Forklift buying guide: diesel vs electric vs LPG, capacity, mast types and attachments

A forklift is often the hardest-working machine in a warehouse or factory, running every shift and lifting your most valuable stock. Buy the right one and it moves goods safely for years. Buy the wrong one and you get a truck that can't reach the top racking, can't handle the real load, or fills an indoor warehouse with fumes.

This guide covers the decisions that matter, in the order a good dealer would ask about them.

Step 1: what are you lifting, and how heavy is it?

Every forklift has a rated capacity, for example 2.5 tonnes or 3 tonnes. But that capacity is only valid at a specific load centre, usually 500 mm or 600 mm: the distance from the face of the forks to the load's centre of gravity.

If your load is longer or its weight sits further out on the forks, the real safe capacity drops. A truck rated for 3 tonnes at 500 mm cannot safely lift 3 tonnes on a long pallet with the weight at 800 mm. Always tell the dealer:

• the heaviest load you will lift
• its dimensions and where its weight sits
• whether loads are on pallets, in crates, coils, drums or bags

Step 2: how high do you need to lift?

Measure the height of your top racking beam and add clearance. The forklift's lift height must reach it, and its residual capacity at that height must still exceed your load. Capacity falls as the mast extends, so check the capacity chart (load chart) for the exact mast you're buying.

Also check:

• Closed mast height: the truck must pass under doors, mezzanines and container roofs.
• Free lift: how high the forks rise before the mast itself extends. Full free lift matters for loading inside containers and under low ceilings.

Mast types

• Duplex (two-stage): simple, good visibility, for moderate lift heights.
• Triplex (three-stage): reaches higher racking with a low closed height. The most common choice for warehouses.
• Quad masts: for very high lifts.

Step 3: diesel, LPG or electric?

Diesel

• Strong pulling power and good for heavy, continuous outdoor work.
• Quick refuelling, no charging downtime.
• Exhaust and noise make them unsuitable for enclosed spaces and food or pharma areas.

LPG (gas)

• Cleaner than diesel, usable indoors with good ventilation and outdoors.
• Quick cylinder change.
• Fuel availability and storage rules for gas cylinders must be considered.

Electric (battery)

• Zero exhaust emissions at the point of use, quiet, and cheaper to run per hour.
• Ideal for indoor warehouses, cold storage, food, pharma and retail.
• Need charging infrastructure and planning for multi-shift operation (spare batteries or opportunity charging).
• Lithium-ion batteries charge faster, need no watering and last longer than lead-acid, but cost more upfront.

As a rough rule: indoor and clean environments point to electric; heavy outdoor yards point to diesel; mixed use can suit LPG or a robust electric truck.

Step 4: tyres

• Pneumatic tyres (air-filled or solid pneumatic) for rough outdoor surfaces.
• Cushion or press-on tyres for smooth indoor floors, with a tighter turning radius.
• Non-marking tyres for food, pharma and areas where black marks on the floor are a problem.

Step 5: other truck types

A counterbalance forklift is not always the best answer:

• Reach trucks work in narrow aisles and reach high racking. Common in modern warehouses.
• Stackers (walkie or ride-on) are compact and economical for light loads and low to medium heights.
• Pallet trucks (manual or powered) move pallets at floor level.
• Order pickers lift the operator to pick individual items from high shelves.

Aisle width decides a lot: measure it before you choose.

Step 6: attachments

Attachments make one truck do more jobs, but they add weight and reduce capacity. Common options:

• Side shifter: moves the forks left and right without moving the truck. Almost always worth having.
• Fork positioner: adjusts fork spacing hydraulically.
• Clamps: for paper rolls, cartons, bales or drums.
• Rotators: tip bins and containers.
• Extended or telescopic forks for long loads.

The capacity with the attachment fitted should be shown on the truck's capacity plate.

New vs used

A well-maintained used forklift can be good value for single-shift work. Check:

• hour meter reading and service records
• mast wear, chains and hydraulic leaks
• battery condition and age on electric trucks
• availability of spares and service for the brand in your area

Safety and operator training

Forklift accidents cause serious injuries. Budget for operator training, overhead guards, seat belts, lights and alarms, and regular inspections. Never exceed the capacity on the plate.

Total cost of ownership

Compare more than the purchase price: fuel or electricity, maintenance, tyres, battery replacement, service contract cost, downtime and resale value. Rental and lease options can make sense for seasonal peaks.

Frequently asked questions

Why can't my 3-tonne forklift lift 3 tonnes?

Rated capacity applies only at the stated load centre and lift height. Longer loads, higher lifts and attachments reduce the safe capacity. Check the capacity plate and load chart for the actual conditions.

Is an electric forklift strong enough for heavy work?

Modern electric forklifts are available in high capacities and can handle demanding work, including some outdoor use. Battery capacity and charging must suit your shift pattern.

What is free lift?

Free lift is how far the forks can rise before the mast extends upward. Full free lift lets you stack inside containers and under low ceilings without the mast hitting the roof.

Should I buy or rent a forklift?

Buying usually costs less for steady, long-term use. Renting or leasing suits seasonal peaks, short projects or when you want maintenance included.

Find forklifts on GlobalMart

Compare manufacturers, dealers and rental companies in forklifts and stackers, conveyors and cranes and hoists. When you post a requirement, include load weight and size, lift height, aisle width, indoor or outdoor use, number of shifts, fuel preference and whether you want to buy, lease or rent.