Forklift introduction
The forklift is one of the workhorses of modern industry. Warehouses, distribution centers,
manufacturing plants, and lumber yards depend on forklifts of many types and sizes to keep their
operations running smoothly. Other businesses only need a forklift to unload deliveries for an hour
or two a day. Either way, having a forklift that can perform well for your specific needs is important.
These answers will help you determine exactly what kind of forklift trucks you need.
Buying a forklift is a big investment for small businesses, and you need to make sure you get one that
can handle your requirements without overspending. This BuyerZone.com Buyer’s Guide will explain the major
choices you have to make and walk you through the questions you should ask before you start buying.
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How to shop for forklift trucks
Before you even start looking at forklift trucks or talking to dealers, you need to determine exactly
what you need the forklifts to do. Here are some questions you should answer before you start comparison shopping:
- How heavy and what size are your typical loads?
- How high do you need to lift the load?
- Will you be using it indoors, outdoors, or both?
- How much room do you have to maneuver? How wide are your narrowest aisles?
- How many hours per day will it be used?
These answers will help you determine exactly what kind of forklift trucks you need.
Capacity
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.
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".
The easiest way to think about this is that a forklift can only lift its maximum weight if the load is a
four-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 the salesperson to determine
the exact capacity you need.
Also consider how much variation there is 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.
Height
A close second to "How much do you need to lift?" is "How high do you need to lift it?" If your primary
use for the forklift is loading and unloading trucks, you may not need much height at all; if your warehouse has shelves
30' high, that is a pretty clear indicator of the reach your lift will need.
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.
New vs. used
Deciding whether you will buy a new or used forklift truck is a good place to start narrowing your options. Here’s a good
rule of thumb: if you are going to be using your forklift more than 4 hours a day, you should invest in new equipment.
Forklifts that are used more than 4 hours per day are major part of your operation. With this much use, the operating
and maintenance costs for used equipment can quickly wipe out the initial savings you gained.
If the lift truck will be used only a couple of hours per day, you can probably benefit from buying a used truck. When
the dealer gets a used lift truck back at the end of a lease, they usually recondition it with a new paint job, new tires,
a thorough engine tune-up, and any other mechanical repairs that need to be made, so you can feel reasonably confident in
the condition of the truck. "As-is" trucks can save you even more money, but may have original paint, worn tires, and
generally not be in the shape you would expect.
Many dealers offer both new and used forklift trucks, so you can compare prices easily. Make sure to inquire about the
difference in service plans between new and used models.
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Forklift fuel choices
The two main options for powering your forklift are electric — powered solely by an on-board battery
— or internal combustion (IC), which use a traditional engine that runs on one of several types of fuel.
Electric
Electric forklifts are powered by large, heavy lead-acid batteries — the same kind found in your car,
but considerably bigger and more powerful. The batteries typically provide enough power for one standard
eight-hour shift, which translates into 5 or 6 hours of constant usage.
There are two primary advantages to electric-powered forklifts. One is that they produce zero emissions
— if you are going to be using your lift indoors, this is a very important consideration. 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.
The other primary advantage is fuel cost. Electric lifts have a lower cost per hour of operation than any
of the internal combustion models. This helps to offset one of their disadvantages — their higher initial
cost. New electric forklifts can cost 20% to 40% more than similarly rated IC forklifts.
Additional advantages of electric forklifts include their quieter operation — a big plus indoors —
and no fuel storage requirements. Because they have fewer moving parts and are often used in cleaner environments
than IC trucks, they also tend to have a longer life span.
The biggest downside of electric lift trucks is the battery downtime. Charging a forklift battery takes 8 hours,
plus 8 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 be charging the next one.
Other disadvantages include the need for a battery charging station. The 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 the batteries. Electric forklifts are also not suited for outdoor use — while you can use them on a well-paved
parking lot, they can't be used in the rain.
| |
Internal Combustion |
Electric |
| Maximum available capacity |
35,000 lbs. or more |
10,000-15,000 lbs. |
| Power source |
Gasoline, diesel fuel, liquid propane gas, or compressed natural gas engine |
Battery |
| Costs |
Lower purchase price
Higher operating costs |
Higher purchase price
Lower operating costs |
| Best used |
Outdoors
(Propane: Indoors or Outdoors) |
Indoors |
| Typical Applications |
Lumber yards, construction,
loading docks |
Indoor warehouses, manufacturing |
| Refueling time |
5-15 minutes |
16 hours to recharge a battery; 20-45 minutes to change batteries |
Internal combustion
Internal combustion engines run on a variety of fuels: gasoline, diesel fuel, liquid propane gas (LPG),
or compressed natural gas (CNG). The main benefit of IC forklifts is their ability to be refueled on the
fly: simply fill it up at a gas pump or load a new LPG canister on and your forklift is ready to continue
working in no time. Their price points are the inverse of electric: they are cheaper to buy initially, but
cost more per hour to run.
