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By the Power Forklifts team, with advice from Jaco Lubbe, Business Development Manager at Power Forklifts. Updated November 2026.

If your warehouse is running out of room, the forklift you choose can matter as much as the racking. Reach trucks and articulated forklifts (such as the Aisle Master, Bendi and JAC MJ20) are both narrow-aisle machines, but they suit different operations. Here’s how to choose.

The short answer

• Choose a reach truck when speed, productivity and high pallet volumes come first, and your aisles are a conventional width.
• Choose an articulated forklift when floor space is limited, storage density is critical, or extra warehouse space is expensive.

Reach trucks: built for speed

“Reach trucks are typically the preferred choice when warehouse space is not a major constraint,” says Jaco Lubbe, Business Development Manager at Power Forklifts. “They are fast, highly manoeuvrable, and ideal for high-volume warehousing operations where productivity and rapid pallet movements are the primary focus.”

As an example, the JAC CQD16 reach truck lifts 1.6 tonnes, turns in a 1,690mm radius, and needs a minimum right-angle stacking aisle of about 2,911mm with a 1100×1100mm pallet. Reach trucks are mainly designed for smooth indoor floors.

Articulated forklifts: built for space

An articulated forklift bends in the middle, so it can turn into the racking from a much narrower aisle than a reach truck or a standard forklift. Combilift says its Aisle Master can work in aisles as narrow as 1.6 metres and lift up to 15 metres, increasing storage capacity by up to 50%. Articulated forklifts can also work indoors and outdoors, so one machine can unload a truck in the yard and put the pallet away in a narrow aisle.

“Articulated forklifts are designed for operations where maximising storage space is the priority,” says Jaco. “They can operate in significantly narrower aisles than traditional forklifts or reach trucks, allowing businesses to install more racking and increase pallet positions without expanding the building footprint.”

Design the warehouse around the forklift, not the other way round

A common mistake is choosing a forklift first, then laying out the racking around its turning circle. With an articulated forklift, you can do the opposite. Plan much narrower aisles from the start, while still reaching full-height racking, often up to 10 metres or more.

A business near us is doing exactly that with a new warehouse. Instead of buying forklifts after the racking was designed, they planned the building around an articulated Aisle Master. That lets them narrow the aisles and fit more pallet locations into the same footprint, adding significant storage capacity without making the building any bigger.

The trade-off

Articulated forklifts are generally not as fast as reach trucks in high-throughput work. Their strength is making the most of your space, not maximum travel speed. “In many cases, the savings achieved through improved space utilisation can outweigh the additional investment in an articulated forklift,” Jaco says, especially for growing businesses where warehouse space is at a premium.

Side-by-side comparison

Aisle widths depend on the model, pallet size and racking layout. Ask us for a layout check before you commit.

Questions to ask before you decide

• How many pallet movements do you do per hour or per shift?
• Are you short on pallet positions, or short on speed?
• What would extra warehouse space cost you to lease or build?
• Do you need to unload trucks outside, as well as store inside?
• How high is your racking now, and in 3–5 years?

Frequently asked questions

What is an articulated forklift?

A forklift that pivots in the middle, so the front section and mast turn independently of the rear. This lets it turn into racking from very narrow aisles.

Is an articulated forklift faster than a reach truck?

Generally, no. Reach trucks are faster in high-throughput work. Articulated forklifts win on storage density and versatility.

How narrow can a warehouse aisle be?

With an articulated forklift such as the Aisle Master, aisles can be as narrow as about 1.6m. A reach truck such as the JAC CQD16 needs about 2.9m with a standard pallet.

Talk to us about your layout

Power Forklifts sells and services JAC reach trucks and the JAC MJ20 articulated forklift, plus used Aisle Master and Bendi articulated forklifts. Send us your floor plan and racking heights and we’ll help you work out which option gives you the most storage and productivity. Call 09 838 0023, or browse reach trucks, new forklifts and used forklifts.

Related: 6 forklift buying mistakes to avoid.

