Choosing Your Model

Forklift capacity: Know typical load weight and size

How heavy and what size are your typical loads? Forklift trucks are rated according to how much weight they can lift, starting at 3,000 lbs and going up to 35,000 lbs and more. 3,000-, 5,000-, and 8,000-lb models make up the bulk of the market, with 5,000 lb forklifts as the industry standard. The size of your typical load will affect the capacity you need.

Forklift capacity is usually based on a 24-inch "load center," meaning that the distance from the center of gravity to the sides of the load is 24 inches. The easiest way to think about this is that a forklift can only lift its maximum weight if the load is a 4 foot cube. If your loads are unusually long or high, the forklift won’t be able to safely lift as much. Knowing the typical dimensions and weight of your loads will allow you to work with sellers to determine the exact capacity you need.

Also consider variation in your loads. If you constantly produce identical pallets of products, you know exactly what capacity you need. However, in a more mixed environment, or one where the load size changes over time, you may want to buy a truck with more capacity than you need currently to make sure it gets the job done now and in the future.

Consider where you plan to use your forklift

How high do you need a forklift to lift a load? If you primarily use forklifts to load and unload trucks, you may not need much height; if your warehouse has shelves 30 feet high, your forklift will need to reach them. Unlike load capacity, your height needs are unlikely to change over time barring new construction or major renovations. Buy for the height you need now. In a warehouse setting, the size of the lift truck may be an issue as well. Standard lift trucks need aisles that are 11 feet wide or larger to be able to operate and turn around. For aisles that are 8 feet to 10 feet wide, you will need a narrow aisle (NA) forklift; for aisles down to 6 feet wide, you will need a very narrow aisle (VNA) truck. These narrow aisle trucks have forks that are turned at a right angle, so they can drive straight down the aisle but pick up loads to the side.

Fuel Your Forklifts

You'll find two main types of forklifts: Electric forklifts powered solely by an on-board battery and internal combustion (IC) forklifts, which use a traditional engine that runs on one of several types of fuel. In most cases an electric forklift will be more expensive than an identically-rated IC lift. Operating costs per hour are critical to determining the real cost of your forklift. This includes the cost of fuel, maintenance, supplies like oil, batteries, and filters, and the time required to take care of the truck.

Look into electric forklifts

Electric forklifts are well-suited for indoor use and use in well-paved parking lots (not in the rain). They're powered by large, heavy lead-acid batteries — the same kind found in your car, but considerably bigger and more powerful. Electric forklifts have several advantages.

• Zero emissions: Electric forklifts produce zero emissions, an important consideration if you plan to use your forklift indoors. Of the internal combustion models, only propane-fueled lifts can be used indoors, and they require very good ventilation. Gas and diesel-powered models can’t be used inside at all.

• Low fuel cost: Although electric forklifts have a higher initial cost than internal combustion forklifts (new electric forklifts can cost 20% to 40% more than similarly rated IC forklifts), they have a lower cost per hour of operation.

• Quieter operation: Electric forklifts produce less noise than IC forklifts, a big plus indoors.

• Long lifespan: Because electric forklifts have fewer moving parts and are often used in cleaner environments than IC forklifts, they also tend to have a longer life span.

Electric forklifts have no fuel storage requirements and the batteries typically provide enough power for one standard eight-hour shift, which translates into five or six hours of constant usage. Keep battery downtime in mind. Charging a forklift battery takes eight hours, plus eight hours of cooling time before it can be used. Due to this slow charging speed, if you need forklifts for two or three-shift operations, you will have to buy extra batteries so you can always charge the next one. You'll also need a battery charging station. Chargers should be located in a dry, ventilated, and temperature-controlled location. If you have multiple batteries, you will also need special cranes to change them.

Choose internal combustion (IC) forklifts

Internal combustion (IC) forklifts can handle the largest loads and are the only choice if you require greater than 15,000 lbs capacity. They typically stand up to certain types of abuse better than electric forklifts — specifically, using a forklift to push or tow loads, instead of lifting and driving — and usually have better acceleration and top speeds. IC forklifts have a lower initial price point, but cost more per hour to run than electric forklifts.

Forklifts with internal combustion engines run on a variety of fuels: gasoline, diesel fuel, liquid propane gas (LPG), or compressed natural gas (CNG). For indoor/outdoor use, duel fuel systems are available that let you switch between LPG and gasoline. You can refuel internal combustion (IC) forklifts on the fly: simply fill them up at a gas pump or load on new LPG canisters and your forklifts are ready to continue working in no time. Of the types of IC engines, fuel costs generally are highest for gasoline and lowest for diesel, with LPG in the middle. Fuel costs vary considerably from state to state, so you should investigate this cost in your area before deciding which option is best for you.

With some IC equipment, you will have to buy refueling equipment. For example, gasoline and diesel fuel require you to have storage tanks and pumps. LPG requires only space for spare tank storage, which is usually managed by a propane vendor. The choice between gas, diesel, and propane is often made based on existing vehicles and equipment.

Look at Forklift Attachments, Comfort, and Safety

Once you know what forklift truck capacity and fuel type are best for your situation, consider safety features, comfort, attachments, and extras.

• Safety features: Most forklifts come standard with safety features such as back-up beepers, flashing amber lights, headlights, and other safety features. State regulations vary; always keep them in mind when you shop.

• Ergonomics: They may seem like amenities, but adjustable seats and comfortable controls can reduce the risk of repetitive stress injuries and make for a more productive workforce.

• Attachments: You can tailor your lift truck to better handle specific types of materials: tools to pick up rolls of cable or steel, tongs for handling 55 gallon drums, flat panels for lifting items that aren’t on pallets, and more. Most attachments are standardized so they can be used on any forklift, so if you only occasionally need to move odd-shaped loads, you may be able to buy one attachment and use it with any of your lift trucks. Attachments like adjustable forks and spool handlers reduce load capacity. Every forklift should have a capacity plate attached to it detailing its capabilities in its current configuration.

• Sideshift: Sideshift, a very popular option, allows an operator to move a load left and right without moving the truck, allowing more precise load placement. Sideshift can reduce load capacity.

• Tilt mast: The ability to tilt the mast and forks forward and back greatly simplifies loading the truck on uneven ground. Tilting the mast back slightly also provides greater stability when moving a loaded truck.

• Service plans: With an expense of this magnitude, it only makes sense to purchase adequate protection for it. The majority of forklift buyers choose a preventative maintenance (PM) plan. These PM plans cover oil and filter changes, transmission servicing, and general check-ups at regularly scheduled intervals. For an additional cost, you can also purchase a full maintenance plan that covers any breakdowns or needed repairs. For a new forklift, you probably won’t need this type of coverage — you will likely have very few breakdowns in the first couple of years. On older equipment, it may be a useful insurance plan. Unless you have an in-house mechanic to perform these maintenance tasks after every couple of hundred hours of operation, it makes sense to lean on the dealer’s expertise.