Buying a Forklift: The Ultimate Guide to Making the Right ...

Buying a forklift can be difficult, especially if you do it for the first time. Why?

For more information, please visit HULKMAN.

There&#;s a lot to consider such as carrying capacity, lifting height, type of motor, tire composition, and operator ergonomics. 

If you&#;re buying a used forklift, you can also look for things like damage to the forklift forks, gaps in the lift chains, mast operations, the condition of the battery, and more.

And then there&#;s consideration of cost and manufacturer. 

So, this post is your ultimate guide to buying a forklift. 

Inside, you&#;ll discover the following:

• Factors involved in buying a forklift.

• Costs.

• Places to buy from.

• What to beware of.

• And LOTS more!

Let&#;s dive in!

 

Buying a Forklift: The Basics

Buying a forklift is an investment for your business, but choosing the incorrect forklift could be a financial burden instead of an asset.

The right forklift will help you save money, decrease overall downtime,  increase productivity, and maintain a stable operation.

So, here are some forklift purchasing factors to check out as you go to buy a forklift, especially buying a forklift for the first time:

1. Research, Forklift Type Selection

When you purchase a forklift, you must know what you want and your operation&#;s requirements. 

Like a car, you&#;ll want to select the best brand, model, and type for your operations.

Because of the wide range of products in the material handling market, you must first know what you&#;re trying to accomplish in your operations.

That means you&#;ll first audit your operation and answer questions such as:

• What environment are you operating in &#; cold room, warehouse, construction, etc.?

• How high do you need your machine to lift?

• Where will the forklift primarily be used &#; indoors or outdoors?

• How wide are the operating area&#;s aisles and doors?

• How many hours will the forklift machine be in use per day?

• What types of

  forklift tires

  will your machine need?

• Are there any specific accessories you will need?

• Do you have properly trained operators as per OSHA requirements?

• What forklift machine/motor type will you need?

• And more

Answering these questions will help you understand the forklift model and type you need before you settle on the brand.

2. Technical Specifications

Buying a forklift is like buying an ordinary car, apart from the technical specs you must check out for such as:

• Weight capacity

• Mast size and function

• Tire type or composition

• Lifting height 

• Motor type

• Operator ergonomics

• Manufacturer&#;s reachability.

• Safety features

• And more!

3. Forklift Model/Brand Selection

Once you understand the forklift type you want and its technical specifications, your next step is to settle on the brand and model.

Since different forklift manufacturers and brands have different models, settling on one can be challenging. 

You need to research and review each forklift manufacturer and their brands using some of the following questions:

• Brands:

  What are the best forklift brands? Refer to this list of

  forklift manufacturers

  for different forklift brands.

• Type:

  What are the different

  types of forklifts

  in the model category among brands?

• Dimensions:

  What is the most popular forklift size in that model category among brands? Can it fit your operations?

• Price:

  How much does the forklift brand and model cost? How much is the cost of a new vs used forklift in the model and brand?

• Ownership:

  How does the ownership model of the truck look? For instance, who will carry out the

  forklift repair

  /maintenance/care? Can you access dealership-provided maintenance?

After addressing these questions, you can confidently select the forklift brand and model that best meets your operational needs. This choice should be the right fit for you unless you discover the need for alternative forklift options.

4. Research Brands and their Dealerships 

Additionally, research the brands and dealers of the forklift(s) you want to settle on. 

Since buying a forklift is a capital investment, you need a dedicated partner for better ROI. A partner can be a forklift manufacturer or a dealership like Conger Forklifts.

The partner you get will help you with all your material handling needs throughout your ownership rather than someone who will sell you a forklift. 

You may find a lesser-known forklift brand and a cheaper up-front price, but how easy will it be to get forklift replacement parts? And why are they lesser known and cheaper?

That is why we recommended dealing with dealerships.

You can visit the dealership and ask about the parts, operators&#; and technicians&#; required skill level, and any references. 

Choosing a dealership means you get a partner for your material handling machine for many years. 

To help you get started, check out the closest Conger dealership location.

5. New or Used Forklift 

Next, you&#;ll decide if you want a new vs. used forklift. 

When deciding between a new or used forklift, several factors come into play:

• Price and cost consideration (what your budget allows, negotiation).

• Forklift operation hours

• Availability 

• Service and dealership access 

• Maintenance costs

• Warranty coverage

As a general rule of thumb, consider a new forklift if you&#;ll run the forklift more than four hours a day. Why?

When factoring in the operation hours and maintenance costs, a new forklift may serve you better in the long run.

But you will also consider its availability, service, dealership access, and cots. If a new one costs beyond your budget, a used forklift can still help you achieve your operation needs.

6. Safety and Operator Considerations

While forklift safety is a technical feature, it&#;s also a subjective requirement. 

Once you check the forklift&#;s safety features during the technical overview, you must also compare its safety to the operating environment and operators. You&#;ll need to consider the safety requirements of your people and your operation. 

For instance, does one of your operators have a bad back? In this case, you must consider the forklift brand with the best ergonomics, such as chair and forklift controls. 

Forklift safety is crucial to operation success and overall worker productivity.

So, select the brand with the best standard safety features for your operations.

Refer to this post for Forklift Safety Tips for Operators, Pedestrians, and Managers based on your operating environment.

7. Settle on a Forklift and Test Drive

After all the research and settling on a particular forklift, you can schedule a demonstration (i.e., a test drive for cars).

With the help of a manufacturer or dealership, you can use the lift truck in your facility for a few days to ensure it works well for your application and that the operator likes it.

You can also check if you have the proper maintenance equipment, such as charging devices and storage for an electric forklift.

Like consulting with family members when buying a car, you can consult with forklift experts before you settle on the forklift.

The important thing is to get the right forklift for your operations.

8. Sign the Paperwork and Forklift Delivery 

Once you have tested the forklift and feel it passes your demo requirements, your next stop is signing the paperwork. Just like you&#;d buy a car. 

Make sure you check everything and tick the right things before you buy the forklift. 

After that, you can drive off (not advisable) or have it delivered if you&#;re buying a forklift. Most dealerships and forklift manufacturers will offer delivery of the forklift to your premises.

 

Buying a Forklift: Key differences between buying a car and a forklift

If you&#;re buying a forklift for the first time, here are some key differences between buying a car and buying a forklift: 

• Consultations and Decision:

  If you&#;re married, you must be clear with your spouse when buying a car. When a business buys a forklift, the president, CFO, operations manager, maintenance manager, and others may have to agree about the forklift. A forklift purchase is a decision by a &#;committee&#; and not an individual decision. 

