Pallet Jack vs Pallet Stacker: 4 Questions That Decide It (With OSHA Rules and Real Prices)
A pallet jack is the right buy when every pallet stays on the floor. It lifts a pallet about 3 to 8 inches, enough to clear the slab and roll it to the dock, into a trailer, or across the building. A pallet stacker is the right buy the day a pallet has to go higher than that: onto a second tier, a rack beam, or a mezzanine edge, because its mast lifts 63 to 118 inches or more. On Warehouse Gear Hub, a 5,500 lb EKKO A25 manual pallet jack is $418.00, a 4,400 lb EKKO EP20JLIC lithium walkie pallet jack is $3,228.10, a 2,200 lb Apollolift A-3003 manual stacker with a 63 inch lift is $1,900.00, and a 3,000 lb EKKO EB14C-118 lithium straddle stacker with a 118 inch lift is $5,299.10. The four questions below take you from your pallets to a part number, with the OSHA text quoted from 29 CFR 1910.178 and 1910.176 and every height, capacity, and weight pulled from the maker's spec sheet or our product page.
- What is the difference between a pallet jack and a pallet stacker?
- Question 1: Does any pallet need to go higher than 8 inches?
- Question 2: How heavy is the pallet, and what kind of pallet is it?
- Question 3: Where does it travel: trailers, ramps, doorways, and aisles?
- Question 4: Who operates it, and what does OSHA require?
- Which should you buy?
- Frequently asked questions
What is the difference between a pallet jack and a pallet stacker?
A pallet jack is a pair of forks on wheels with a hydraulic pump between them. Pumping the handle lifts the forks a few inches so the pallet clears the floor, and that is the whole lift. Per EKKO's page for the A25, the forks sit at 2.95 inches lowered and top out at 7.5 inches. Our product page for the electric EP20JLIC lists 2.95 inches lowered and 7.48 inches raised. Powered or not, a pallet jack moves pallets; it does not stack them.
A pallet stacker puts the same forks on a mast. The forks rise along the mast to a set height, and a pair of legs under or around the pallet keeps the machine upright while they do. The Apollolift A-3003 lifts to 63 inches; the EKKO EA15A-118 and EB14C-118 lift to 118 inches. OSHA sorts the two machines into its own categories: the agency's powered industrial truck classes page lists "Low Lift Walkie Pallet" under Class III, Lift Code 2, and "High Lift Straddle" under Class II, Lift Code 1 and Class III, Lift Code 6.
The price spread follows the lift. On our site a manual pallet jack starts at $418.00 and a manual stacker at $1,900.00; a lithium walkie pallet jack is $3,228.10 and a lithium straddle stacker is $5,299.10. The questions below tell you which column you are in.
Question 1: Does any pallet need to go higher than 8 inches?
This question decides most purchases on its own. Walk the floor and list every place a pallet lands: the dock, the trailer, a floor lane, a second tier on a floor stack, a rack beam, a mezzanine. If every landing spot is the floor, the 7.5 inch lift of a pallet jack is all you will ever use, and the money you save buys a second jack. If one landing spot is above the floor, you need a mast, and the height of that spot picks the stacker.
Lift height has to clear the stack below plus a few inches. The 63 inch A-3003 puts a second pallet on top of a bottom load that stands about 55 inches, which covers most two-high floor stacking of cased goods. A 118 inch EB14C-118 or EA15A-118 reaches a rack beam at about 112 inches, using the 6 inch load-to-beam clearance from our walkie stacker sizing guide, which also covers capacity loss at full height.
