Hand Operated Forklift Trucks

Hand operated forklift trucks provide lifting and stacking capability without the cost, complexity, and space requirements of powered equipment. From simple pallet jacks to manual stackers reaching rack level, these human-powered tools remain essential where low volume, tight spaces, or simplicity outweigh the benefits of motorized alternatives.

The term "hand operated forklift" encompasses various manual material handling equipment—primarily pallet jacks for floor-level transport and manual stackers for lifting to height. Understanding the options helps match equipment to applications where manual operation makes practical and economic sense.

This guide covers types of hand operated lift trucks, their capabilities, applications, and how to choose between manual and powered options.

Types of hand operated lift trucks

Hand pallet trucks (pallet jacks)

The most common manual lift truck—transports pallets at floor level.

Lift height. Just enough to clear floor—typically 75-200 mm (3-8 inches).
Capacity. 2,000-3,000 kg (4,400-6,600 lb) typical.
Operation. Pump handle to lift, manual push/pull to move.
Best for. Floor-level pallet transport, loading docks, short distances.
Cost. $250-700.

For complete details, see our pallet jack types guide.

Manual stackers (hand stackers)

Add vertical lift capability to reach rack levels.

Lift height. 1.2-3+ metres (4-10+ feet) depending on model.
Capacity. 500-1,500 kg (1,100-3,300 lb) typical, decreasing with height.
Operation. Hand pump or foot pump hydraulic lift.
Types. Straddle leg, counterbalance, and adjustable leg designs.
Best for. Low-volume stacking, occasional height access.
Cost. $800-3,000.

High-lift pallet trucks

Hybrid between pallet jack and stacker.

Lift height. 0.5-1 metre (20-40 inches).
Design. Pallet jack frame with extended hydraulic cylinder.
Best for. Truck loading, die handling, workstation feeding.
Cost. $500-1,500.

Manual platform trucks

Flat platform with hydraulic lift.

Lift height. Variable—from low lift to workbench height.
Platform. Solid deck rather than forks.
Best for. Non-palletized loads, oddly shaped items.
Cost. $400-2,000.

Manual scissor lift tables

Portable lift tables with manual hydraulic operation.

Lift height. Varies by model—typically 0.5-1.5 metres.
Operation. Foot pump hydraulic.
Best for. Ergonomic work positioning, workstation use.
Cost. $500-2,500.

Manual stacker configurations

Straddle leg stackers

Most common manual stacker design.

Design. Outrigger legs straddle the pallet.
Pallet access. From front or side of pallet.
Limitation. Cannot access pallets from narrow side.
Advantage. Stable, lower cost than counterbalance.
Leg width. Typically adjustable to accommodate pallet widths.

Counterbalance stackers

No straddle legs—can access pallets from any side.

Design. Heavy counterweight in rear provides stability.
Pallet access. Open front allows any approach angle.
Advantage. More flexible pallet access.
Limitation. Heavier, more expensive.
Capacity. Often lower than equivalent straddle design.

Adjustable/powered leg stackers

Legs move independently for different pallet sizes.

Flexibility. Handles various pallet dimensions.
Complexity. More adjustment mechanisms.
Best for. Operations with varied pallet types.

Specifications

Manual stacker specifications

Specification	Light Duty	Standard Duty
Capacity	500-750 kg (1,100-1,650 lb)	1,000-1,500 kg (2,200-3,300 lb)
Max lift height	1.2-1.6 m (4-5.2 ft)	1.6-3 m (5.2-10 ft)
Fork length	800-1,000 mm (31-39 in)	1,000-1,150 mm (39-45 in)
Overall width	700-900 mm (28-35 in)	800-1,000 mm (31-39 in)
Lowered fork height	75-90 mm (3-3.5 in)	85-100 mm (3.3-4 in)
Weight	80-120 kg (176-265 lb)	150-250 kg (330-550 lb)

Capacity vs. height

Manual stacker capacity typically decreases with lift height:

Rated capacity applies at lowest lift position
May be 60-80% of rated capacity at maximum height
Check load chart for specific capacity at desired height

When to choose manual

Manual equipment advantages

Low cost. Fraction of powered equipment price.
No charging/fueling. Always ready to use.
Minimal maintenance. Simple hydraulic systems.
Compact. Smaller footprint than powered equipment.
Simple training. Less certification complexity.
Quiet operation. No motor noise.
No emissions. Safe for any indoor environment.

Best applications for manual

Low volume—fewer than 10-15 lifts per day
Short travel distances—under 30 metres
Light to moderate loads
Occasional stacking needs
Backup equipment
Tight spaces where powered equipment won't fit
Applications where simplicity is valued

When powered makes more sense

High volume operations
Heavy loads exceeding manual capacity
Long travel distances
Frequent lifting throughout shifts
Operator fatigue concerns
Need for speed and efficiency

Operating considerations

Physical demands

Pushing/pulling. Manual movement requires operator effort.
Pumping. Raising loads requires pumping action.
Rolling resistance. Heavier loads require more effort to move.
Floor conditions. Rough floors dramatically increase effort.

Reducing operator strain

Keep loads as light as practical
Maintain smooth floors
Keep wheels clean and lubricated
Consider semi-electric options for heavy loads
Rotate tasks to avoid repetitive strain

Safety considerations

Never exceed rated capacity
Secure loads before lifting
Keep clear of pinch points during operation
Use parking brake/chocks when stacker at height
Maintain clear visibility when moving loads
Watch for pedestrians

Semi-electric options

Hybrid solutions offer powered lift with manual travel (or vice versa).

Electric lift, manual travel

Powered hydraulics for lifting—reduces pumping effort
Manual push/pull for horizontal movement
Best for frequent lifting, short distances
Lower cost than fully powered
Price range: $2,000-5,000

Manual lift, powered travel

Hand pump for lifting
Electric drive for travel
Best for longer distances, occasional lifting
Less common configuration

Maintenance

Regular maintenance

Check hydraulic oil level monthly
Inspect for leaks at pump, cylinder, hoses
Clean and lubricate wheels
Check wheel condition
Inspect chain/cable if equipped
Test lowering valve function

Common issues

Won't lift. Low oil, air in system, worn pump.
Won't hold load. Internal leak, worn seals.
Hard to push. Dirty wheels, damaged bearings, bent fork.
Jerky lift. Air in system, contaminated oil.

See our pallet jack maintenance and pallet truck repair guides for details.

Pricing guide

Equipment Type	Price Range
Hand pallet truck	$250-700
High-lift pallet truck	$500-1,500
Manual straddle stacker	$800-2,000
Manual counterbalance stacker	$1,500-3,500
Semi-electric stacker	$2,000-5,000

Top manufacturers

Vestil. Wide range of manual material handling equipment.
Wesco. Good selection of stackers and pallet trucks.
Presto. Quality lift equipment including manual options.
Bishamon. Ergonomic-focused designs.
Noblelift. Value-oriented options.
Big Joe. American manufacturer with manual and powered options.