By the Power Forklifts team, with advice from Jaco Lubbe, Business Development Manager at Power Forklifts. Updated November 2026.

Most forklift problems we see don’t come from a bad machine. They come from a forklift that was the wrong fit for the job. Here are the most common buying mistakes we see, how to avoid them, and when to choose a triplex mast over a duplex.

Mistake 1: Buying for today instead of the next 3–5 years

“One of the most common mistakes buyers make is purchasing a forklift that is too small for their future requirements,” says Jaco Lubbe, Business Development Manager at Power Forklifts. Buyers focus on today’s job and the purchase price, and forget about growth: more racking, heavier loads, more pallets a day.

“It is not uncommon for businesses to outgrow their forklift within 12 to 24 months,” Jaco says. The result is lost productivity and an early, expensive upgrade. His advice is to size the forklift “not only for today’s needs but also for where the business is likely to be in the next three to five years.”

Mistake 2: Ignoring capacity at height

A forklift’s rated capacity, say 2.5 tonnes, applies at a set load centre (usually 500mm) and at a lower lift height. Lift higher, or carry a longer or deeper load, and the safe capacity drops. As an example, on a 4.8m triplex mast at a 500mm load centre:

If your heaviest pallet weighs 1,800 kg and goes on the top rack at 4.5m or more, a 2.5 tonne forklift is not enough. Always check the load chart on the machine’s load plate against your heaviest load at your highest racking. WorkSafe’s training code reminds operators that the rated capacity at height can be much less than the nominal capacity, and must never be exceeded.

Mistake 3: A mast that’s too tall for your site

Measure every doorway, roller door, mezzanine, roof beam and sprinkler pipe the forklift has to pass under. Also measure any container or truck curtain it has to work inside. A standard shipping container door opening is only about 2.26–2.28m high, and a high cube is about 2.56–2.59m.

The figure to check is the mast’s lowered (collapsed) height, along with the height of the overhead guard. Don’t go by the maximum lift height alone.

Mistake 4: Not checking aisle widths and turning circles

A forklift that can’t turn into your aisle with a pallet on the forks will slow the whole operation down, or damage racking. Measure your narrowest working aisle and compare it with the forklift’s right-angle stacking aisle figure on the specification sheet. If your aisles are tight, see our guide to articulated forklifts vs reach trucks.

Mistake 5: Buying on price alone

The cheapest forklift up front isn’t always the cheapest to own. Jaco recommends comparing the total cost of ownership: running costs, servicing, parts availability, reliability, downtime and resale value. A machine with local service support and parts on the shelf keeps working. One without can sit idle for weeks waiting on a part.

Mistake 6: Forgetting future racking, loads and shifts

Will you add a higher row of racking next year? Take on heavier products? Add a second shift? Each of these changes what you need: more capacity at height, a taller mast, or a battery or fuel type that suits longer hours. Tell your supplier where you’re heading, not just where you are now.

Triplex vs duplex masts: which do you need?

A duplex (2-stage) mast has two sections. A triplex (3-stage) mast has three, so it can reach a similar or greater height from a much lower collapsed height. Most triplex masts also have full free lift: the forks can rise well over a metre before the mast itself gets any taller.

Here is how a 2–2.5 tonne JAC J Series compares:

“I generally recommend a triplex mast for most modern applications,” says Jaco. “A triplex mast offers a lower collapsed height while providing significantly greater lift height, making it ideal for warehouses with limited doorway clearance, container loading, and higher storage racking.” Free lift lets operators raise and stack loads inside a container or under a low ceiling without the mast getting any taller.

When a duplex still makes sense: basic jobs where lift heights are low and overhead clearance isn’t an issue. Even then, a triplex gives you room to grow, which is why nearly all the new JAC forklifts we stock come with a 4.8m full free lift triplex mast.

