Your Definitive UK Buyer’s Guide to the Heavy-Duty Walk-Behind Counterbalanced Stacker with Electronic Power Steering, Duplex and Triplex Mast Options, and Full-Pallet Versatility

Introduction: The Heavy-Duty Pedestrian Stacker That Replaces a Forklift

The 1600kg pedestrian counterbalance stacker sits at the top of the pedestrian stacker capacity range, occupying the critical space between lighter walk-behind stackers and full-sized counterbalance forklift trucks. With a rated capacity of 1,600 kilograms, it handles the vast majority of palletised loads encountered in UK warehousing, manufacturing, distribution, and retail operations—yet it retains the compact dimensions, zero-emission electric powertrain, and walk-behind simplicity that make pedestrian stackers so practical for space-constrained environments.

For businesses that need genuine heavy-duty pallet handling capability but cannot accommodate, afford, or justify a full counterbalance forklift, the 1600kg pedestrian counterbalance stacker represents the most capable and cost-effective alternative available. It lifts heavier loads than the more common 1,000kg and 1,200kg models, reaches higher racking tiers with duplex and triplex mast options extending to 4,500mm and beyond, and incorporates professional features such as electronic power steering, automatic speed deceleration, and tilt functionality that were once exclusive to ride-on equipment.

This comprehensive guide examines the 1600kg pedestrian counterbalance stacker in complete detail. From the counterbalance operating principle and technical specifications through to mast selection, electronic power steering technology, UK regulatory compliance, industry applications, maintenance strategies, and total cost of ownership, this article provides everything you need to make a confident purchasing decision. Whether you are upgrading from a lighter stacker, replacing an ageing forklift, or equipping a new facility, this guide will demonstrate why the 1600kg pedestrian counterbalance stacker is one of the smartest material handling investments on the market.

What Is a 1600kg Pedestrian Counterbalance Stacker?

The Counterbalance Principle: Legless Design for Universal Pallet Handling

A 1600kg pedestrian counterbalance stacker is a battery-powered, walk-behind lifting machine capable of raising, lowering, transporting, and stacking loads weighing up to 1,600 kilograms. The operator walks behind or alongside the machine, controlling all movement and hydraulic functions through an ergonomic tiller arm. There is no cab, seat, or riding platform; the operator remains on foot, maintaining close control and full situational awareness at all times.

The counterbalance principle is the same engineering concept used in full-sized counterbalance forklift trucks. An integrated counterweight at the rear of the chassis offsets the turning moment created by the load carried on the forks at the front. This balance of forces maintains stability during lifting, lowering, and horizontal transport without the need for external straddle legs or outrigger arms. The result is a machine with a completely unobstructed front profile: no legs to foul on the bottom beams of racking, no straddling arms to restrict pallet type, and no forward-projecting structure to limit the approach angle.

This legless design is the single most important advantage of the counterbalance configuration. It enables the 1600kg pedestrian counterbalance stacker to handle every type of pallet and load carrier without restriction. Open-bottomed pallets, closed-bottomed pallets, Euro pallets, UK standard pallets, non-standard pallets, stillages, plastic containers, metal bins, crates, and custom load platforms can all be lifted, transported, and stacked. Straddle stackers, by comparison, are limited to pallets with open bottoms and sufficient ground clearance for the legs to pass beneath—a restriction that excludes a significant proportion of the load carriers found in modern UK supply chains.

Why 1,600kg? The Capacity Sweet Spot

The 1,600kg capacity represents the upper end of the pedestrian stacker range and covers the handling requirements of the vast majority of palletised loads in UK commerce and industry. A standard Euro pallet loaded with consumer goods, packaged products, or retail stock typically weighs between 400kg and 1,200kg. A fully loaded UK standard pallet of building materials, automotive components, or industrial consumables commonly weighs between 800kg and 1,500kg. The 1,600kg rated capacity provides a comfortable safety margin above these working loads, ensuring that operators rarely encounter situations where the stacker’s capacity is insufficient.

