted and lowered electrically with the help of the lifting motor in a power-saving manner. The stacker is moved manually. These models are suitable for occasional stacking operations up to 3000 mm lifting heights.
• All-electric drive: Forklifts with this type of drive have a lift motor and a drive motor. Both are supplied with energy via the vehicle battery. This allows the high lift truck to be moved easily and with low power consumption. Loads can be raised and lowered electrically with this device. We recommend all-electric stacker trucks for longer transport distances and continuous lifting processes, as well as stacking and unstacking loads at heights.

Lifting height

One of the most important selection criteria of a high lift truck is the lifting height. This determines the maximum height to which you can lift pallets and other load carriers. When using high lift trucks indoors, however, there are other parameters to consider, including the following:

High lift trucks in our range are available with different mast types, but the functional principle is the same for all versions. The lift carriage with the fork and the load is moved vertically within the stand mast or lift mast by a motor (semi- and fully electric stackers), or hydraulically (hydraulic stackers). On some models, the mast can be telescopically extended two or even three times. In this way, much higher storage spaces can be reached without restricting mobility in lower working areas. You can find more information on this in our guide to forklift dimensions.

Rated capacity (load capacity)

The weight-specific limit with which a high lift truck can be loaded is referred to as the load capacity or rated capacity. This must not be exceeded in order not to overload the load-bearing parts of the truck and jeopardise safe handling. The load capacity diagram, which can be seen on electric high lift trucks and hydraulic forklifts, shows how the rated load capacity depends on the lifting height and centre of gravity of the load.

The residual load capacity must also be considered. If, for example, attachments are used on the high lift truck, the general load capacity is reduced because the load centre of gravity also changes. You can find more information in our guide to carrying capacity of forklift trucks and pallet trucks. 

Load

All high lift trucks available in our range are suitable for picking up standardised Euro pallets. Pallets in special sizes, however, can be picked up with our wide-gauge electric stacker trucks and wide-gauge hydraulic stackers. With high lift trucks in wide-gauge design, it is also possible to pick up Euro pallets crossways. The special feature here is that, due to the laterally extended wheel arms and the forks that can be lowered to the ground, the wide-track forklift truck drives underneath the load unit when picking up the load. This means that Euro pallets or even closed pallets can be picked up. In addition, it is also possible to use the forklifts to move boxes, transport crates or mesh trolleys, as well as collection trays that have forklift pockets. To ensure that delicate goods such as glassware, electronic components or other sensitive goods are not damaged during loading and unloading, we also offer trucks with proportional hydraulics. These are integrated into the tiller, enabling sensitive lifting, and lowering.

Tyres

Our high lift trucks all have a four-point chassis.

• Manual high lift trucks always have two swivel wheels and are also equipped with single or tandem fork rollers. Tandem rollers are particularly suitable for uneven floors or if you must overcome speed bumps in your warehouse. They also do not wear as quickly as single fork rollers and can stabilise the load better.
• Electric high lift trucks have a drive wheel, a support wheel and single or tandem fork rollers.

The castor material most suitable for your high lift truck depends on the operating and physical conditions of the working environment. Factors to consider include:

• Load capacity of the floor
• Floor condition (paved/unpaved, degree of contamination, floor covering)
• Floor slope
• Noise level
• Hygiene requirements
• Climatic conditions
• Starting and rolling resistance
• Impact load
• Environmental influences such as chemicals, oils, or moisture
• Ambient temperature
• Electrical conductivity requirements

Tyre material

Field of application

Properties

Nylon

Field of application

• Suitable for hard and even surfaces

Properties

• Hard and resilient

• Best choice for heavy loads

Polyurethane

Field of application

• Suitable for universal use

Properties

• Highly resilient and hard-wearing

• Also suitable for intensive use

• Quiet and stable running

Rubber

Field of application

• Ideal for uneven floors

Properties

• Good grip

• Suitable for soft surfaces

• Shock-absorbing

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Pedestrian or ride-on operation

We stock high lift trucks that are designed for pure pedestrian operation. However, models that enable ride-on operation are also available on request.

• High lift truck for pedestrian operation: With all pedestrian models, the industrial truck is controlled via an ergonomic multi-function tiller. This allows you to comfortably control the transport speed, steering, as well as lifting and lowering, while accompanying the truck on foot.

• High lift truck with combined pedestrian/passenger operation: With these models, the driver can comfortably ride along on a fold-out platform, making these trucks suitable for use on longer routes. Additional grab rails provide additional safety. However, you may need a forklift licence for high-lift trucks with platforms. These models are only available on request.