• Safety of operation:

  People buying a car think about keeping their passengers (like friends or family) safe and comfortable. Businesses buying a forklift care about the safety and comfort of their operators. But when different people use the same forklift, it is hard to make a decision that everyone is okay with.

• Technical aspects of forklifts:

  There are many technical factors to consider when purchasing a forklift. These factors include the type of fuel the forklift uses , which depends on where it will operate and any restrictions in that area. You also need to consider the type of tires based on the terrain, how much weight the forklift needs to lift , how high it needs to lift things, its physical size, and more. For instance, you need to check if the forklift can fit through doorways and if it&#;s too heavy to use in certain areas like docks. Private car buyers don&#;t need to think about these specific details.

What Can Go Wrong When Buying a Forklift?

There&#;s a lot of information about what you should do when searching for the best forklift for your unique operations. 

But, have you ever wondered why someone didn&#;t warn you when you were about to make a mistake on your forklift decision you can&#;t get back? 

Here are some of the things that may go wrong when buying a forklift:

1. Compromised Safety

Examples of compromised safety situations include:

• Buying a forklift that&#;s too heavy for the application, causing a failure and injuries, for example (loading a semi-trailer with a very heavy forklift).

• Using an unprotected forklift in a sensitive environment (flour mills, because of the fine powder, can be an explosion risk.)

• Using a &#;regular&#; forklift that can emit a spark could be disastrous, thus the need for a specialized explosion-proof forklift.

Find a forklift designed for the specific operation and your business&#;s unique needs.

2. Buying on Price Alone

While the cheapest forklift that meets your minimum capacity requirements is tempting to purchase, it&#;s not a great idea.

There are many other important factors to consider before buying a forklift, and the upfront price is only one.

Don&#;t just ask how much is a used forklift or how much is a new forklift. 

Also, check out to ensure you&#;re not paying expensive upfront costs with related expensive maintenance costs. 

Not considering the total cost of ownership is disastrous. 

Spending a little more upfront cost can be an investment, especially if your operations can become more efficient and productive over time.

3. Not Buying from a Dependable Dealer

We recommend buying a forklift from a dealer, but you must research and ensure the dealer you&#;re buying from is reputable and dependable. 

Buy your forklift from a reputable and dependable dealer who will provide emergency and general maintenance when needed. 

Otherwise, you risk considerable downtime if your forklift breaks down.

4. Not Trying the Forklift Before You Buy

Once you&#;ve decided on the make, model, and manufacturer of the forklift you want, there are two things you can do:

• Request a demo from a dealer with enough time to try out the forklift.

• Rent a similar make and model to try it out in your work conditions. 

You must do this to ensure your operators have input on the forklift type and operation. They will be the ones driving and operating the machine all day.

5. Wasted Money

If you can&#;t use the forklift because it&#;s the wrong fit, it&#;ll just sit there for whatever reason. Idle forklifts don&#;t make money &#; they only cost money.

6. Look bad

Whoever buys the forklift will be held accountable. If your boss sees the lift truck sitting unused, how will you defend the decision? 

If you buy a forklift that all your operators hate, they might resent you for buying it (and they probably won&#;t use it either, a &#;double-whammy&#; of a problem.

Yet, no one wants to look bad. So, you can consult and make the right decision when buying a forklift.

7. Not Considering the Forklift&#;s Maintenance Plan

Obtaining an initial maintenance plan helps you gauge whether or not you have the proper infrastructure and qualified personnel for the forklift. Additionally, you&#;ll determine if the manufacturer or dealer offers regular emergency forklift maintenance. This preparation aids in effectively planning for forklift maintenance to avoid significant downtimes.

10 Benefits of Buying a New Forklift

Deciding which forklift manufacturer and model to buy can be a challenge.

Determining how to procure that equipment, however, shouldn&#;t be difficult.  If you&#;re deciding to buy new vs used forklifts, here are the benefits you&#;d get if you purchase a new forklift:

1. Best condition

A new forklift comes in the best condition: new, no wear, new features, and better performance. 

In addition, you have no doubt where it came from, its utilization, how it&#;s been cared for, etc.

2. Access to Updated or Latest Features 

Much like other automobiles, forklifts are constantly updated and improved. These can be feature improvements like:

• Integrated dashboards with onboard diagnostics.

• Enhanced safety features.

• Better emission controls.

• More comfortable operator compartments.

• More attachment options. 

• And more.

Forklift manufacturers and engineers constantly try to make forklift equipment safer, more productive, and more ergonomic.

Buying a new forklift means you get these latest features, smoother operation with less downtime and more safety. New equipment has the latest safety and productivity features.

3. Excellent performance guaranteed 

When you purchase a new forklift, you can be sure it will perform at its best. It will bring peace of mind to your business because you&#;re getting a never-used forklift, ensuring reliability and top-notch performance.

4. Return on Investment

Buying a forklift provides a better return on investment (ROI) than long-term rentals. Why?

• You get the forklift&#;s maximum performance at peak.

• It&#;s the only way you can resale the forklift and earn from its residual value.

• Rental fees are higher than monthly financing costs.

With low, predictable utilization and when properly maintained, the lift truck will hold a respectable residual value.

5. Ability to Customize 

Customization is a key factor to consider when you&#;re acquiring a forklift. 

Buying a forklift means you have ownership of it, similar to owning a car, and hence have the right to customize it tailored to your applications and operation&#;s needs. 

You can make more modifications to the forklift than you could with a rented or leased vehicle.

6. Availability 

New equipment gives you the advantage of being very specific with your requirements. 

Buying new equipment allows you to be highly specific with your requirements.

Unlike purchasing a used forklift, where you&#;re limited to what&#;s available in the secondary market, buying new lets you benefit from the features tailored to your needs that you will not find elsewhere.

7. Warranty 

New forklifts generally have a multi-year warranty, whereas used forklifts may only have a multi-month warranty.

Depending on the manufacturer, your new forklift will probably come with a warranty lasting 12 to 36 months or up to 2,000 hours or so.

Compared to used forklifts, which either have 30 or 60-day warranties or even no warranty, you&#;ll come away with much greater peace of mind with a new forklift.

8. Tax Deduction

Unlike rented or leased vehicles, forklifts purchased NEW can be eligible for tax deductions.