Only IC forklifts are capable of handling the largest loads — if you require greater than 15,000 lbs
capacity, you definitely need an internal combustion engine. IC forklifts also stand up to certain types of
misuse better than electric lifts — specifically, using a forklift to push or tow loads, instead of
lifting and driving — and usually have better acceleration and top speeds.
Of the types of IC engines, fuel costs generally are highest for gasoline and lowest for diesel, with LPG
somewhere 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 a significant extra expense for refueling equipment — 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.
For indoor/outdoor use, duel fuel systems are available that let you switch between LPG and gasoline.
Other fuel options
The wave of the future in forklift power is fuel cells. Hydrogen fuel cells have the advantages of electric
power — zero emissions and quiet operation — plus the ability to be refueled as quickly as diesel
or gasoline engines, with no recharging time. Experimental fuel cell forklifts are already in use, and will
start to be available more widely in coming years.
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Choosing lift truck options
Once you know what lift truck capacity and fuel type are best for your situation,
there are other options to consider as well.
There are two types of tires to choose from: cushion tires, which are made of solid rubber, and pneumatic
tires, which are inflated with compressed air. For internal applications, cushion tires are the best choice;
for outdoor work, you may want more expensive pneumatic tires.
A third option, solid pneumatic tires, are ideal for outdoor environments where there’s a high risk of
popping regular pneumatic tires: lumber yards or recycling centers where nails or glass can be scattered around.
They combine the solid-rubber construction of cushion tires with the rough terrain capabilities of pneumatic tires,
and typically are more expensive than the other two types.
Because they are used for inside work, electric lift trucks are usually only available with cushion tires.
For heavy-duty lifting outdoors on uneven terrain, a gasoline or diesel lift truck with pneumatic tires is the
most common choice. The salesman should be able to provide guidance on your specific application.
In a warehouse setting, the size of the lift truck may be an issue as well. Standard lift trucks need aisles
that are 11' wide or larger to be able to operate and turn around. For aisles that are 8' to 10' wide, you will
need a narrow aisle (NA) truck; for aisles down to 6' 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.
Other considerations you should take into account:
- Safety features. Back-up beepers, flashing amber lights, headlights, and other safety features are
sold standard with most fork lift trucks. State regulations vary, but we recommend that you always include them
in your shopping.
- Ergonomics. They may seem like amenities, but for employees who will be using your lift trucks all day
long, 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.
- Sideshift. This very popular option allows the operator to move the load left and right without moving the
truck, allowing much more precise placement of loads.
- 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 while moving a loaded truck.
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Test drive your fork lift trucks
Knowing what specs and options your fork lift trucks should include is only the first step in making a
good purchasing decision. Once you have the choices narrowed down to a few models from different dealers,
you should ask.
At the very least, most dealers will bring the lift truck models you are considering to your location and let
you use it for an hour or two. In many cases, the dealer will let you keep the truck for one to three days, giving
you the chance to put it to the test in a live environment.
A full day or more of using the truck will give you the best idea of how it fits with your specific application.
Personal preferences about the controls and ergonomics can play a big role in your decision, and having the truck at
your location gives you the chance to include more of your lift truck drivers in the decision-making.
In addition, fork lift truck salespeople will help you evaluate your facility and requirements. By measuring
doorways and aisles and examining your typical loads, they can help you make sure you choose a forklift suited
to your particular needs.
Rent to evaluate
If you aren’t very familiar with the different brands and types of lift trucks, consider renting. By renting a forklift
for a month, you can really get a sense of whether its capabilities are appropriate for your needs without the pressure
of a long-term lease or major investment. In addition, with a rental, you never have to worry about maintenance or repairs
— if anything goes wrong, the rental company will simply replace it.
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Choosing a fork truck dealer
When choosing a fork truck, you are also choosing a fork truck dealer. The dealer will provide the service
and support to keep your lifts running smoothly, so it is important that you find one who is reputable, stable,
and can provide top-notch service.
Some important questions to ask when evaluating fork truck dealers:
- How long have you been a customer of theirs? How many forklifts have you purchased?
- Did you get the right forklift for your application?
- Has the dealer done a good job with maintenance and repairs?
- Would you buy from this dealer again?
- What could the dealer improve about their operation?
In addition to having a demo at your location, you may want to visit the dealer’s facility. Simply seeing the parts
warehouse and service areas can give you a good sense of their capabilities.