This capacity also positions the 1600kg pedestrian counterbalance stacker as a credible direct replacement for small counterbalance forklift trucks in many applications. Operations that currently use a 1.5-tonne or 1.8-tonne forklift primarily for indoor pallet handling may find that the pedestrian counterbalance stacker performs the same tasks at substantially lower cost, in less space, and with fewer regulatory complications—while keeping the same effective load capacity.

Counterbalance Versus Straddle: Understanding the Fundamental Difference

Straddle stackers use two outrigger legs that extend forward beneath the forks, straddling the pallet on either side to provide stability. While effective, this design restricts the machine to open-bottomed pallets and creates practical problems in environments where the straddle legs can foul on racking uprights, dock edges, floor irregularities, or floor-level obstructions. The legs also increase the overall width of the machine and prevent it from approaching pallets or loads that sit directly on the ground without ground clearance.

The 1600kg pedestrian counterbalance stacker eliminates all of these limitations. With no forward-projecting structure, it approaches pallets from the front, inserts the forks, and lifts cleanly regardless of the pallet construction, base type, or surrounding environment. In cluttered workshops, congested loading areas, and facilities that handle goods from multiple suppliers on varied pallet types, this universal compatibility is an enormous practical advantage that straddle stackers simply cannot match.

The trade-off is that the counterbalance stacker’s rear counterweight makes the overall machine length greater than an equivalent straddle stacker, resulting in a larger turning radius. At the 1,600kg capacity level, the turning radius is typically 1,700mm to 1,950mm. While this is larger than lighter counterbalance models, it remains considerably tighter than a full counterbalance forklift, and for the majority of warehouse and stockroom layouts it presents no operational constraint.

Technical Specifications and Key Features

Comprehensive Specifications Overview

Electronic Power Steering: A Defining Feature at 1,600kg

At the 1,600kg capacity level, the combined service weight of the stacker, counterweight, and load places considerable physical demands on the steering system. The 1600kg pedestrian counterbalance stacker addresses this with electronic power steering as a standard feature—a technology that transforms the operator experience compared to lighter models that rely on manual steering effort alone.

Electronic power steering uses a dedicated electric motor to assist the operator’s steering input through the tiller arm, reducing the physical effort required to manoeuvre the machine to a minimum. The result is fingertip-light steering that eliminates the fatigue and strain associated with manually steering a heavy machine through repeated turns, right-angle stacking manoeuvres, and confined aisle navigation. Over the course of a full working shift, this reduction in physical effort is substantial, and it enables the operator to maintain precision and control throughout extended operating periods without the progressive loss of accuracy that accompanies muscular fatigue.

Electronic power steering also delivers superior manoeuvrability. The system provides consistent, proportional assistance regardless of surface conditions, load weight, or operating speed, enabling the operator to execute smooth, precise turns in tight spaces. In warehouse environments where the stacker must navigate between racking, around corners, and through narrow doorways, this precision translates directly into improved productivity, reduced product damage, and lower risk of collisions with racking, walls, or other equipment.

AC Motor Technology

The 1600kg pedestrian counterbalance stacker typically employs AC motor technology for both the drive and hydraulic pump systems. AC motors offer significant advantages over older DC motor designs: they deliver smoother acceleration and deceleration, consume less energy for equivalent performance, require substantially less maintenance due to the absence of brushes and commutators, and provide more precise speed control. The improved energy efficiency translates directly into longer operating time between battery charges, while the reduced maintenance requirement lowers the machine’s total cost of ownership over its service life.

The AC drive motor delivers consistent torque across the speed range, ensuring that the stacker maintains full performance when loaded to capacity and responds predictably to the operator’s input. The AC hydraulic pump motor provides smooth, proportional lift and lower speeds, enabling the operator to position loads with precision at any height within the mast’s travel range.

Duplex and Triplex Mast Options

The 1600kg pedestrian counterbalance stacker is available with both duplex and triplex mast configurations, giving buyers the flexibility to match the machine’s lifting capability precisely to their operational requirements. The duplex mast is the standard offering, providing maximum lift heights from 1,400mm to 4,000mm depending on the model. This two-stage telescopic design is well-suited to operations stacking to two or three racking tiers and offers a good balance between lift height, collapsed mast height, and machine weight.