For instance,  when you buy a new forklift, the equipment becomes an asset you can claim depreciation on and borrow against.

9. No Liability and Usage Restriction 

Rental and lease forklifts must be returned after a set period and in a reasonable condition based on the conditions in your contract.

If you buy a new forklift, it belongs to you, so cosmetic damage isn&#;t as much of a concern.

This benefit means you won&#;t get charged at the end of the lease for things like worn tires, cosmetic damage, etc. And you&#;ll use it as often as you need with no hourly usage restrictions or overtime charges.

10. Employee Satisfaction

Believe it or not, employee satisfaction helps increase efficiency in your warehouse operations. 

Just think, who will complete more work: a frustrated worker or a happy one?

Buying a new forklift simplifies the operator&#;s job because it comes with enhanced features, offers greater versatility and safety, and helps reduce downtime.

In short, you&#;re making the employees&#; lives easier and showing that you care about them.

It will boost their morale and satisfaction. 

(We also have a detailed overview of forklift pros and cons to help you decide on the forklift you want.)

5 Benefits of Buying a Used Forklift

Why buy a used forklift?

Buying a used forklift (second-hand forklift) also comes with some advantages and benefits, such as the following:

1. The Lower overall initial cost

Used forklifts have an overall lower initial cost compared to new forklifts.

Take advantage of forklift depreciation to get &#;nearly new&#; equipment at a steep discount over &#;actually&#; new equipment. 

The concept of &#;driving off the lot&#; immediately makes a vehicle lose value.

It also allows you to negotiate for a lower price on the used forklift and upgrades, like large forks, new tires, or an upgraded attachment.

2. Shorter Lead Times; Get it Faster 

Sometimes, you have the advantage of availability when buying new forklifts, but sometimes it&#;s when buying used ones.

Most forklift dealerships have ample stock of a variety of material handling equipment. So, when you order a used forklift, you won&#;t have to wait for it to ship from the factory.

In many cases, you can get a used forklift the same day, but you&#;ll face a much longer lead time buying a new one. 

It works best if you&#;re not too picky with specifications, you have an urgent need, and renting isn&#;t viable.

3. Seasonality Needs 

Renting or buying additional forklifts for seasonal needs is a cost-effective strategy.

When buying a used forklift at a lower price, you can use it throughout the season, then dispose of it during the off season.

For instance, you might acquire a used diesel forklift for a specific harvest season and then sell or return it once the harvest is over.

4. Larger selection

You can find used forklifts at dealerships, as they often have large quantities available compared to their new stock.

Since they have more used forklifts, you can easily find a used forklift that meets your application and material handling requirements.

That will save you on costs like research and transportation.

5. Faster RIO

The &#;get it faster&#; component of used forklifts also means you can start being productive faster. 

The sooner you get the lift, the sooner you can put it to work.

And the sooner you can put it to work, the faster you can recoup your initial investment. For example, a used propane forklift will arrive faster, and if it&#;s in good working condition, you can put it to work immediately.

6.

Installed Add-ons

An advantage of buying used forklifts is that desired add-ons may installed, saving you additional money on parts and components.

Purchasing add-ons and special equipment for a new forklift can be costly. So, if you find a used forklift with the add-ons paid for by a previous owner, you&#;ll reap the benefits.

9 Items to Inspect Before Buying a Used Forklift

After buying a used forklift, you must ensure you get risk-free equipment. This implies you have to inspect the forklift before you &#;drive it off the lot&#; to give it a clean bill of health.

In addition to considering the price of the used forklift, carefully assess its physical condition and thoroughly examine every crucial aspect of the vehicle.

Here are nine items regarding what to look for when buying a used forklift (pre-purchase forklift evaluation):

1. Frame

Check the chassis and structural integrity of the lift truck. Look out for issues like:

• Cracked welds in the frame

• Signs of damage or weakening

• Twisting

• cowling 

• Signs of repair or modifications

• Any other physical damage.

Also, check the counterweight, especially how it seats into the frame and its security.

Don&#;t worry about little dings and scratches on a forklift body when buying a used forklift. These are normal for a machine that moves heavy loads around a warehouse all day.

However, large dents or frame areas that appear hammered out could indicate significant damage or rough use.

If the forklift&#;s overall condition doesn&#;t match the hours on the odometer and its known use, this is a cause for concern.

2. Engine or Motor

See what shape the Engine & transmission (for internal combustion) or motors and battery (electrics) of the forklift are in.

Generally, the engine should be clean and free of leaks.

After running the forklift for a few minutes, open the engine compartment and do the following:

• Inspect for any leaks, cracks in the hoses, accumulation of dirt, and other signs of wear or damage.

• Pull out the dipstick and check the engine oil. Low oil might suggest that there is a leak.

• Check the belts and make sure they&#;re tight and well-lubricated.

• Check for leaking transmission/torque converter seals

• Ensure the engine head gaskets are in place.

• Check for burning oil, losing oil, compression problems

• Check for coolant leakage in the combustion chamber.

• Check the forklift hours to determine if it&#;s nearing its

  forklift useful life

  or has surpassed it.

Most of these issues don&#;t exist in electric lift trucks, though there are other components to check, such as battery life, drivetrain, and the condition of electric wires.

But ensure the battery is clean, with good connections and no corrosion around the posts.

Assess its overall value and aim to identify any significant issues before making the decision to purchase to determine if it is worth it.

Also, check the hour meters, key-on, travel, lift/lower, and more. For instance, 5,000 engine hours on a Toyota lift truck is when it&#;s &#;just getting started.&#; Some customers have gotten over 25,000 hours. Moreover, Toyota electric models are renowned for surpassing 50,000 key-on hours.

Other common forklift useful hours to check include

•  Hours per year: The average forklift is usually between 1,000 and 2,000. Beyond that is an overuse. 

• Forklift useful life

  : Generally, expect aforklifts to last about 10,000 hours. Beyond that, the forklift might not help you. Most forklifts don&#;t last up to 15,000 hours.

• Number of years in use. The forklift hours are about five years, based on an 8-hour, 5-day workweek. Beyond this timeframe, a forklift is considered overused.

3. Hydraulics

On a used forklift, carefully inspect the hydraulics and thoroughly check all hoses, looking for:

• Signs of leaks on hoses and connections (fittings), both before and after a test drive.

• Worn hoses (can see metal poking through the hoses).