Quick buyer’s checklist

• Heaviest load, and its size (load centre)
• Highest racking level, now and in 3–5 years
• Lowest doorway, roof or obstruction, and any container or truck work
• Narrowest aisle
• Indoor, outdoor or both, and the floor surface
• Hours per day and number of shifts (this affects your fuel or battery choice)
• Service, parts and support from your supplier

Frequently asked questions

What size forklift do I need?

Start with your heaviest load at your highest lift height, then check the forklift’s load chart at that height. Allow for growth over the next 3–5 years.

Is a triplex mast better than a duplex?

For most modern sites, yes. A triplex mast has a lower lowered height, more lift height and full free lift, so it can work in containers and under low doorways. A duplex suits simple, low-lift jobs with plenty of overhead clearance.

Can a forklift fit in a shipping container?

Many can, if the mast’s lowered height and the overhead guard are under the container door height (about 2.26–2.28m on a standard container). A triplex mast with full free lift lets you stack inside without the mast hitting the roof. Check your forklift’s specification before you try.

Get the right fit

Tell us your heaviest load, racking height, doorways and aisles, and we’ll recommend the right forklift and mast. Call 09 838 0023, or browse new forklifts in stock and our counterbalanced range. Comparing power types? Read LPG vs diesel vs electric vs lithium forklifts.

By the Power Forklifts team, with technical input from Rohit Jaswal, Service Technician at Power Forklifts. Updated November 2026.

A used forklift can be great value, but some of the most expensive faults are the hardest to spot on a quick look. These are the five problems our service team finds most often on used forklifts, what each one costs to fix, and how to check for it before you buy.

Costs are rough New Zealand guides from our workshop. They vary with the make, model and size of the machine.

1. Worn mast chains: about $1,500 or less

The lift chains carry the whole load. Over time they stretch, rust and lose lubrication, and a chain failure under load is a serious safety risk.

How to check: look for rust, stiff or kinked links, and uneven chain tension between the left and right chains. Ask when the chains were last inspected or replaced.

2. Worn solid tyres: about $3,000 for a full set, fitted

Solid tyres wear down, chunk and crack, especially on rough concrete or outdoors. As an example, a full set of solid tyres supplied and fitted on a 2-tonne LPG forklift recently came to about $3,050 excl GST. Bigger machines with bigger tyres cost more.

How to check: look for chunks missing, cracks, flat spots and the wear line. Worn tyres reduce stability and braking, and replacing them is often a sign the machine has done a lot of work.

3. A weak lead-acid battery: about $1,000 a cell, or up to about $10,000 for a full replacement

On a used electric forklift, the battery is often the single biggest cost. A battery that has been under-watered, left flat or charged badly loses capacity, and it may only run for part of a shift. One failed cell can sometimes be replaced for about $1,000. A full replacement battery can cost up to about $10,000, depending on its size.

“9,000–13,000 hours is possible with proper maintenance, but not guaranteed. It depends on how well operators look after it,” says Rohit Jaswal, Service Technician at Power Forklifts.

How to check: ask how old the battery is and how many hours it has done. Look for corrosion, low electrolyte or a swollen case. Ideally, have each cell tested. A battery check costs far less than a surprise replacement.

4. Hydraulic cylinder leaks: about $500 for a seal repair

Leaking lift or tilt cylinders let the mast creep down under load and leave oil on the floor. Replacing the seals in a cylinder costs about $500 including labour. It costs more if the cylinder rod is scored or bent.

How to check: lift a load to height and watch whether the forks creep down. Look for oil on the cylinders, hoses and floor, and pitting or rust on the chrome rods.

5. Electrical faults: about $3,000 for a new controller and motor

Intermittent faults in the controller, wiring or motors can be hard to find and expensive to fix. Replacing a controller and motor can cost about $3,000.

How to check: watch the dashboard for fault codes or warning lights. Drive the forklift and use every function, forwards and backwards, under load. Hesitation, jerky movement or cutting out are warning signs.

What about used lithium forklifts?