For operations requiring access to higher racking tiers or needing to work under restricted headroom, the triplex mast with full free lift is available. This three-stage telescopic design offers maximum lift heights from 3,700mm to 4,500mm—and on some models up to 5,500mm—while maintaining a significantly lower collapsed mast height than a duplex mast reaching the same elevation. The full free lift function means the forks rise to their maximum free-lift height before the outer mast sections begin to extend, a feature that is critical when operating beneath mezzanine floors, inside shipping containers, or in any area where overhead clearance restricts the overall mast height.

The choice between duplex and triplex mast should be guided by three factors: the maximum height to which loads must be stacked, the overhead clearance available in the operating environment, and any need to work inside shipping containers or beneath mezzanine floors. For most operations stacking to 3,000mm or below, the standard duplex mast provides excellent performance at the lowest cost and weight. For operations requiring higher reach or restricted-headroom capability, the triplex mast delivers the necessary performance without compromise.

Intelligent Safety Systems

The 1600kg pedestrian counterbalance stacker incorporates a suite of intelligent safety systems designed to protect the operator, the load, and the surrounding environment. Automatic mast deceleration reduces the lift speed progressively as the forks approach the upper reaches of the mast travel, preventing sudden stops at height that could dislodge or destabilise the load. Automatic truck deceleration reduces the travel speed when the load reaches a specified height, ensuring stability during high-level transport.

Automatic cornering speed reduction detects when the operator is executing a turn and progressively limits the travel speed to prevent the load from shifting or the machine from becoming unstable through excessive lateral force. An emergency stop button on the tiller arm brings the machine to an immediate halt in any critical situation, while a reverse safety switch prevents unexpected rearward movement. These systems work in combination to create a comprehensive safety envelope around the machine’s operation, reducing the likelihood and severity of incidents.

Tilt Functionality for Precision Load Handling

Many 1600kg pedestrian counterbalance stacker models offer a tilt function, enabling the operator to tilt the mast and forks forward or backward through a controlled arc. Backward tilt cradles the load against the mast during transport, improving stability and reducing the risk of the load sliding forward on the forks. Forward tilt assists with accurate placement of loads onto racking beams, ensuring that the pallet sits squarely and securely on the support surfaces.

This tilt capability is a feature traditionally associated with full counterbalance forklift trucks, and its inclusion on the 1600kg pedestrian counterbalance stacker further blurs the line between these two equipment categories. For operations that demand precise load placement at height—particularly those stacking onto narrow racking beams or handling loads that are sensitive to positional accuracy—the tilt function is a valuable standard or optional feature.

Key Advantages of the 1600kg Pedestrian Counterbalance Stacker

Maximum Pedestrian Stacker Capacity

At 1,600 kilograms, this is the highest capacity commonly available in the pedestrian counterbalance stacker format. It covers virtually all standard palletised loads encountered in UK warehousing, retail, manufacturing, and distribution without requiring the operator to check and calculate capacity margins on every lift. For operations that previously had to choose between an underpowered 1,000kg stacker and an expensive forklift truck, the 1,600kg model fills the gap precisely.

Universal Pallet Compatibility

The legless counterbalance design handles every pallet type in circulation: open-bottomed timber pallets, closed-bottomed plastic pallets, Euro pallets, UK standard pallets, non-standard custom pallets, stillages, metal bins, and plastic containers. In third-party logistics, contract warehousing, and any operation receiving goods from multiple suppliers on varied load carriers, this universal compatibility eliminates the delays, workarounds, and material damage that occur when a straddle stacker encounters an incompatible pallet.

Genuine Forklift Alternative at a Fraction of the Cost

The 1600kg pedestrian counterbalance stacker performs the core pallet handling tasks of a small counterbalance forklift truck—front-approach lifting, adjustable forks, powered stacking to racking height, tilt function, and electronic power steering—at a purchase price that is significantly lower than an equivalent forklift. The ongoing cost advantages are equally compelling: lower energy consumption, simpler maintenance, faster and less expensive operator training, reduced insurance premiums, and a smaller spatial footprint. For operations where the work does not require a seated operator, high travel speeds, or outdoor capability on rough terrain, the pedestrian counterbalance stacker delivers equivalent functionality at dramatically lower total cost.