• Hydraulic valve and pump (liable to wear out over time/use).

Also, check the hydraulic control levers and hydraulic operations. It should be a smooth operation, not too slow, or no strange noises from the forklift controls.

Test and ensure all the hydraulic or forklift controls are functioning properly.

4. Electrical

Check if the forklift&#;s electricals are in good operation. Check the:

• Dashboard: It lights up, functions and all the gauges are in good working order.

• Wires and wire harnesses: Especially for corrosion and loose connections. 

Also, test the horn, lights, and other electoral components to see if they&#;re in good working order.

You must also verify the forklift odometer reading and ensure it has not reset. The easiest method to verify this is by examining the frame and wear on significant components. If they don&#;t correspond with the recorded hours, it&#;s probable that the hour meter was reset.

5. Mast

First, make sure that the truck has the right forklift mast height, carriage and load backrest, rails, rollers, capacity, and cylinders. After that, you need to check each component&#;s condition. 

• Look for gaps in the lift chains or missing or damaged links in the chains.

• Look along the mast for cracks or welding marks indicating previous repairs. A poor weld will affect the structural integrity of the mast.

• Check the lift chains for any missing or corroded links/pins.

• Watch how smoothly the mast operates up to the second or third mast and ensure no hiccups.

• Make sure the mast rollers are not worn and are lubricated/well-maintained.

• Check the speed of the rollers and mast and ensure they&#;re within the required levels.

• Check the mast chains and anchors (wear, breaks, elongation) for tears/wear, and note down the positions you think might need action.

• Check the rails for cracks, dents, or excessive wear, and confirm that the mast rollers are in good condition. The rollers should be round, not oval, in shape.

• Watch for too many repairs or poorly performed maintenance of forklift mast chains. 

Refer to this post for more about forklift masts.

6. Attachment

Check out the forklift attachments and make sure they&#;re working correctly.

Whether it is just the forklift forks on a carriage or an attachment such as a paper roll clamp or side shifter, each component should undergo inspection for signs of wear and damage.

Ask the dealership rep if any other attachments are missing or that they can use.

7. Brakes

Breaks can be part of the hydraulic system but you need to ensure they&#;re working properly for safety. Check the following:

• Stopping ability

• Leaks in the cylinders

• Moisture in the brake fluid.

• Concerning noises, vibrations, grinding, burning smells, etc.

If the brakes don&#;t function properly, that&#;s a cause for alarm. You can consider a different forklift equipment.

8. Tires

The condition of forklift tires is a critical factor that requires thorough examination prior to purchasing a used forklift. Look out for chunking, tears, and separation between the rim and tread.

Get down and look/feel for any signs of chunking, which resembles a portion of the tire &#;being bitten off.&#; Chunking is a significant issue that requires attention.

Another tell-tale sign of tires being in rough shape is when the tread is low or non-existent.

Look/feel the wear line or the safety line. If the tire has worn past this line or is nearing it, it will require replacement.

If the tire does not have a wear line, examine the lettering on the sidewall. Once the wear reaches the top of the lettering, the tire needs to be replaced.

You can also perform the penny test on the tire. An old but effective method is to check if the top of Lincoln&#;s head on a penny is visible when inserted upside down into the tire tread. If it is visible, it indicates that the tire tread is low and may need replacement.

Refer to this post for more about forklift tires.

9. Safety Devices

Never forget to examine safety features when buying a used forklift.

Test forklift safety features like the horn, lights, backup alert, backup alarm,  brakes and levers, and seatbelt. Ensure that they&#;re all in good working order and operable. 

For instance, OSHA may have a problem if you have a backup alarm installed, but it doesn&#;t work, the volume has faded, or it&#;s not loud enough.

Inspect the forklift&#;s overhead guard frame carefully. Any damage to this component could jeopardize the operator&#;s safety. For example, OSHA requires that overhead guards have damage less than 3/4&#; deflection.

Look carefully at the frame of the cab area. Ensure that it is structurally sound, without bent or damaged metal. Also, ensure that windows are not broken or missing glass.

Buying a Forklift Battery: Everything You Need to Know

Your electric forklift must have the proper forklift battery to function.

If buying a used forklift, check if it has a compatible battery for the truck. What kind of shape is it in? The only way to know is by load testing.

The battery should also be clean, with good connections and no corrosion around the posts.

If buying new, there are lots of considerations, including:

Battery Types

Check that the battery installed in the forklift is the right one. There are 

• Lead-acid batteries 

• Lithium-ion batteries

   

• Other (gel batteries)

Forklift Battery Voltages

Forklift batteries come in different voltages, depending on the size of your equipment, such as:

• 12 Volts: 

  Small and light lift equipment such as powered pallet jacks.

• 24 Volts: 

  Small electric lift equipment such as center riders, end riders, walkie stackers, and electric walkie-pallet jacks.

• 36 Volts: 

  Mid-sized electric lift trucks, including narrow aisle forklifts and 3-wheelers.

• 48 Volts:

   Larger lift machines such as 4-wheel counterbalanced forklifts.

• 80 Volts: 

  Large material handling such as pneumatic counterbalanced forklifts.

However, some equipment requires specific voltages to operate.

Confirm the voltage your forklift can handle because a wrong voltage can cause significant damage to the equipment.

Also, ensure that the Voltage and amp-hour match. Is the battery 36V? 48V? 68V? Does it match the right Ah?

Don&#;t get any of these considerations when selecting a battery.

If unsure, consult the lift truck data plate or owner&#;s manual. If you have a clean, readable data tag, you&#;ll see the amp house abbreviated &#;Ah.&#;

Battery Physical Size

The battery&#;s physical size (battery dimensions) must match the battery compartment dimensions of the forklift.

It must also match minimum weight requirements, as batteries often act as counterweights.

Depending on your lift truck&#;s size, brand, make, and model. There are hundreds of different forklift battery sizes.

The larger the forklift you operate, the larger the battery size.

Often, you can find the size displayed on the battery&#;s nameplate or the cell connectors nearest to the positive terminal. Alternatively, you will find the battery size on the model number, serial number, and weight stamped.

You should know how to read the battery model number because it will show you the battery size and voltage. For instance, take model 18-85-17, where:

If you are looking for more details, kindly visit 5 ton forklift diesel consumption per hour.

• The first number (18) indicates the number of cells, doubling as the voltage since each cell is 2 volts. Therefore, an 18-cell battery is 36 volts.