Lithium batteries need much less routine maintenance than lead-acid. The key part is the battery management system (BMS) inside the pack. From Rohit’s experience repairing lithium battery management systems, a BMS controller repair typically took 5–6 hours of labour and cost about $4,500 in total. Prices vary by manufacturer. Ask for the battery’s history and buy from a dealer who can support it.

Used forklift checklist

• Service history and hour meter reading. Do the hours match the wear?
• Mast chains, rollers and forks: wear, rust and cracks
• Tyres: chunking and the wear line
• Battery: age, hours, a cell test, and any corrosion or low water
• Hydraulics: leaks, and whether the mast creeps down under load
• Brakes, steering, horn and lights
• Dashboard fault codes, and a test drive using every function
• The load plate: does the capacity at your lift height suit your loads?
• LPG and diesel: starting, smoke and exhaust

Before you buy, also make sure the machine suits your site: capacity at your racking height, mast height for your doorways, and aisle width. See 6 forklift buying mistakes to avoid.

Buying used from a dealer

Buying from a forklift dealer instead of privately means the machine should have been inspected by a technician, problems fixed or disclosed before sale, and parts and service available afterwards. Always ask what warranty comes with the machine and what the pre-delivery check covers.

Frequently asked questions

What should I check when buying a used forklift?

Mast chains, tyres, the battery (on electric models), hydraulic leaks and electrical faults are the five most common hidden problems. Ask for the service history, and test drive the forklift under load.

How much does it cost to replace forklift tyres in NZ?

As a guide, a full set of solid tyres supplied and fitted on a 2-tonne forklift costs about $3,000 excl GST. Larger forklifts cost more.

How long does a forklift battery last?

A well-maintained lead-acid forklift battery can last 9,000–13,000 hours, but that depends heavily on charging and watering habits.

Find a used forklift

Browse our used forklifts for sale and new forklifts in stock, or call 09 838 0023. For servicing, see our guide to forklift service intervals. Comparing power types? Read LPG vs diesel vs electric vs lithium forklifts.

By the Power Forklifts team, with technical input from Rohit Jaswal, Service Technician at Power Forklifts. Updated November 2026.

Regular servicing is the cheapest way to keep a forklift safe, reliable and worth more when you sell it. This guide sets out the service intervals we use in our Henderson workshop, what each service covers for LPG, diesel and electric forklifts, and the warning signs that mean a service is due early.

The short answer

“Where the manufacturer specifies a shorter interval, that should take priority,” says Rohit Jaswal, Service Technician at Power Forklifts. Intervals should also be adjusted for how hard and how often the machine works. A forklift doing two shifts a day in a dusty yard needs more attention than one moving a few pallets a week.

Why cold stores need servicing twice as often

Cold, condensation and moving in and out of freezers are hard on forklifts. Lubricants thicken, seals and hoses harden, moisture gets into electrical connections, and batteries work harder. Halving the interval catches these problems before they cause a breakdown in the middle of a shift.

What’s included in a forklift service

Every forklift

• Brakes and steering checked
• Hydraulics, including hydraulic cylinders, checked for leaks and wear
• Mast chains, rollers and forks inspected for wear or damage
• Tyres checked
• Fluid levels checked
• Electrical system and battery condition checked
• All grease points lubricated

LPG and diesel forklifts

• Engine oil, oil filter and air filter replaced. Some engine manufacturers specify oil changes as often as every 250 hours, so check your operator’s manual.
• LPG models: spark plugs, ignition leads and distributor caps inspected and replaced when needed
• Transmission oil and filters changed as required, usually around 1,000 hours
• Hydraulic oil usually changed around 2,000 hours, depending on its condition

Lead-acid electric forklifts

• Battery water levels checked and topped up with distilled water
• Electrical compartments cleaned
• Motor brushes inspected (where fitted)
• Braking system, hydraulic motor, pump and hydraulic oil condition checked
• Hydraulic oil usually replaced around 2,000 hours

Lithium electric forklifts

• Serviced much like lead-acid models, but the battery is sealed: no watering and no routine internal maintenance
• Battery electrical components inspected for damage

Signs your forklift needs attention before its next service

• Oil on the floor where it is parked, or wet hydraulic cylinders
• The mast lowering on its own (creeping), or jerky lifting
• Brakes that feel soft or pull to one side
• Steering that is heavy or has excess play
• Chunks missing from tyres, or tyres worn down to the wear line
• Electric forklifts: the battery running flat noticeably earlier than it used to
• LPG and diesel forklifts: hard starting, rough running or dark exhaust smoke

Report any of these straight away. Small hydraulic leaks or worn chains are cheap to fix early and expensive when they are left.