Stacking on the floor has its own OSHA line. 29 CFR 1910.176(b) reads: "Bags, containers, bundles, etc., stored in tiers shall be stacked, blocked, interlocked and limited in height so that they are stable and secure against sliding or collapse." A stacker is how you build that tier without a forklift; the rule is how high you are allowed to build it.
| Model we stock | Type | Max lift | Forks lowered | Capacity | Service weight | Price as listed |
|---|---|---|---|---|---|---|
| EKKO A25 manual pallet jack | Manual pallet jack | 7.5 in | 2.95 in | 5,500 lb | 160 lb | $418.00 |
| EKKO EP20JLIC lithium walkie pallet jack | Electric pallet jack, lift and drive | 7.48 in | 2.95 in | 4,400 lb | Not listed on our page | $3,228.10 |
| Apollolift A-3003 manual stacker | Manual stacker, foot pump, fixed legs | 63 in | 3.5 in | 2,200 lb at 19.7 in load center | 550 lb | $1,900.00 |
| EKKO EA15A-118 semi-electric straddle stacker | Electric lift, manual push, straddle legs | 118 in | 2.6 in | 3,300 lb at 20 in load center | 1,212 lb | $3,950.00 |
| EKKO EB14C-118 lithium straddle stacker | Electric lift and drive, straddle legs | 118 in | 2.6 in | 3,000 lb at 20 in load center | 1,430 lb | $5,299.10 |
Sources for the table: EKKO's A25 product page, our EP20JLIC and A-3003 product pages, and EKKO's EA15A spec sheet and EB14C spec sheet. Prices are as listed on Warehouse Gear Hub as of this writing.
5,500 lb capacity, forks 2.95 in lowered to 7.5 in raised, 63 in overall length, 160 lb service weight, German seal system hydraulic pump, polyurethane wheels, robotic welds, 3 year limited warranty.
Question 2: How heavy is the pallet, and what kind of pallet is it?
Read the capacity column in the table again, because it runs the opposite way from the price. The $418.00 manual pallet jack carries 5,500 lb. The $5,299.10 lithium stacker carries 3,000 lb, and only at a 20 inch load center, which is a 48 inch pallet with the weight spread evenly. Raising a load on a mast is the hard part of the job, so stackers are rated lower than jacks at every price point, and a 4,000 lb pallet of flooring or drums that a jack rolls all day will not go up on any stacker in this table.
OSHA puts that number on the machine and holds you to it. 29 CFR 1910.178(o)(2) reads: "Only loads within the rated capacity of the truck shall be handled," and 1910.178(a)(6) adds that "the user shall see that all nameplates and markings are in place and are maintained in a legible condition." Weigh the heaviest pallet in the building before you pick, and buy the machine whose plate covers it.
Pallet construction is the second half of this question. A pallet jack's forks roll into any pallet with open fork pockets. A fixed-leg stacker like the A-3003 runs its legs under the pallet: per our product page they sit 12.7 inches apart inside and 21.8 inches outside, so the pallet needs an open bottom, which means skids, or pallets with no bottom boards where the legs go. A straddle stacker runs its legs outside the pallet instead. The EB14C-118's legs adjust from 35.4 to 51.2 inches inside and the EA15A-118's from 35 to 51 inches per EKKO, which wraps a 40 inch or 48 inch pallet with bottom boards and all. Our straddle vs counterbalanced stacker guide works through the pallet-type question in full, including closed-bottom pallets in narrow aisles.
2,200 lb at a 19.7 in load center, 63 in lift from a foot pump at nearly 1 in per stroke, forks adjustable 11.6 to 36.6 in wide and 42 in long, 37.6 in overall width, 48.6 in turning radius, 84.5 in recommended aisle, 550 lb, ships assembled by motor freight.
Question 3: Where does it travel: trailers, ramps, doorways, and aisles?
A pallet jack goes anywhere a pallet goes. The A25 is 63 inches long, 27 inches wide, and 160 lb per EKKO, so it rides into a trailer on top of the load, crosses a dock plate without a second thought, and parks under a bench. A stacker carries a mast and a lot of steel. The EB14C-118 weighs 1,430 lb and stands 85 inches with the mast lowered per EKKO's spec sheet, the EA15A-118 weighs 1,212 lb and stands 85 inches, and the A-3003 stands 82.3 inches per our product page. Measure every door, trailer opening, and mezzanine header on the route against that lowered height, and check the dock plate's rating against the service weight plus the load.