• The second number (85) represents the plate design capacity.

• The third number (17) {always an odd number) shows the number of plates in each cell.

Thus, an 18-85-17 is a smaller battery than an 18-85-29.

Battery Weight

You might wonder how much a forklift battery can weigh.

Overall, forklift batteries can weigh between 600 lbs. And 5,000 lbs. or more for the larger electric forklift trucks.

The weight of forklift batteries serves two purposes:

• To power the lift truck based on forklift size.

• To act as a counterbalance for the forklift&#;s stability.

So, the bigger the forklift, the more the battery will weigh. Check and make sure that your forklift has the correct battery size.

Installing a heavier or lighter battery than the manufacturer recommends could create a safety hazard because of counterbalance issues.

To understand the forklift&#;s recommended battery weight, check the forklift data plate.

Battery Operating Requirement and Safety 

The forklift battery manufacturer or forklift manufacturer should outline the battery operation requirements.

For example:

•  Is the battery for a single shift or 24/7 operation? 

• What is the charging method of the battery? Opportunity/fast charging needs?

Ensure you get a battery with the right forklift charging equipment at the right time. 

You also need to ensure that you have the appropriate requirements for a forklift battery charging station, including:

• Fire extinguisher

• Emergency for communication

• Ready access to water

• Eyewash station 

• Readily available neutralization materials (such as soda ash or baking soda)

• Adequate ventilation to disperse flammable hydrogen gas

• Hazard signs such as no smoking. Smoking in the charging area is prohibited to prevent accumulated hydrogen from exploding.

• Appropriate personal protective equipment such as goggles, hard hats, face shields, rubber aprons, rubber/neoprene gloves, and safety toe footwear

Forklift Battery Maintenance

Maintaining the forklift battery is just as crucial as the battery itself.

Proper forklift battery maintenance helps preserve the useful life span of your forklift battery.

Maintenance requirements depend on the type of forklift battery and your work operations.

For example, Lithium-ion batteries are sealed and require little to no maintenance. However, lead-acid batteries require frequent maintenance to prevent degradation of the chemical process and preserve their operating capacity and general lifespan.

The key activities in lead-acid forklift battery maintenance include:

• Forklift battery charging

• Regular Watering

• Proper charging

• Regular Equalization

• Washing

Check that you have all the support infrastructure for battery maintenance or whether you should buy them together with the battery.

Prices and Warranty

In addition to assessing the battery pricing, account for the manufacturer warranty.

Forklift battery prices will vary depending on the model, size, weight, and manufacturer.

But focus on warranty. 

Warranty coverage = peace of mind if the battery goes wrong.

Buying a Forklift Battery Charger: Everything You Need to Know

To charge your forklift battery effectively, get the correct forklift battery charger. 

After knowing the forklift battery&#;s type, weight, voltage and amp hours, operating requirements, and maintenance, you turn to the charger.

Here are some factors to help you choose the proper forklift battery charger:

1. Match the Battery Amp Hours to the Charger Amp Hours

Ensure the charger is within 10% of your forklift battery&#;s amp hour (Ah) rating. Otherwise, you over or undercharge the battery.

To find the battery&#;s amp hours (the amount of current it can produce in one hour), use these three methods:

• Check the battery&#;s data plate/ta

• Inspect the intercell connector located near the positive terminal.

• Calculate the amp hours. Check here for the formula to

  calculate the amp hours

  . 

Once you know the battery&#;s amp hours, check the charger&#;s amp hour rating to ensure they&#;re compatible.

2. Select the Correct Output Voltage

The forklift battery&#;s voltage must match the battery&#;s charger&#;s output voltage. Otherwise, you may damage the battery, charger, or both.

Also, understand that some chargers are multi-voltage and can accept multiple battery voltages. But you need to be careful and ensure you get the right one.

But most are single-volt and only work with batteries of the same voltage.

So, check the charger voltage and ensure it&#;s the right one for your forklift battery before you buy it. 

You can always see this information in the battery&#;s data plate or intercell connector.

You should see either a single voltage or a range that it can work with.

3. Select the Correct Input Voltage

You must select a charger with the correct input voltage, similar to the output voltage, to ensure compatibility and proper charging.

While the output voltage is the voltage between the forklift battery charger and the battery, the input voltage is the voltage between the charger and your power source.

And you must buy a charger that accepts (designed for) your facility&#;s input voltages. This information is also in the charger data plate.

Unsure about the voltage wired in your facility? You can check with an electrician.

4. Select the Correct Input Phase

When it comes to power load distribution, you can choose between two types of input phases:

• Single-phase power (a two-wire AC (alternating current) power circuit.)

• Three-phase power (has a three-wire AC power circuit.).

Most industrial facilities have three-phase power lines to deliver power steadily and constantly.

Ensure your battery charger matches your facility&#;s phase line. You can check with your facility&#;s electrician. 

5. Select a Battery Charger With an Equalize Setting

As recommended by most manufacturers, you should equalize your forklift battery periodically.

Equalizing is a deliberate forklift battery overcharging to reverse sulfation and stabilize the battery. It helps preserve the battery&#;s integrity and lifespan.

But not all chargers have an equalizer setting. You might incur an additional cost for equalization setting, but it is worth it. 

So, check the interface or the owner&#;s manual to determine if the charger has an equalization setting. 

Otherwise, transporting the battery to other places for equalization will incur additional costs.

The Best Forklifts You Can Own

There are many forklift manufacturers, including top manufacturers and forklift dealers.

In this section, you&#;ll learn about the nine best forklift brands and best forklift models.

9 Best Forklift Brands

The following forklift manufacturers listed are the best forklift brands:

Reuse the Forklift Manufactures post &#; nothing fancy in this section, just a short recap of company history, location, offerings, and link to the website.

1. Toyota

   Headquartered in  Columbus, Indiana, Toyota Industries Corporation is a world leader in manufacturing lift trucks, marketed under three brands: Toyota, Raymond, and CESAB. Founded in , it is the top-selling brand in the United States. Toyota manufactures narrow aisle electric lift trucks and internal combustion lifts for heavy loads such as lumber, stone material, harbor freight, reach trucks, and pallet jacks, and more. 

