Forklift Buying Guide: How to Choose the Right Forklift

Step 1: Assess Your Requirements

Before shopping for a forklift, answer these key questions:

Load Specifications

• Weight: What's the heaviest load you'll lift? (Add 20% safety margin)
• Dimensions: Pallet size, load height, and width
• Frequency: How many lifts per shift?
• Distance: How far will loads be transported?

Operating Environment

• Indoor vs Outdoor: Smooth floors or rough terrain?
• Space constraints: Aisle width and ceiling height
• Surface type: Concrete, asphalt, gravel, or mixed?
• Ventilation: Well-ventilated or enclosed spaces?

Usage Patterns

• Hours per day: Light (1-4h), medium (4-8h), or heavy (8+ h)
• Shifts: Single, double, or triple shift operation
• Seasonal: Year-round or seasonal peaks

Step 2: Choose Power Source

Electric Forklifts

Best for: Indoor use, smooth surfaces, 8-hour shifts

Pros:

• Zero emissions (safe for indoor use)
• Quieter operation
• Lower operating costs (electricity cheaper than fuel)
• Less maintenance (fewer moving parts)
• Better for cold storage applications

Cons:

• Higher upfront cost ($20,000-$50,000)
• Requires charging infrastructure
• Downtime for battery charging/changing
• Battery replacement costs ($3,000-$5,000 every 5-7 years)

Propane (LPG) Forklifts

Best for: Indoor/outdoor use, all-day operation, rough surfaces

Pros:

• Can operate indoors (minimal emissions with proper ventilation)
• Quick refueling (no downtime)
• Consistent power output
• Works in all weather conditions
• Lower upfront cost than electric ($15,000-$30,000)

Cons:

• Fuel costs higher than electric
• Emissions require ventilation
• More maintenance than electric
• Fuel storage requirements

Diesel Forklifts

Best for: Outdoor use only, heavy loads, rough terrain

Pros:

• Most powerful option (up to 50,000+ lbs capacity)
• Best for outdoor and rough terrain
• Long runtime between refueling
• Durable in harsh conditions
• Good torque for inclines

Cons:

• High emissions (outdoor use only)
• Loudest option
• More maintenance required
• Higher fuel costs

Step 3: Determine Load Capacity

Load capacity is the maximum weight a forklift can safely lift at a specified load center.

Common Capacities:

• 3,000 lbs (1,360 kg): Light-duty, small warehouses
• 5,000 lbs (2,270 kg): Most common, general warehousing
• 8,000 lbs (3,630 kg): Heavy-duty applications
• 10,000+ lbs (4,540+ kg): Industrial, construction, lumber

Load Center Explained:

Standard load center is 24 inches (measured from the fork face to the load's center of gravity).

Example: A 5,000 lb forklift with a 24" load center:

• Can lift 5,000 lbs if load center is at 24"
• Can lift only ~3,500 lbs if load center is at 36"
• Can lift ~6,500 lbs if load center is at 12"

Pro Tip: Always buy 20-30% more capacity than your heaviest load to account for uneven loads, worn equipment, and future growth.

Step 4: Select Mast Type and Lift Height

Mast Types:

1. Simplex Mast (Single Stage)

• Lift height: Up to 10 feet
• Collapsed height: Same as lift height
• Best for: Loading/unloading trucks, no overhead clearance issues

2. Duplex Mast (Two-Stage)

• Lift height: 10-15 feet typically
• Collapsed height: Lower than lift height
• Best for: Low ceilings, need moderate lift

3. Triplex Mast (Three-Stage)

• Lift height: 15-20+ feet
• Collapsed height: Much lower than lift height
• Best for: High stacking with low overhead clearance
• Most common in warehouses

4. Quad Mast (Four-Stage)

• Lift height: 20-25+ feet
• Collapsed height: Minimal
• Best for: Very high stacking, shipping containers

Calculating Required Lift Height:

Required lift height = Rack height + 6 inches clearance + Fork height (usually 4-6 inches)

Example: For 15-foot racking:

15 feet + 6 inches + 6 inches = 16 feet minimum lift height needed

Step 5: Consider Tire Options

Cushion Tires

Best for: Indoor use, smooth surfaces, tight spaces

• Solid rubber construction
• Smaller turning radius
• Lower cost
• Good for smooth concrete or asphalt

Pneumatic Tires

Best for: Outdoor use, rough surfaces, all-terrain

• Air-filled or solid pneumatic options
• Better shock absorption
• Can handle rough, uneven surfaces
• Suitable for outdoor yards and gravel

New vs Used: Making the Choice

Buy New When:

• Heavy daily use (8+ hours)
• Long-term investment (10+ years)
• Warranty and support are critical
• Latest technology and efficiency needed
• Budget allows ($15,000-$50,000+)

Buy Used When:

• Light to moderate use
• Budget constraints ($5,000-$20,000)
• Temporary or seasonal needs
• Willing to handle more maintenance
• Reputable dealer with inspection reports

Used Forklift Inspection Checklist:

• Hour meter reading (< 10,000 hours ideal)
• Mast condition (no cracks or excessive wear)
• Hydraulic system (no leaks)
• Tire condition (50%+ tread remaining)
• Fork condition (no cracks, proper thickness)
• Battery condition (electric models - test capacity)
• Maintenance records available
• Test drive under load

Total Cost of Ownership

Don't just consider purchase price. Calculate 5-year total cost:

Electric Forklift Example:

• Purchase: $30,000
• Electricity (5 years): $6,000
• Maintenance (5 years): $5,000
• Battery replacement: $4,000
• Total: $45,000

Propane Forklift Example:

• Purchase: $20,000
• Fuel (5 years): $15,000
• Maintenance (5 years): $8,000
• Total: $43,000

Note: Actual costs vary by usage, local fuel/electricity rates, and maintenance practices.

Related Equipment

Depending on your needs, you may also want to consider alternative material handling equipment:

• Floor jacks for automotive and maintenance work - available in 2 ton, 3 ton, and 4 ton capacities
• Pallet material selection affects forklift operation and load handling
• Appliance dollies and heavy-duty dollies for specialized moving tasks