Grades separate the two machines further. 29 CFR 1910.178(n)(7)(i) reads: "When ascending or descending grades in excess of 10 percent, loaded trucks shall be driven with the load upgrade," and (n)(7)(iii) adds that the load "shall be tilted back if applicable, and raised only as far as necessary to clear the road surface." EKKO rates the EB14C at 5 percent gradeability loaded and 10 percent unloaded. The A-3003 and the EA15A-118 are pushed by hand, so a ramp means a person pushing 1,212 lb of machine plus the pallet uphill; keep those two on flat floors.
Aisles are the last check. 29 CFR 1910.176(a) reads: "Where mechanical handling equipment is used, sufficient safe clearances shall be allowed for aisles, at loading docks, through doorways and wherever turns or passage must be made." Apollolift lists the A-3003 at a 48.6 inch turning radius and an 84.5 inch recommended aisle. EKKO lists the EB14C at a 57.5 inch turning radius and the EA15A at 59 inches, and lists the EP20JLi walkie pallet jack, the same family as our EP20JLIC, at 53.7 inches on its product page. On speed, the EB14C travels 2.5 mph loaded or empty per its spec sheet, and the EP20JLi is listed at 4.2 km/h loaded and 4.5 km/h empty, about 2.6 and 2.8 mph. Long horizontal hauls favor the jack, and vertical work is the stacker's whole reason to exist.
Question 4: Who operates it, and what does OSHA require?
The dividing line is the motor, not the mast. 29 CFR 1910.178(a)(1) covers "fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines." OSHA's September 19, 2023 letter applies that text to an electric cart and two motorized trolleys and concludes that equipment "powered by electric motors and designed to carry, push, or pull material" is "subject to the requirements of 29 CFR 1910.178." A lithium walkie pallet jack and a full electric stacker are in. A hand pallet jack and a foot-pump stacker have no motor and no engine, so 1910.178 does not reach them, though 1910.176's aisle and stacking rules still do. A semi-electric stacker, with an electric lift and a manual push, is the gray area; the cheapest way to be sure is to train the operator as if it were covered.
For the powered machines, the training rule is specific. 1910.178(l)(1)(ii) reads: "Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the training required by this paragraph (l)." Under (l)(6) the employer certifies it, and the certification "shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation." Under (l)(4)(iii), "an evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years."
Moving from a jack to a stacker triggers more training. 1910.178(l)(4)(ii)(D) requires refresher training when "the operator is assigned to drive a different type of truck," and OSHA's June 15, 1999 letter explains that an operator "must be trained and evaluated in the safe operation for the type of truck" assigned, with no new training needed for "the same type of truck" from a different manufacturer. Two more lines apply every shift: 1910.178(q)(7), "Industrial trucks shall be examined before being placed in service," with the examination "made at least daily," and 1910.178(m)(3), "Unauthorized personnel shall not be permitted to ride on powered industrial trucks."
4,400 lb capacity, 48V lithium battery and charger included, forks 2.95 in lowered to 7.48 in raised, 45.2 in fork length, pinwheel capability for tight turns, polyurethane wheels, robotic welds, 3 year limited warranty. Covered by 1910.178, so train and certify the operator.
3,000 lb at a 20 in load center, 118 in lift, 85 in lowered mast, 57.5 in turning radius, 2.5 mph travel, 2.2 kW lift motor, Curtis controller, straddle legs adjustable 35.4 to 51.2 in, forks adjustable 8.7 to 32.1 in and 45.3 in long, 24V battery with internal charger, 1,430 lb service weight.
Which should you buy?
Match your building to the line that describes it.
- Every pallet lands on the floor, fewer than a few dozen moves a shift: EKKO A25 manual pallet jack ($418.00). 5,500 lb, 160 lb to push around, no training rule under 1910.178.
- Every pallet lands on the floor, long runs or trailer loading all day: EKKO EP20JLIC lithium walkie pallet jack ($3,228.10). 4,400 lb with powered lift and drive, which puts it under 1910.178(l) training and certification. Our electric vs manual pallet jack guide has the shift-volume math.
- Two-high floor stacking, light pallets, skids or open-bottom pallets, flat floor: Apollolift A-3003 manual stacker ($1,900.00). 2,200 lb to 63 inches from a foot pump, no motor, 84.5 inch aisle.