   Website: Toyota

2.  CLARK

   Headquartered in Kentucky, Clark Material Handling was founded in . Its claim to fame is the invention of the world&#;s first forklift truck with hydraulic lifting. The company has sold over 250,000 lift trucks in North America and 350,000 worldwide. Clark offers forklifts ranging from 1,500 to 18,000 pounds. Its lifts include IC trucks, electric trucks, pallet jacks, and narrow aisles with electric, LPG, dual fuel, or diesel engine options. Its dealer network spans over 230 locations in North America and over 550 in more than 80 countries worldwide, including distribution warehouses in Louisville and South Korea.

   Website: CLARK MHC

3. Combilift

   Headquartered in County Monaghan, Ireland, Combilift was founded in . It is the world&#;s largest manufacturer of multi-directional forklifts and long-load handling solutions. Its types of forklifts include Articulated trucks, multi-directional trucks, pedestrian stackers, poultry, and side loaders. The company&#;s line includes 23 multi-directional lifts, ten multi-directional side loaders, four articulated forklifts, and seven pedestrian stackers with different power options such as diesel, electric, and LPG.

   Website: CombLift

4. Raymond

   Acquired by Toyota Industries Corp. in , Raymond operates under the Toyota Material Handling Corp. The company was founded as Raymond Corporation in Greene, New York in and established itself as a key forklift manufacturer. It designed and patented the modern wooden pallet and the first hydraulic hand pallet jack back in . It also created the first narrow aisle lift truck in and the first very narrow aisle fork truck in the s. Today, Raymond offers 11 categories of electric lift trucks.

   Website: Raymond Forklifts

5. Hyster

   Known as Hyster-Yale Materials Handling, Hyster was founded in in Portland, Oregon, while Yale was founded in . The company manufactures lift trucks and is currently headquartered in Cleveland, Ohio.  Hyster-Yale lift trucks&#; heavy-duty forklifts and material handling equipment capacities range from 2,000 to 115,000 pounds. The trucks have pneumatic or cushion tires, extended reach, and container handlers. Its global network includes more than 100 dealers. 

   Website: Hyster-Yale mh

6. Kion Group

   Kion Group manufactures a diverse line of diesel and electric forklifts with customers in 100 countries. Kion is the largest manufacturer of forklift trucks in Europe but also has a presence in the Americas, India, and South Asia. Kion&#;s North American products are through Linde Material Handling, the largest electric forklift manufacturer globally, producing electric counterbalanced trucks with cushion or pneumatic tires and narrow aisle electric trucks. Linde&#;s Lift Truck Coop. is based in Summerville and is a major forklift manufacturer in South Carolina, producing forklifts for the U.S. market.

   Kion Group Website: KION Group

   Linde material handling website: Linde MH
   

7. CAT

   CAT Lift Truck, also known as Caterpillar, is a renowned manufacturer of forklift trucks and is recognized as a global leader in the industry. Founded in , CAT forklifts has its headquarters in Houston, Texas, and maintains a vast network of dealers spanning across the United States, Europe, Africa, and the Middle East. CAT produces electric, diesel, and LPG-powered forklifts. Its electric lifts can maneuver in tight spaces and lift to heights of 23 feet. Diesel lifts feature capacities ranging from 4,400 to 22,000 pounds. The company also offers other warehouse material handling equipment such as Pallet jacks, reach trucks, stackers, aisle trucks, side loaders, and order pickers.

   Website:

   CAT Lift Trucks

    

8. UniCarriers

   UniCarriers is a brand of forklifts and material handling equipment that combines three brands with a history of over 100 years: Barrett, TCM, and Nissan. The three companies merged to form UniCarriers and are headquartered in Marengo, IL. UniCarriers offers various forklifts and equipment with customized options to meet your material handling needs. In , UniCarriers began operating under the brand of Mitsubishi Logisnext, which became the provider of UniCarriers products.

   Website: UniCarriers

9. Mitsubishi

   Mitsubishi Logisnext Co. Ltd is headquartered in Tokyo, Japan. The company comprises multiple global forklift brands, including Mitsubishi Forklifts, Mitsubishi CAT, UniCarriers, Rocla, Nichiyu, and TCM. It is known for various forklift types, including small and midsize IC forklifts, reach trucks, electric trucks, pallet trucks, stackers, and order pickers.

   Website:

   UniCarriers

The 8 Best Forklift Models

The following is a list of the best forklift models based on forklift classes you can choose from:

1.

3-wheel electric forklift models 

Three-wheel electric forklifts are fast becoming one of the most popular forklift types. These forklifts boast a tight turning radius, enabling operators to easily navigate easily around crowded warehouses and production lines.

Their capacities range from 3,000 lbs to 4,000 lbs.

Common industries of 3-wheel electric forklift use include:

• Food/beverage

• Light manufacturing

• General warehousing 

Examples of 3-wheel eclectic forklift models are:

 

2. 4-wheel electric forklift models

Like the 3-wheel forklift models, 4-wheel forklift models start from 3,000 lb to 12,000 lb. capacity. 

But the difference is that 4-wheels don&#;t have the maneuverability of 3-wheels. 

4-wheel electric forklifts find common usage in:

• Beverage plants.

• General warehousing

• Cold storage warehouses

• Food, beverage, and grocery

• Medical/pharmaceuticals

Examples of 4-wheel forklift models are:

3. Narrow aisle forklifts forklift models

Narrow aisle forklift truck models belonging to Class II forklifts are electric-powered motors designed to operate in tight and narrow spaces.

They&#;re often used indoors as side loaders or pickers to pick up, move, and deliver materials. Some have double-deep reach capabilities, allowing them to pick pallets from the second position in pallet racking.

Due to extreme lifting heights, most narrow aisle forklifts have lower lift capacities (mostly 3,500 lbs. to 5,500 lbs.).

Their applications include:

• General and specialty warehousing (e.g., high-volume/high-density warehouses)

• Retail

• Manufacturing

Electric narrow aisle trucks include reach trucks, order pickers, Articulated forklifts, and Pivoting-mast forklifts.

Examples of narrow aisle forklifts are:

4. Hand truck forklift models 

These are also called electric motor hand trucks or hand/rider trucks and belong to class III of forklifts. They have a hand-controlled lever for acceleration and steering as the operator walks behind (walkie) or rides.  

The three main categories of  hand truck forklift models are

• Stackers (e.g., electric stackers)

• Pallet trucks (e.g., pallet jacks)

• Tow tractors

Examples are Material lifts, Hand pallet jacks, Electric walkie pallet jacks, Walkie/rider pallet jacks, Center-controlled pallet jacks, paper roll handlers, Walkie stackers, and more.