Zero Emissions and Low Noise for Indoor Operations

The electric powertrain produces zero direct emissions during operation, making the 1600kg pedestrian counterbalance stacker fully compliant with the indoor air quality standards required in food storage, pharmaceutical environments, clean rooms, and temperature-controlled facilities. The absence of exhaust fumes eliminates the need for expensive ventilation infrastructure and protects the respiratory health of operators and co-workers in enclosed spaces.

Noise levels remain very low, typically below 75 decibels even under heavy load, enabling operations during noise-sensitive hours and in proximity to offices, retail areas, and public spaces. For businesses operating in shared buildings, residential areas, or extended trading hours, this quiet operation avoids the complaints and restrictions that diesel or LPG-powered equipment would generate.

Electronic Power Steering Reduces Operator Fatigue

The electronic power steering system fitted as standard on the 1600kg pedestrian counterbalance stacker is not merely a convenience feature—it is a practical necessity at this capacity level and a genuine differentiator from lighter models. By reducing the physical effort required to steer a machine with a service weight of 1,400kg to 2,100kg to near-zero, electronic power steering enables operators to work full shifts without the cumulative muscular fatigue that degrades performance, accuracy, and safety. For operations running multiple shifts or employing operators who rotate between tasks, this reduction in physical demand is a measurable benefit to workforce welfare and productivity.

Compact Footprint Despite Heavy-Duty Capability

Despite its substantially higher capacity and heavier counterweight, the 1600kg pedestrian counterbalance stacker maintains a compact footprint that allows it to operate in environments where a full forklift would be impractical. With an overall width typically between 890mm and 1,050mm, the machine passes through standard commercial doorways, enters goods lifts, and navigates the aisles found in most warehouse and stockroom layouts. When parked, it occupies a modest floor area and can be charged from a standard mains socket via the built-in or external charger—no dedicated charging infrastructure, bunded fuel storage, or expanded parking bays are required.

Applications and Industries

Warehousing and Distribution Centres

The 1600kg pedestrian counterbalance stacker excels as a primary material handling machine in small to medium warehouses and as a supplementary workhorse in larger distribution centres. Its 1,600kg capacity handles the full range of standard palletised goods, from lightweight consumer products to heavy industrial consumables, while the duplex or triplex mast provides access to multiple racking tiers. In busy despatch and goods-in areas, the electronic power steering enables rapid, precise positioning of pallets without the operator fatigue that would accumulate with a manually steered machine over the course of a full shift.

For growing businesses that are outgrowing their initial manual handling capabilities but are not yet at the scale where a full forklift fleet is justified, the 1600kg pedestrian counterbalance stacker provides an ideal transitional solution. It eliminates the manual lifting and carrying that contributes to musculoskeletal injury—the largest single category of workplace injury in the UK—while keeping capital expenditure, training requirements, and operational complexity firmly within reach of smaller organisations.

Manufacturing and Production Environments

Manufacturing facilities handling raw materials, work-in-progress components, sub-assemblies, and finished goods weighing up to 1,600kg benefit from the precision and versatility of the pedestrian counterbalance stacker. The legless design allows it to approach workbenches, machinery, production cells, and storage racking without straddle legs fouling on floor-level fixtures. The zero-emission electric operation maintains air quality in enclosed production spaces, while the low noise output supports concentration and communication in busy manufacturing environments.

In automotive parts manufacturing, aerospace component handling, precision engineering workshops, and electronics production, the 1600kg pedestrian counterbalance stacker’s combination of capacity, precision, and cleanliness makes it an indispensable daily tool. The tilt function and electronic power steering enable operators to position heavy components accurately onto workstations, assembly jigs, and inspection benches, supporting the quality and throughput standards demanded by modern manufacturing processes.

