Forklift Buyer's Guide
Forklifts are one of the workhorses of modern industry. They come in a variety of types and sizes to keep operations at warehouses, distribution centers, manufacturing plants, and lumber yards running smoothly. Other businesses also use forklifts to unload deliveries for an hour or two each day. Know your choices and business requirements so that you can find forklifts that not only perform well, but meet your specific needs.
This buying guide provides information regarding the types of forklifts available on the market today, as well as important aspects and features of the forklift market to help you make the best decision for your situation. Learn whether you need an internal combustion forklift, an electric forklift, what type of tires your forklift needs, whether or not you will need certain attachments to accommodate your daily usage, and more.
Forklift Features
Much like automobiles, forklift pricing varies widely by brand, and pricing does not always correlate to overall quality and reliability. Prices can vary depending on geography, your specific needs, and the seller. Top-tier brands typically cost more and offer advanced technology, higher tolerance of abuse and harsh environments, and greater long-term reliability.
Before you start looking at forklift trucks or talking to dealers, determine exactly what you need your forklifts to do. As with any large piece of equipment, safe use should be your top priority. Make sure you review all the safety instructions for the forklift you buy before using it.
Forklift Capacity: Knowing Typical Load Weight and Size
In order to select the best forklift for your work situation, determine the typical load weight and size the forklift will be used for. 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. While 3,000-lb, 5,000-lb, and 8,000-lb models make up the bulk of the market, 5,000-lb forklifts are the industry standard. The size of your typical load will determine 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 will not 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, buy a truck with more capacity than you need currently to make sure it gets the job done now and in the future.
Forklift Height: How High Do You Need 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 that are 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 eight feet to 10 feet wide, you will need a narrow aisle (NA) forklift; for aisles down to six feet wide, you will need a very narrow aisle (VNA) truck. NA and VNA forklifts have forks that are turned at a right angle so they can drive straight down the aisle but pick up loads to the side.
Forklift Tires: Where Will You Use Your Forklift?
Forklifts should have tires appropriate for the location or environment. Knowing the different types of forklift tires available on the market will ensure that the forklift can accomplish its specific job in the necessary location.
Types of Forklifts: Electric versus Internal Combustion Engine
There are 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, and supplies like oil, batteries, and filters.
Electric Forklifts
Electric forklifts are well suited for indoor use and on well-paved parking lots, but they cannot be used in the rain. They are powered by large, heavy lead-acid batteries, the same kind found in a car but considerably bigger and more powerful. Electric forklifts have several advantages over their IC counterparts.
Internal Combustion 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, when using a forklift to push or tow loads, rather than lifting and driving, IC forklifts usually have better acceleration and top speeds. IC forklifts also 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, including gasoline, diesel fuel, liquid propane gas (LPG), and compressed natural gas (CNG).
For indoor/outdoor use, duel fuel systems are available that let you switch between LPG and gasoline. You can refuel IC forklifts on the fly: simply fill them up at a gas pump or load new LPG canisters and 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. With some IC forklifts, you will have to buy refueling equipment. For example, gasoline and diesel fuel require 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.
Forklift Attachments, Comfort, and Safety.
Once you know what forklift features and which fuel type are best for your situation, consider safety features, comfort, attachments, and extras. The following criteria are often features that buyers may not consider immediately in their purchase but will add both comfort and functionality to the machine, making it a high-quality addition to the workplace. None of the following are absolutely necessary (aside from the legally regulated safety features, and employee training). However, this list should be considered before making a purchase to ensure that the forklift you are considering will be capable of the specific jobs you have in mind.
This buying guide provides information regarding the types of forklifts available on the market today, as well as important aspects and features of the forklift market to help you make the best decision for your situation. Learn whether you need an internal combustion forklift, an electric forklift, what type of tires your forklift needs, whether or not you will need certain attachments to accommodate your daily usage, and more.
Forklift Features
Much like automobiles, forklift pricing varies widely by brand, and pricing does not always correlate to overall quality and reliability. Prices can vary depending on geography, your specific needs, and the seller. Top-tier brands typically cost more and offer advanced technology, higher tolerance of abuse and harsh environments, and greater long-term reliability.
Before you start looking at forklift trucks or talking to dealers, determine exactly what you need your forklifts to do. As with any large piece of equipment, safe use should be your top priority. Make sure you review all the safety instructions for the forklift you buy before using it.