They&#;re often used for moving loads over short distances, loading and unloading trailers, and moving loads to staging areas. And they&#;re great for moving loads over short distances in narrow aisles.

Examples of popular hand truck forklift models are:

5. Internal combustion cushion forklift models

Best for indoor warehouse use.

The name sums up what they are: IC (Internal Combustion) counterbalance lift trucks with solid (cushion) tires. They run on diesel, gasoline, LPG, or compressed natural gas engines (CNG).

IC combustion cushion tire forklifts are all sit-down forklifts designed primarily for indoor use on smooth, flat surfaces.

They are high-capacity forklifts, with lifting capacities ranging from 3,000 lbs. to 100,000 lbs.

Their applications include: 

• Factories

• Retail stores

• Distribution and logistics

• Warehousing (large

  warehouse types

  )

Examples of Internal combustion cushion forklift models include:

6. Internal combustion pneumatic forklifts

Best for outdoor use.

These are Class V forklifts, similar to Class IV forklifts IC combustion cushion tire forklifts, except they have pneumatic tires rather than cushion tires.

The key advantage pneumatic tires have over cushion tires is that they can work indoors and outdoors.

Internal combustion pneumatic forklifts are generally used in outdoor operations, such as:

• Construction sites

• lumber yards

• shipyards

• Other environments that require lifting heavy loads.

They are high-capacity forklifts with lifting capacities ranging from 3,000 to 125,000 lbs. or more, depending on the manufacturer and model.

The main types are:

• High-capacity pneumatic

• Container handlers

• Marina forklifts

Examples of Internal combustion pneumatic forklifts include

7.

Rough terrain forklifts (straight mast and telehandlers)

Rough terrain forklifts is a generic term that describes heavy-duty forklifts used on unimproved terrains (disturbed or natural), such as construction sites.

Most have diesel engines and are 4-wheel drive, but there are a few though 2-wheel drive models.

They have large tractor-like tires for better maneuverability on poor or uneven terrains. They have a wide choice of different masts, including:

• Vertical mast forklifts 

• Telescoping mast forklifts (telehandlers)

• Truck or trailer-mounted forklifts

Their applications include:

• Lumber yards

• Construction

• Agriculture and farming

Examples of Rough terrain forklifts include:

8. Electric and Internal Combustion Engine Tractors

These are specialized industrial trucks classified as tractors rather than forklifts. Their design allows for pulling loads within warehouses. Most tow tractors are sit-down models, equipped with either battery/motor systems or internal combustion engines powered by LPG, gasoline, or diesel.

They can pull/tug at a capacity of up to 50,000 lbs. And have quick acceleration and relatively high top speeds.

They are applicable in areas where loads need to be pulled/tugged, such as:

• Large warehouses

• Airports

• Manufacturing assembly lines

Examples of tow tractor models are:

Forklift Financing: Your Options Explained

The time has now come to order a new or used forklift. You have researched your options and know what truck and brand you want, but what about financing?

Selecting the right forklift financing is as important as choosing the right equipment.

So, what forklift financing options are there?

The main options for financing a forklift purchase are:

1. Buying it outright (large capital investment)

2. Financing the purchase

3. Lease the forklift 

4. Lease-to-Own

Buying a forklift outright with your own money 

As discussed throughout this post, buying a forklift is a capital investment and requires a large amount of initial capital.

Financing the purchase 

You can also agree with the dealership to finance the forklift purchase.

Most forklift purchases are financed over a 36 or 60-month term, often with equal monthly payments.

But, depending on your negotiation, a finance term can also be as short as 12 months or up to 72 months. 

Payments depend on the equipment&#;s purchase price, the customer&#;s budget, and credit rating.

Some brands and dealerships also allow customized financing, such as seasonal payments. For example, a farmer who only sells within seasons can agree to pay only on the seasons when the cash flow is high. 

Generally, financing a forklift is more complicated than buying a car. Why?

You&#;re purchasing a forklift as a business and must consider tax implications, corporate structures, etc. 

It can be good to go through a dealership (like Conger Industries) to guide you through the process, especially with our partnership with Toyota Commercial Finance.

Leasing the forklift 

Another way to own a forklift is to lease a forklift. Up to 0% of companies in the US lease some or all of their equipment. 

For both economic and practical reasons, forklift leases are popular.

• Operating lease payments are typically lower than finance payments, allowing you to have more cash on hand.

• Leasing flexibility

  enables

   the ability to &#;trade up&#; to new models when lease terms end;

• Leased equipment is not depreciated or capitalized; lease payments can be written off ( consult a tax professional).

• Leasing allows you to use the newest equipment, which can be a competitive advantage in some industries. 

Forklift leases can range from 12 to 72 months. But the most common duration is 36 to 60 months.

Refer to this detailed forklift leasing guide to help you understand more about forklift leasing.

Lease-to-Own

Another option can be an agreement to buy a forklift at the end of the lease &#; called lease to own.

In this case, a fair market assessment is conducted when the lease reaches maturity, and payments are refinanced based on the assessed value.

You can plan for this in advance (better option) or decide when the lease term ends.

Where to Buy a Forklift: The Good, the Bad, and the Ugly

You&#;ve acquired all the crucial information needed to purchase a new or used forklift.

Now, you have to decide where to shop for a used forklift.

The options everyone has regarding where to buy a forklift are limited. The forklift buying options include the following:

The ugly: Buying from Private sales

This instance involves buying a forklift from individual companies (that no longer need their forklift). For example, if you see a &#;For Sale&#; sign on a forklift parked outside, classified ads, Craigslist, etc. 

This option is &#;ugly&#; because it requires the buyer to do all the legwork, there&#;s lots of risk, and the forklift might not be in good shape.

The bad: Buying from Online and Auctions

You can also buy forklifts online from a website specializing in industrial equipment sales or online auctions. 

Richie Bros is one of the largest auction websites featuring many types of equipment, including forklifts &#; which may not be open to the &#;public&#; or individual businesses.

Other websites to buy a forklift are:

• IronPlanet.com

• LiftsToday.com

• EquipmentTrader.com

• Craigslist forklift

However, buying a forklift online is considered a &#;bad&#; option as it still requires a lot of legwork from the buyer, plus there&#;s still a risk of getting a &#;junk&#; truck. You may never confirm that the forklift you&#;re buying is the same as the one delivered to you. Shipping the equipment might also be expensive, especially if the seller is in a different state or country.