Retail, Wholesale, and Cash-and-Carry Operations

Large retail stores, wholesale depots, and cash-and-carry operations handle pallets of consumer goods that frequently approach or reach 1,600kg—cases of beverages, tinned goods, household products, and bulk retail stock. The 1600kg pedestrian counterbalance stacker handles these heavy pallets comfortably, enabling stockroom teams to receive deliveries, stack to racking, and replenish the shop floor efficiently and safely. The quiet, emission-free operation allows material handling to continue during trading hours without disrupting customers or compromising air quality.

Food, Beverage, and Cold Storage

In food and beverage warehousing, the 1600kg pedestrian counterbalance stacker meets the stringent hygiene and air quality requirements of temperature-controlled and ambient food storage environments. Pallets of packaged food products, beverages, dairy items, and frozen goods frequently weigh between 800kg and 1,500kg, placing them squarely within the stacker’s comfortable operating range. The counterbalance design’s ability to handle closed-bottom plastic pallets and hygienic containers—the load carriers mandated in many food operations—makes it the natural choice for this sector.

In cold storage environments, the stacker’s electric operation avoids the condensation and icing problems that internal combustion engines can create, while the robust construction and sealed electronics tolerate the temperature differentials encountered when moving between ambient and chilled zones. For operations requiring extended cold store duty, cold-specification packages with heated controls, condensation-resistant electronics, and cold-rated lubricants may be available from the manufacturer.

Container Loading and Unloading

The 1600kg pedestrian counterbalance stacker’s compact dimensions and, when equipped with a triplex mast, its full free-lift capability make it highly effective for loading and unloading shipping containers. The stacker enters a standard shipping container through its 2,340mm wide opening, positions pallets inside the container, and uses the free-lift function to double-stack pallets without the mast top exceeding the container’s internal ceiling height. This capability is particularly valuable at distribution centres, freight forwarding depots, and import/export operations where container handling is a daily requirement.

Third-Party Logistics and Contract Warehousing

Third-party logistics providers and contract warehousing operations face the unique challenge of handling goods from multiple clients on a wide variety of pallet types, weights, and dimensions. The 1600kg pedestrian counterbalance stacker’s combination of high capacity and universal pallet compatibility makes it the default choice for these versatile environments. Whatever the client’s pallet specification—Euro, UK standard, closed-bottom plastic, non-standard timber, or custom stillage—the counterbalance stacker handles it without adaptation.

Printing, Paper, and Publishing

The printing industry handles paper reels, palletised printed products, and heavy flat loads that commonly reach or exceed 1,000kg. The 1600kg pedestrian counterbalance stacker provides the capacity to handle fully loaded pallets of paper stock and finished publications, the precision to navigate the tight layouts typical of print workshops, and the emission-free operation needed to protect printed products from contamination. The adjustable forks accommodate the varied load widths encountered in printing, from narrow reel pallets to wide flat-bed loads.

Educational, Healthcare, and Institutional Facilities

Universities, hospitals, research facilities, and government buildings have material handling requirements that are well-matched to the 1600kg pedestrian counterbalance stacker’s capabilities. Moving heavy equipment, furniture, laboratory supplies, medical consumables, and bulk stores within multi-storey institutional buildings requires a machine that is compact enough to enter goods lifts and navigate corridors, powerful enough to handle substantial loads, and clean enough to operate indoors without air quality or noise concerns. The pedestrian counterbalance stacker meets all of these requirements.

UK Regulations and Compliance

Health and Safety at Work Act 1974

The Health and Safety at Work Act 1974 imposes a general duty on employers to ensure the health, safety, and welfare of their employees so far as is reasonably practicable. This duty encompasses all work equipment, including the 1600kg pedestrian counterbalance stacker. Employers must conduct risk assessments covering stacker operations, implement appropriate control measures, ensure the equipment is properly maintained, provide adequate training, and maintain documented records of all safety-related activities.

LOLER 1998: Thorough Examination Requirements

The Lifting Operations and Lifting Equipment Regulations 1998 require that the 1600kg pedestrian counterbalance stacker undergoes a thorough examination by a competent person at intervals not exceeding 12 months. This examination assesses the structural integrity of the mast, forks, carriage, chassis, hydraulic system, chains, and all load-bearing components. The competent person issues a written report identifying any defects, and the employer must act promptly to rectify any issues before the stacker is returned to service. Examination reports must be retained and made available to the Health and Safety Executive on request.