Forklift Capacity: Knowing Typical Load Weight and Size
In order to select the best forklift for your work situation, determine the typical load weight and size the forklift will be used for. 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. While 3,000-lb, 5,000-lb, and 8,000-lb models make up the bulk of the market, 5,000-lb forklifts are the industry standard. The size of your typical load will determine 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 will not 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, buy a truck with more capacity than you need currently to make sure it gets the job done now and in the future.
Forklift Height: How High Do You Need 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 that are 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 eight feet to 10 feet wide, you will need a narrow aisle (NA) forklift; for aisles down to six feet wide, you will need a very narrow aisle (VNA) truck. NA and VNA forklifts have forks that are turned at a right angle so they can drive straight down the aisle but pick up loads to the side.
Forklift Tires: Where Will You Use Your Forklift?
Forklifts should have tires appropriate for the location or environment. Knowing the different types of forklift tires available on the market will ensure that the forklift can accomplish its specific job in the necessary location.
- Cushion Tires: Cushion tires are made of solid rubber and work best for internal applications. Electric forklifts designed for interior work typically have cushion tires.
- Pneumatic Tires: Pneumatic tires are inflated with compressed air and cost more than cushion tires and also make a better choice for outdoor work. For heavy-duty lifting outdoors on uneven terrain, gasoline- or diesel-fueled forklifts are most commonly found with pneumatic tires.
- Solid Pneumatic Tires: Solid pneumatic tires are ideal for outdoor environments where there is a high risk of popping regular pneumatic tires, such as lumber yards or recycling centers where glass or nails can be scattered. Solid pneumatic tires combine the solid-rubber construction of cushion tires with the rough terrain capabilities of pneumatic tires and typically cost more.
Types of Forklifts: Electric versus Internal Combustion Engine
There are 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, and supplies like oil, batteries, and filters.
Electric Forklifts
Electric forklifts are well suited for indoor use and on well-paved parking lots, but they cannot be used in the rain. They are powered by large, heavy lead-acid batteries, the same kind found in a car but considerably bigger and more powerful. Electric forklifts have several advantages over their IC counterparts.
- Zero Emissions: Electric forklifts produce zero emissions, which is 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 cannot 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. The price of gas and diesel fuels makes IC forklifts more expensive hourly than rechargeable, battery-powered electric forklifts.
- Quieter Operation: Electric forklifts produce less noise than IC forklifts, which is a plus for indoor usage.
- 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 lifespan.
Internal Combustion 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, when using a forklift to push or tow loads, rather than lifting and driving, IC forklifts usually have better acceleration and top speeds. IC forklifts also 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, including gasoline, diesel fuel, liquid propane gas (LPG), and compressed natural gas (CNG).
For indoor/outdoor use, duel fuel systems are available that let you switch between LPG and gasoline. You can refuel IC forklifts on the fly: simply fill them up at a gas pump or load new LPG canisters and 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. With some IC forklifts, you will have to buy refueling equipment. For example, gasoline and diesel fuel require 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.
Forklift Attachments, Comfort, and Safety.
Once you know what forklift features and which fuel type are best for your situation, consider safety features, comfort, attachments, and extras. The following criteria are often features that buyers may not consider immediately in their purchase but will add both comfort and functionality to the machine, making it a high-quality addition to the workplace. None of the following are absolutely necessary (aside from the legally regulated safety features, and employee training). However, this list should be considered before making a purchase to ensure that the forklift you are considering will be capable of the specific jobs you have in mind.
- Safety Features: Most forklifts come standard with safety features such as back-up beepers, flashing amber lights, and headlights. State regulations vary; always keep them in mind when you shop.
- Ergonomics: They may seem like luxuries, 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 forklift to better handle specific types of materials. There are specific tools to pick up rolls of cable or steel, tongs for handling 55-gallon drums, flat panels for lifting items that are not 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 is a popular option that allows an operator to move a load to the left or right without moving the truck, allowing more precise load placement. Sideshift can reduce load capacity, so again, be sure to check capacity plates.
- 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 purchase a full maintenance plan that covers any breakdowns or needed repairs. For a new forklift, it is unlikely that you will 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.
- Employee Training: The Occupational Safety and Health Administration (OSHA) has very specific rules about forklift operator training and licensing. Operators must pass classroom training and a driving test before being licensed, and they must be re-certified every three years. Many dealers provide training at their location for a small number of operators, or dealers may organize a class at your location if you have enough trainees. Check with OSHA about its rules and requirements.
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