The Good: Buying from Authorized dealerships 

A good forklift option is buying directly from a dealership like Conger. You can get refurbished forklifts or new ones, depending on your budget.

This option is considered a &#;good and best&#; choice for several reasons:

• Purchase advice.

  Dealerships have factory-trained technicians to guide you through the forklift inspection

  , ensuring the forklift you are purchasing is certified. 

• Inspection

  .

  Dealers thoroughly inspect/repair equipment before the sale.

• In-person transaction.

  Local dealerships allow you to see the forklift in person.

• After-sales support. 

  After-sale support like warranties provides significant peace of mind for buyers. For instance, if you encounter an issue with the lift, you can utilize your purchase warranty, and the dealer can dispatch a technician to your location for inspection and repair.

• Professional sourcing.

  If you&#;re looking for a lift truck the local dealer doesn&#;t have, they&#;ll help you source it from the manufacturer or other dealers. 

Test drive. Dealerships can allow a test drive if you are in person at their shop.

Answers to Common Forklift Buying Questions

What Questions Should You Ask When Buying a Forklift?

Here are some questions to ask when buying a forklift:

• Brand:

  What brand of forklift is the best for your needs?

• Technical specifications:

  Consider things like its carrying capacity, lifting height, type of motor, tire composition, and operator ergonomics.

• Forklift fuel type:

  Should you choose electric, propane, or diesel?

• Capacity:

  What capacity do you need?

• Environment:

  In what kind of environment will the forklift be operated?

• New vs used:

  Should I buy a new or used forklift? 

• Usage:

  How many hours a week will the forklift be in operation?

• Maintenance:

  What are the forklift&#;s maintenance requirements and costs?

• Attachments:

  Are attachments available, and what are their costs? 

• Tires:

  Should you choose a cushion or pneumatic tire forklift?

• Safety features:

  Make sure the safety features work

• Used forklift: Check the forks for damage, look for gaps in the lift chains, find out if there are leaks, make sure the safety features work, and more.

What Are the Different Types of Forklifts?

As per OSHA, there are seven classes (types) of forklifts:

• Class I:

  Electric motor rider trucks

• Class II:

  Electric motor narrow aisle trucks

• Class III:

  Electric motor hand trucks or hand/rider trucks

• Class IV:

  Internal combustion engine trucks (solid/cushion tires)

• Class V:

  Internal combustion engine trucks (pneumatic tires)

• Class VI:

  Electric and internal combustion engine tractors

• Class VII: Rough terrain forklift trucks

What Is the Most Popular Forklift Size?

Answer: 20 Ton Forklifts

The 20-ton unit, commonly used for light to medium-weight loads, is the most popular forklift size. They can lift objects from 2,000 lbs to 15,000 lbs depending on the load capacity (rating).

What Height Should a Forklift Be?

A standard warehouse forklift is about 85-90 inches tall, with the mast lowered about seven to seven-and-a-half feet. When the masts extend to the full height, the forklift can reach about 165-175 inches, about 13.5-14.5 feet.

What Is the Capacity of a Forklift?

Forklift capacities range from about 3,000 lbs up to more than 70,000+ lbs. You can find the rated capacity of a forklift on its data plate. The largest forklift capacity ever recorded was 198,000 lbs. from Kalmar Forklifts, a Swedish manufacturer.

What Safety Features Should You Look for in a Forklift?

If you&#;re looking for ways to keep your people, forklift equipment, and products safer, here are safety accessories that should be on your radar.

• Seatbelt

  &#; for operator safety.

• Forklift handle for baking up with horn

   &#; for manageable reversing.

• Blue Spotlights

  &#; to increase visibility for pedestrians and warn off approaching forklifts.

• Red Forklift Warning Lights

  &#; for visual warning to pedestrians inside the forklift operating area. 

• Integrated Cameras &#;

  to provide spatial awareness and visibility operators need and the footage for audits by safety directors. 

• Fork Guidance Lasers &#;

  For warehouse and very narrow aisle settings to guide forklifts and reduce risks of misaligned forks.

  Most ideal for QFV mast forklifts, reach trucks, and other specialized warehouse models.

• Backup Alarm &#;

  addition to visual add-ons to help warn pedestrians and other forklift operators.  

• Weather Cap &#;

  to protect operators from rain and inclement weather. 

• Brakes &#;

  for forklift stopping and control.

Overhead guard: Protects the operator from things falling over them.

Do Forklifts Hold Their Value?

Yes, forklifts hold their value well. You can expect to pay about 75% of the original cost for a used forklift under good maintenance. If you wish to get the best resale value (residual value) on your forklift, consider retiring it below 9,000 working hours, although this varies from make and model. Forklift trucks with more than 16,000 work hours will fetch significantly less.

How Long Do Forklifts Last?

The average forklift hours per year are usually between 1,000 and 2,000. In general, forklift lifespans are expected to last between 10,000 and 15,000 hours, equivalent to approximately 5 to 8 years based on an 8-hour, 5-day workweek. Some forklifts, like Toyota, can last between 10,000 and 20,000 hours or even more. Also, in general, electric forklifts last longer than internal combustion forklifts.

How Much Does a Forklift Cost?

Forklift prices vary based on numerous factors. A brand new, electric forklift with standard capacity might cost $26,000 &#; $90,000 (USD) and up with an increase of $2,500 &#; $5,000 for a battery and charger. An internal combustion forklift with standard capacity will cost approximately $20,000 &#; $50,000. A used forklift can cost between  $9,000 and $56,000 (USD) based on make, brand, model, capacity, and hours. Brand new forklift prices are admittedly expensive and more difficult to find than used forklifts.

How Much Does It Cost to Maintain a Forklift?

As a rule of thumb, the forklift maintenance costs can range from $0.48 to $1.67 per operating hour or above. Factors such as forklift engine, brand, forklift operating hours, fuel usage, operating environment, and age influence cost. Therefore, your costs may vary year to year, even for the same lift. In addition, the annual maintenance cost for an electric forklift is approximately one-third of what it costs to maintain a similar internal combustion (IC) forklift.

Conclusion

Before buying a forklift, compare as many as possible to find the best one for your business.

If you&#;re buying a used forklift, the comparison will also help you get the most stable one at a competitive used forklift price. 

Remember, buying a used forklift can be a great option when you do everything right.