PUWER 1998: Work Equipment Requirements

The Provision and Use of Work Equipment Regulations 1998 require that the stacker is suitable for its intended purpose, maintained in a safe condition, inspected at appropriate intervals, and used only by persons who have received adequate training and information. PUWER also requires that the machine is fitted with appropriate safety devices—including the emergency stop, braking system, and audible warning device that are standard on the 1600kg pedestrian counterbalance stacker—and that documented records of maintenance and inspection are maintained.

Operator Training and Certification

All operators of the 1600kg pedestrian counterbalance stacker must receive adequate training before using the equipment. Training for pedestrian-operated stackers is typically shorter and less complex than for ride-on counterbalance forklift trucks, with courses generally lasting one to two days for novice operators. Experienced operators converting from other equipment types may complete training in a single day. Training should cover pre-operational checks, safe operating procedures, load assessment and capacity awareness, stacking and de-stacking techniques, battery charging safety, and emergency protocols.

Training must be provided by a competent instructor and documented to demonstrate compliance. Employers are advised to arrange refresher training at intervals of three to five years, and whenever an operator changes role, moves to a different type of equipment, or is involved in a near-miss or incident. While pedestrian stacker operation does not require the same licence category as a counterbalance forklift, the training must be specific to the machine type and the operational environment in which it will be used.

Battery Charging and Electrical Safety

Battery charging should follow the manufacturer’s documented procedures and take place in a designated area free from trip hazards and ignition sources. Sealed maintenance-free batteries present minimal risk, but adequate ventilation should still be provided in the charging area. For models fitted with vented lead-acid batteries, hydrogen gas may be evolved during charging, requiring enhanced ventilation and prohibition of naked flames or sparking equipment. The built-in charger found on many models simplifies the process, but operators should still be trained to connect and disconnect the charging cable safely and to recognise abnormal conditions such as excessive heat, unusual odour, or battery swelling.

Choosing the Right 1600kg Pedestrian Counterbalance Stacker

Assessing Your Load Requirements

Document the weights, dimensions, and pallet types of the loads you handle most frequently and identify your maximum expected load weight. If your loads regularly approach 1,500kg or you handle a mix that occasionally reaches 1,600kg, the 1600kg pedestrian counterbalance stacker provides the necessary capacity with a comfortable safety margin. If your loads consistently remain below 1,000kg, a lighter and more compact model may be more appropriate.

Measuring Your Operating Environment

The turning radius of the 1600kg pedestrian counterbalance stacker is typically 1,700mm to 1,950mm, which determines the minimum aisle width for right-angle stacking. Measure your working aisles, doorways, goods lift openings, and any constriction points to confirm compatibility. The overall width of 890mm to 1,050mm will pass through most standard commercial doorways, but verify this against your actual measurements, allowing clearance for the operator and the tiller arm.

Selecting the Correct Mast Configuration

Choose the mast type and lift height that match your highest stacking requirement plus an adequate clearance margin for safe pallet placement and retrieval. If your maximum stacking height is 3,000mm or below and you have no overhead clearance restrictions, the standard duplex mast provides excellent performance at the lowest cost and weight. If you need to stack above 3,000mm, operate under mezzanine floors, or work inside shipping containers, the triplex mast with full free lift delivers the additional capability you need.

Remember that mast height directly affects the collapsed mast height and overall machine weight. A taller mast increases the collapsed height, which may affect the stacker’s ability to pass through doorways or enter goods lifts. It also increases the overall weight, which affects mezzanine floor loading and transport logistics. Specifying only the mast height you genuinely need avoids unnecessary cost, weight, and dimensional penalties.

Battery Specification and Charging Strategy

At the 1,600kg capacity level, the battery is typically a 24V unit with capacity ranging from 210Ah to 400Ah. Higher-capacity batteries extend operating time between charges, which is essential for intensive multi-shift operations. Standard sealed lead-acid batteries are the most common and most affordable option, offering reliable performance with overnight charging. Lithium-ion battery options are available on some models, providing faster charging, opportunity charging during natural breaks, maintenance-free operation, longer cycle life, and lighter weight.