Since fork truck dealers typically have exclusive territories for the brands they sell, it can be fairly easy to get
a sense of the firm’s general reputation. Talking to other businesses in your area can be a great source of insight into
a dealer’s strengths and weaknesses. You should also ask the dealer for customer references, preferably of customers with
fork lift applications similar to yours.
When checking references, you can ask questions like these:
- How long have you been a customer of theirs? How many buildings have you purchased?
- Would you buy from this dealer again?
- Did they deliver your building on time?
- Did you get the right building for your application?
- What could the dealer improve about their operation?
If you decide to rent first, you can turn to a third-party equipment rental company instead of a dealer. Rental companies
often offer multiple brands of fork trucks. By trying out a different fork lift each month, you will have a much better sense
of which brand and type is best for your application after a few months.
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New and used forklifts pricing
When choosing a fork truck, you are also choosing a fork truck dealer. The dealer will provide the service
and support to keep your lifts running smoothly, so it is important that you find one who is reputable, stable,
and can provide top-notch service.
Much like automobiles, forklift pricing varies widely by brand, and pricing does correlate to overall
quality and reliability. Top-tier brands are more expensive due to technology advantages, better tolerance
of abuse and harsh environments, and greater long-term reliability.
These prices are highly variable and depend on geography, your specific needs, and the dealer you choose
to work with, so consider them only rough guidelines.
The 5,000 lb forklift is the industry standard. New electric 5,000 lb forklifts typically retail for $18,000
to $25,000, plus $2,000 to $5,000 for one battery and a charger. 5,000 lb internal combustion forklifts start at
around $16,000 and can cost up $28,000 or more, depending on the options you choose. In most but not all cases,
an electric forklift will be more expensive than an identically-rated IC lift.
A 10,000 lb capacity diesel lift can go for $28,000 to $45,000. High-end lifts, with capacities of 35,000 lbs
or more, cost $100,000 and up.
TCO
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.
You can expect an hourly operating cost of anywhere from $1 for small electric trucks to $20 or more for the largest IC trucks.
Used equipment
Buying used equipment can save you quite a bit up front – but even a used forklift is still
a significant expense. A reconditioned 3,000 lb electric forklift might go for around $8,000 to $10,000, less than half
the cost of a new one. A 5,000 lb IC forklift that might cost $25,000 new could cost $10,000 or $11,000 reconditioned.
Remember, if you are using your forklift more than four hours a day, you may quickly find that the costs of downtime and
repairs quickly cancel out the savings of buying a used forklift.
Forklift Leasing, financing, and long-term rentals
Because of the high initial cost, almost all forklifts are
either leased or financed. Some manufacturers provide financing and forklift leasing through their dealers; in other cases the
dealer may have an arrangement with a third-party bank or leasing company. When manufacturers subsidize the forklift loans or
forklift lease, they often offer very favorable terms; if dealing with a third party, you may want to compare the financing terms
to what you can get from your own business bank.
Another alternative is the long-term rental. Usually defined as a rental for over 12 months, a long-term rental differs from a
lease in that it is based on a monthly fee and can be cancelled at any time after the minimum. With a lower monthly rate than
short-term rentals and all regular maintenance included, long-term rentals can be an economical choice for temporary projects or contractors.
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. 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.
For an additional cost, you can also purchase a full maintenance plan — one that covers any breakdowns or repairs that are
needed. 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.
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, must be over 18 years of
age, and must be re-certified every three years. Many dealers provide training at their location if you only have a couple of
operators, or can organize a class at your location if you have enough trainees. Costs can be from $75 to $200 per person and vary
with location and the number of participants.
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Forklifts buying tips
Keep on top of lift trucks training.
OSHA training may seem like an unnecessary hassle and
expense, since the rules are not strictly enforced. However if you have a lift truck accident, OSHA will
investigate your training and licensing procedures and can levy significant fines if you have not followed
all the procedures.
Know your capacity.
Attachments like sideshift, adjustable forks, and spool handlers reduce
load capacity of lift trucks. Every lift truck should have a capacity plate attached to it detailing what
its capabilities are in its current configuration.
Try multiple brands…
If you aren’t familiar with lift trucks, we strongly recommend
renting a couple of different models for a month each. You will be able to get a much better sense for the
strengths and weakness of different types of lift trucks.
… but stick with one brand once you decide.
If you plan to buy multiple lift trucks,
standardizing on one brand gives you the advantage of dealing with one dealer for all your warranty and repair
needs. Your operators will also benefit by not having to learn the control and handling quirks of multiple
types of lift trucks. In some cases, this may not be possible, since not every manufacturer makes every type
of fork lift and you may need multiple specialized machines.
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