• Forklift truck with driver's stand: Also available on request, we can supply vehicles with an integrated driver's stand where the driver can sit or stand. You may also need a forklift licence for these kinds of vehicles.

3. What types of high lift trucks are there and what advantages do they offer?

At Jungheinrich PROFISHOP you can buy forklift and stacker trucks in various designs:

Hydraulic forklift

Our compact and manoeuvrable hydraulic high lift trucks are specially adapted to narrow warehouse aisles. Forklifts and stacker trucks can be used to transport, and stack loads up to 1500 kg. The movement of the high lift truck is purely manual, with manual lifting work supported by hydraulic cylinders that offer variable lift. With these hydraulic stacker truck models, you can transport loads over shorter distances and store them at heights of up to 3 m.

Advantages

• Easy to operate

• Cheaper to buy than electric models

• Low maintenance

• Good load capacity despite low dead weight

• Ideal for loading and unloading trucks at ground level or on intermediate floors

Disadvantages

• Relatively high effort required for operation

• Above 300 kg, the load should only be lifted with the drawbar lift or via the foot lever

Go to hydraulic stacker trucks

Electric stacker trucks

For heavy daily work requirements, longer transport distances and intensive work intervals, our robust electric stacker trucks are more suitable. Due to the range of functions and performance, these stackers are more efficient than manual models. Electric high lift trucks have one or two motors, depending on the model:

• In semi-electric models, loads are stacked and retrieved at heights of up to 3570 mm with the help of a powerful lifting motor. The time-consuming pumping work on the tiller or by pedal is no longer necessary.
• In addition to the lift motor, fully electric stacker trucks also have an electrically driven motor. This also takes over the forward and reverse movement of the high lift truck. This allows you to transport loads effortlessly over longer distances in the warehouse.

Both motors are powered by a battery. The operating time of an electric pallet truck depends on the performance of the battery, which must be charged regularly. If a lead-acid battery is the energy source, demineralised water must also be refilled regularly.

Advantages

• Physical relief for employees, as trucks can be operated without muscle power

• Enables ergonomic and efficient work

• Practical features facilitate pallet handling

• Different masts and lifting heights available for every application

• Available with maintenance-free lead-gel or innovative lithium-ion technology

Disadvantages

• Higher purchase costs

• Models with lead-acid batteries are more expensive to maintain (demineralised water must be refilled regularly)

Go to electric stacker trucks

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Electric counterbalanced trucks

We also have practical electric three-wheel forklifts available for passenger operation. Electric counterbalance trucks with a load capacity of up to 2000 kg can either be ordered with a robust weatherproof cabin or a full cabin. Depending on the model, these trucks can reach a travel speed of up to 17 km/h. The industrial trucks are powered by powerful lead-acid batteries with low-maintenance hydraulic systems. Thanks to innovative three-phase current technology, the counterbalance trucks are highly efficient. As a option to purchasing, you can also order the trucks as leasing models.

4. FAQs about stacker trucks

What should be considered when operating a stacker truck?

When transporting loads with a high lift truck, you should always watch out for moving or tipping loads. This is especially important when driving the equipment over uneven ground or on bends. Machine operators are responsible for avoiding accidents with other people. Likewise, you must ensure the stability of the load before lifting or lowering. Also, remember never to overload the industrial truck.

Is a forklift driving licence required to operate a stacker truck?

If your stacker truck is a pedestrian operated device, you do not need a forklift driving licence. However, employers must train employees who will be working with the industrial trucks on occupational health and safety aspects. All operators should be given the opportunity to learn the correct handling of a high lift truck and to be able to apply all safety regulations.

An exception are forklifts that have a ride-on feature, for example in the form of a folding platform, when a forklift licence is required.

Which inspections must be carried out daily or at regular intervals on forklift trucks?

To prevent accidents at work, all operators of stacker trucks are required to check the vehicle before starting work. A visual inspection should include the brake system, the lifting device, wheels, and electrics. Furthermore, you should make sure that the tiller can be moved properly in all directions. Leaking fluids are also a warning sign of a defect.

In addition to the visual inspection, every fork lift truck must have a thorough examination at least once a year according to the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER). However, LOLER 98 makes it clear that depending on the type of truck and its use, inspections may need to be more frequent than this.

Further advice on the subject:

• Obligations for crane systems and lifting equipment inspections
• Battery technology for forklift trucks and industrial trucks
• Pallet truck repair – simple guidance for minor damage