- Rack beams up to about 112 inches, standard bottom-boarded pallets, short pushes: EKKO EA15A-118 semi-electric straddle stacker ($3,950.00). 3,300 lb to 118 inches with an electric lift and a manual push, 1,212 lb.
- Rack beams up to about 112 inches, pallets moved more than a few feet, ramps up to 5 percent loaded: EKKO EB14C-118 lithium straddle stacker ($5,299.10). 3,000 lb to 118 inches, 2.5 mph, 1,430 lb, full 1910.178 training.
- Pallets over 3,300 lb that have to go up, or beams above 118 inches: call before you buy. That is a counterbalanced stacker or a forklift, and our walkie stacker vs forklift guide draws that line.
Every model above is in our pallet jacks collection or stackers collection. If the building lands between two lines, call 1-800-794-1049, 8 AM to 4 PM Central, with the heaviest pallet weight, the highest landing spot, and the narrowest aisle. We will pick it in one call, match any authorized dealer's price, and send a written quote for approval, with volume pricing for more than one unit.
Frequently Asked Questions
Can a pallet jack stack pallets?
No. A pallet jack lifts its forks a few inches to clear the floor: 7.5 inches on the EKKO A25 and 7.48 inches on the EKKO EP20JLIC per their product pages. Putting a pallet on top of another pallet, a rack beam, or a mezzanine takes a mast, which is what makes a stacker a stacker. The Apollolift A-3003 lifts to 63 inches and the EKKO EA15A-118 and EB14C-118 lift to 118 inches.
How high can a pallet jack lift?
About 3 inches at rest and about 7.5 inches at full pump on a standard model. EKKO lists the A25 at 2.95 inches lowered and 7.5 inches raised, and our EP20JLIC page lists 2.95 and 7.48 inches. That is enough to clear a dock plate or an uneven slab and nothing more.
Can a pallet stacker replace a pallet jack?
For floor moves it can, at a cost. A walkie stacker travels at 2.5 mph per EKKO's EB14C spec sheet, weighs 1,430 lb, needs an 85 inch door with the mast lowered, and is rated at 3,000 lb, against 5,500 lb for a $418.00 manual jack. Most buildings run both, with the jack working the dock and the trailer while the stacker handles the tier or the beam.
What kind of pallet does a stacker need?
It depends on the legs. A fixed-leg stacker like the Apollolift A-3003 runs its legs under the pallet, 12.7 inches apart inside per our product page, so it needs skids or an open-bottom pallet. A straddle stacker like the EKKO EB14C-118 runs its legs outside the pallet, adjustable from 35.4 to 51.2 inches inside per EKKO, so a standard pallet with bottom boards works.
Do you need OSHA training to use a pallet jack or a pallet stacker?
For any model with a motor, yes. 29 CFR 1910.178(a)(1) covers industrial trucks "powered by electric motors or internal combustion engines," and 1910.178(l)(1)(ii) requires completed training before an employee operates one, with employer certification under (l)(6) and an evaluation at least every three years under (l)(4)(iii). A manual pallet jack or a foot-pump stacker has no motor, so 1910.178 does not apply to it, while 1910.176's aisle and secure-storage rules apply to every pallet in the building.
How much does a pallet stacker cost compared with a pallet jack?
On Warehouse Gear Hub as of this writing, the EKKO A25 manual pallet jack is $418.00, the Apollolift A-3003 manual stacker is $1,900.00, the EKKO EP20JLIC lithium walkie pallet jack is $3,228.10, the EKKO EA15A-118 semi-electric straddle stacker is $3,950.00, and the EKKO EB14C-118 lithium straddle stacker is $5,299.10. The step from floor to mast costs about $1,500 at the manual end and about $2,100 at the lithium end.
Answer the four questions, then buy once
Manual and lithium pallet jacks, manual, semi-electric, and full electric stackers from EKKO and Apollolift, with lift height, capacity, and lowered mast height on every product page.
Shop pallet stackers →Questions on pallet type, aisle width, or a multi-unit quote: call 1-800-794-1049 (8 AM to 4 PM Central) or email info@warehousegearhub.com.