It’s easy to underestimate how crucial forklifts are to a busy warehouse or job site. But once you’ve seen a forklift in action (moving heavy cargo from point A to point B without breaking a sweat), you realize how vital it is to pick the right one. The wrong choice can hold back productivity, lead to safety concerns, or cost you far more in maintenance than expected.
If you’re in the market for a new or used forklift, you’ve probably discovered how many options are out there. How do you sort through all the specs, like lifting height, load capacity, tire type, and engine type, without getting lost in the details?
This article will explore everything businesses should consider before choosing forklifts. It will also look at what to do if you’re leaning toward a used forklift since that comes with its checklist. By the end, you should know the right path, whether outfitting a massive distribution center or a small workshop.
Table of Contents
The core factors to consider first
1. Load capacity
2. Lifting height
3. Operating environment
Other factors to consider before choosing forklifts
1. Explore different forklift types
2. Pay attention to tires and ergonomics
3. New vs. used: The big question
4. Inspecting a used forklift: Your essential checklist
5. Manufacturer reputation and dealer support
Final questions to ask before you commit
Wrapping it up
The core factors to consider first
Think carefully about your day-to-day reality before diving into brands, financing, or anything else. Start with the basics:
1. Load capacity
Are you usually handling 2,000 lbs. pallets or 5,000 lbs. of construction materials? Each forklift has a rated capacity; going over that limit is a big safety no-no. Always give yourself a little buffer above your heaviest load—some forklifts even go as high as 4 tons.
2. Lifting height
How high do you need to stack your goods? If your top rack is at ten feet, a forklift designed for six feet will come up short. This may seem obvious, but it’s amazing how many buyers overlook their racking height until the forklift arrives and can’t reach that last shelf.
3. Operating environment
Will you work on smooth concrete floors indoors, in a yard with gravel or uneven ground, or somewhere in between? Electric forklifts with cushion tires are great for enclosed spaces, while pneumatic tires (often paired with an internal combustion engine) are better for rougher surfaces.
When you know these core details, narrowing down the rest is much simpler.
Other factors to consider before choosing forklifts
1. Explore different forklift types
Choosing between an internal combustion (IC) model and an electric one is a major fork in the road (pardon the pun). However, each type has its strengths worth considering:
Internal combustion forklifts
They are perfect if you need high torque and plan to work outdoors on uneven surfaces. They run on fuels like diesel, propane, or gas. Although rugged, combustion models produce emissions, so they aren’t always the best choice for tightly confined indoor spaces.
Electric forklifts
Electric forklifts are quieter and cleaner, with no tailpipe exhaust. These models offer better value if your warehouse environment demands minimal noise and improved air quality. Plus, they typically have a lower cost of ownership over time, even though the upfront price can be higher.
2. Pay attention to tires and ergonomics
Tires might not be the most exciting part about choosing a forklift, but they make a huge difference. Here’s what to consider:
- Cushion (solid) tires do best on smooth floors—think standard warehouses with polished concrete.
- Pneumatic tires (air-filled or solid rubber) offer more grip on bumpy or outdoor terrain.
Then, there’s the operator’s comfort to consider. A forklift that runs like a dream but tortures the driver’s back with a stiff seat or awkward controls will hurt productivity in the long run. Look for:
- A comfortable, adjustable seat with good support.
- Intuitive controls and dash readouts.
- Clear lines of sight so the driver can see around the load and the aisle.
If your team operates forklifts all day, it’s worth putting ergonomics near the top of your list.
3. New vs. used: The big question
A brand-new forklift comes with zero wear, a shiny warranty, and cutting-edge features. However, used forklifts can save you a significant amount of money if you pick them carefully. So how do you decide?
Choose new if:
- You rely on heavy forklift use, day in and day out.
- You need the latest safety or efficiency features.
- You want peace of mind from a factory warranty.
Buy used if:
- Your workload is lighter or seasonal, so major wear and tear is less of a concern.
- You want a lower upfront cost.
- You’re willing to inspect carefully and accept some cosmetic dings or higher maintenance as the machine ages.
4. Inspecting a used forklift: Your essential checklist
You don’t want hidden surprises if you’re leaning toward the used forklift route. Here’s a quick rundown of what to do before you sign on the dotted line:
- Scan the frame: Small scratches and chipped paint usually aren’t a big deal. However, cracked welds, visible hammered-out dents, or major damage around the counterweight can signal past rough handling.
- Check the engine or motor: For internal combustion models, run it for a bit, check for oil leaks, and listen for odd rattles. For electric models, open the battery cover and look for corrosion or loose cables. If taken care of, a forklift with a decent battery can last thousands of operating hours.
- Look at the hydraulics: Are there any leaks in the hoses or fittings? Does the mast move up and down smoothly, or does it jerk and squeal?
- Test the electrics: Ensure all work of the horn, lights, and dashboard gauges or displays. If anything is flickering or unresponsive, you might have bigger wiring issues later.
- Focus on the mast and attachments: Lift the forks to their top height and listen for abnormal grinding or halting. Furthermore, approach cautiously if you see messed-up welds or rust in the mast chains.
- Kick the tires (literally): Look for serious chunking, worn treads, or missing chunks in the tires. Replacing tires isn’t the end of the world, but factor that into your final cost.
- Check the brakes and safety features. Is it stopping properly without squeaking or skidding? Do the seat belts function? Backup alarms? Lights?
Used forklifts aren’t automatically a bad bet. Many have a ton of life left in them. But a thorough once-over can help ensure you’re not taking home somebody else’s problem.
5. Manufacturer reputation and dealer support
It’s not just about the machine. It’s also about who stands behind it. A reputable brand typically offers better warranty terms, easier access to spare parts, and more consistent quality. And if you have a local dealer with great service technicians, that can be a real lifesaver when you’re in a pinch.
Final questions to ask before you commit
1. Are you sure about the lift height and weight capacity? Double-check your racking system and heaviest pallets, then confirm that you have some wiggle room.
2. Do you know the forklift’s hours (if it’s used)? Sometimes, the meter can be reset or is inaccurate. Do some extra digging if the machine looks heavily worn for its recorded hours.
3. Does everything line up with your environment? If you’re mainly indoors, an electric cushion-tire forklift might be perfect. Outdoors, you might need pneumatic tires and more horsepower from an internal combustion engine.
4. Do you have a plan for training and upkeep? Even the best forklift can become a nightmare if operated poorly or maintained haphazardly.
Wrapping it up
Choosing a forklift doesn’t have to be a nerve-racking experience. The key is to know what you need in real-world terms: how much weight, how high, how often, and on what kind of surface. Once you have those basics down, it’s about picking a forklift type that suits your situation. And if you opt for a used forklift, do the proper legwork (or “fork-work”) to ensure you’re not walking into a lemon.
A forklift that fits your operation well can make a night-and-day difference in efficiency, morale, and safety. Take your time, trust your instincts, and don’t be afraid to ask many questions. After all, it’s not every day you invest in a piece of equipment that does the heavy lifting for your business.