Consider your daily duty cycle, the availability of charging time, and whether the stacker will operate across single or multiple shifts. For single-shift operations with overnight charging availability, standard lead-acid batteries are typically sufficient. For multi-shift operations, high-intensity use, or environments where the stacker must be available throughout extended operating hours, lithium-ion batteries or higher-capacity lead-acid units provide the necessary endurance.

Essential and Optional Features

The 1600kg pedestrian counterbalance stacker comes with a comprehensive standard feature set, typically including electronic power steering, AC motor technology, adjustable forks, emergency stop, and automatic safety deceleration systems. Optional features that may enhance your operation include tilt function for improved load stability and placement accuracy, side-shift carriage for lateral fork adjustment without repositioning the stacker, LED work lights for improved visibility in dimly lit areas, audible reversing alarms, blue spot safety lights to warn pedestrians of the stacker’s approach, and non-marking tyre compounds for operations where floor aesthetics or hygiene are important.

Maintenance, Servicing, and Long-Term Care

Daily Pre-Operational Checks

Every operating session should begin with a structured pre-operational inspection. The operator should visually inspect the forks for cracks, bending, excessive wear, or misalignment; test the mast through its full range of travel for smooth, unrestricted movement; confirm the electronic power steering responds correctly; verify the horn and any warning systems; inspect all wheels for damage or excessive wear; test the service brake and parking brake; check the tiller arm controls for correct function; and confirm the battery charge level is adequate for the planned work. Any defects must be reported immediately and the stacker removed from service until the issue is resolved.

Scheduled Preventive Maintenance

Follow the manufacturer’s recommended service schedule, which typically specifies intervals at every 500 to 1,000 operating hours or at least annually for lower-utilisation machines. Preventive maintenance should encompass inspection and lubrication of mast chains, rollers, and guide channels; hydraulic system inspection including cylinders, hoses, fluid level, and filter condition; testing of the braking system; inspection of all electrical connections, wiring, and controller components; verification of battery and charger function; calibration check of the electronic power steering system; and comprehensive testing of all safety systems including automatic deceleration and cornering speed reduction.

The AC motor technology fitted to the 1600kg pedestrian counterbalance stacker reduces maintenance requirements compared to older DC motor designs. Without brushes to inspect, replace, or maintain, the AC drive and pump motors require only periodic electrical connection checks and external cleaning. This reduced maintenance burden contributes to higher machine availability and lower servicing costs over the equipment’s service life.

LOLER Thorough Examinations

The mandatory 12-monthly thorough examination under LOLER must be conducted by a competent person and includes a detailed structural assessment of the mast, forks, carriage, chassis, counterweight attachment, hydraulic system, lift chains and anchor points, and all safety devices. The competent person issues a formal report that must be retained by the employer. Any defects identified must be rectified within the specified timeframe, and the stacker must not be returned to service until all critical defects are resolved.

Total Cost of Ownership: The Financial Case

Running Cost Comparison

The financial advantage of the 1600kg pedestrian counterbalance stacker over a full counterbalance forklift is substantial and sustained across every dimension of ownership cost.

When acquisition cost, energy, maintenance, training, insurance, and infrastructure are combined, the 1600kg pedestrian counterbalance stacker delivers a total cost of ownership that is typically 40 to 60 percent lower than an equivalent electric counterbalance forklift, and 60 to 75 percent lower than a diesel or LPG forklift of comparable capacity. For businesses operating within the stacker’s capacity and throughput envelope, the financial case is compelling.

Residual Value and Service Life

A well-maintained 1600kg pedestrian counterbalance stacker delivers reliable service for many years. The robust chassis, heavy-duty counterweight, and AC motor technology contribute to a long service life with predictable maintenance requirements. Battery replacement is the largest single maintenance cost over the machine’s life: sealed lead-acid batteries are typically replaced every three to five years, while lithium-ion batteries offer substantially longer cycle life. The used equipment market for pedestrian stackers is active in the UK, and machines in good condition retain reasonable resale value, fur