If you are trying to design rail-guidance for Raymond or Toyota orderpickers, you need to know how to calculate the width between the guidance rails. See below for our handy calculator and reference guide.

  1. Select the width of the baselegs from the drop-down list.
  2. Enter the fork elevation of the orderpicker you are installing rail-guidance for.
  3. Enter the length of the load or the platform (whichever is greater).
  4. Enter the width of the load or platform (whichever is greater).
  5. Ender the OAW guide roller width from the ranges below based on the guide roller diameter or whether there is a support bar or not.
  6. List the number of inches the palletized load over hangs the endframe dimension. HINT: On a 42″ frame, a 48″ pallet overhangs by 3″.
  7. The Recommended values are to be used as a guide only. Consult with a paid professional to confirm these dimensions.

Rail-guided orderpickers are essential tools in modern warehouses and distribution centers, allowing efficient and precise movement of goods. One crucial aspect of their design and operation is determining the rail-to-rail distance. The rail-to-rail distance refers to the space between the inner edges of the two guide rails that the order picker travels along. Ensuring the correct rail-to-rail distance is crucial for maximizing safety, efficiency, and productivity. In this article, we will explore the steps to accurately determine the rail-to-rail distance for a rail-guided order picker.

Step 1: Consult the Manufacturer’s Guidelines

Before making any measurements or adjustments, it is vital to refer to the order picker’s user manual or consult with the manufacturer. The manufacturer’s guidelines often provide essential information about the proper rail-to-rail distance specific to the model you are using. Adhering to the recommended distance will help maintain the order picker’s stability, safety, and overall performance.

Step 2: Safety Precautions

Ensure that the order picker is parked securely and the power supply is disconnected before attempting to measure or adjust the rail-to-rail distance. Additionally, consider using safety equipment such as gloves, safety glasses, and appropriate tools to avoid accidents.

Step 3: Measure the Existing Rail-to-Rail Distance

To determine the current rail-to-rail distance, you will need a measuring tape or a suitable measuring tool. Position the measuring tape at the inner edge of one rail and extend it to the inner edge of the opposite rail. Take accurate measurements at multiple points along the length of the rails to account for any irregularities.

Step 4: Verify Tolerance Levels

Compare the measured rail-to-rail distance with the manufacturer’s recommended tolerance levels. Most manufacturers specify a range within which the rail-to-rail distance must fall for optimal performance. If the measured distance is within the recommended range, no further adjustments are needed.

Step 5: Make Adjustments (if necessary)

If the measured rail-to-rail distance falls outside the manufacturer’s specified range, adjustments are necessary. The process for making adjustments may vary depending on the order picker model. However, the general steps involve loosening the bolts securing the guide rails and moving them to the desired position. Use the measuring tape to verify the distance as you make adjustments, ensuring both rails are aligned correctly.

Step 6: Test the Order Picker

After making the adjustments, perform a series of test runs with the order picker to ensure smooth movement along the guide rails. Test the order picker’s stability, steering, and overall performance to ensure that the new rail-to-rail distance is suitable for operational use.

Step 7: Regular Maintenance and Inspections

Once you have determined and set the correct rail-to-rail distance, it is essential to incorporate regular maintenance and inspections into your operational routine. Routinely check for any wear and tear on the guide rails and their alignment to prevent issues from arising and ensure the safety and efficiency of the order picker over time.


Determining the correct rail-to-rail distance for a rail-guided order picker is crucial for maintaining safety, optimizing efficiency, and prolonging the equipment’s lifespan. By following the manufacturer’s guidelines, taking accurate measurements, and making necessary adjustments, you can ensure that your order picker operates at its best. Regular maintenance and inspections will further guarantee its continued performance, allowing for smooth and seamless order picking operations in your warehouse or distribution center.

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