Daily pre-start checks are still the operator’s job

Servicing doesn’t replace the operator’s daily check. Before each shift, operators should check the tyres, forks, chains, hydraulics, brakes, steering, horn, lights and fluid or battery levels, using the checklist for that machine. WorkSafe’s forklift guidance sets out what employers should have in place.

If your forklift is driven on a public road, it also needs registration and a Warrant of Fitness, and the operator needs an F endorsement.

Keep a service record

A full service history is one of the first things a buyer asks for, and it can make a real difference to resale value. Keep every service report, note the hour meter reading each time, and record any repairs between services.

Frequently asked questions

How many hours between forklift services?

Every 500 operating hours or 6 months in normal conditions, and every 250 hours or 3 months in freezers, chillers and other demanding conditions. Follow the manufacturer’s schedule if it is shorter.

Do electric forklifts need servicing?

Yes. They have no engine oil to change, but the brakes, hydraulics, mast, chains, tyres and electrics still need regular checks. Lead-acid batteries also need regular watering.

Do lithium forklift batteries need maintenance?

Lithium batteries are sealed and need no watering. We check their electrical components at each service.

When should forklift hydraulic oil be changed?

Typically around every 2,000 hours, depending on its condition.

Book a service

Power Forklifts services JAC and other brands of forklift, from our Henderson workshop. Call 09 838 0023 or send us a message to set up a service schedule that suits your hours and conditions.

Choosing a new forklift? Read LPG vs diesel vs electric vs lithium forklifts.

By the Power Forklifts team, with technical input from Rohit Jaswal, Service Technician at Power Forklifts. Updated November 2026.

Choosing between LPG, diesel, lead-acid electric and lithium electric affects what a forklift costs to run, where you can use it, and how your shift is organised. This guide uses real figures from our own service workshop in Henderson, Auckland, not brochure claims, so you can compare the options for your site.

The short answer

• Diesel suits outdoor work: yards, timber, building supplies and rough ground.
• LPG suits mixed indoor and outdoor work, and long or multiple shifts, because a bottle swap only takes a few minutes.
• Lead-acid electric suits indoor, single-shift work where the forklift can charge overnight.
• Lithium electric suits indoor or mixed work where you want zero exhaust, little maintenance and the option to top up the battery during breaks.

Side-by-side comparison

Runtimes and fuel use are approximate figures from our service team and vary with load, operator and site.

How long does a forklift run on one charge or fill?

These are the real-world figures our service technician sees on customer machines:

Why the lithium figures look shorter

The lithium battery in this table stores 14 kWh. The lead-acid batteries store 24 kWh and 34.8 kWh. Comparing them side by side is like comparing a 40-litre fuel tank with an 80-litre one.

Adjusted for size, they come out about even. At light use, each 10 kWh of battery gives roughly 4.0 hours on both lead-acid batteries and roughly 4.3 hours on lithium. Lithium’s real advantage is not a longer run on one charge. It is how quickly and how often it can be recharged.

Topping up on breaks (opportunity charging)

Lithium batteries can be charged in short bursts during smoko and lunch breaks without harming the battery. On an 80V/175Ah battery:

• a 50A charger adds about 10% in 20 minutes
• a 100A charger adds about 19% in 20 minutes

Standard lead-acid batteries usually need a full charge cycle and a cooling period, unless they are designed for opportunity charging. That is why lead-acid sites often run overnight charging or a spare battery.

Size the battery to your shift

Worked example (estimate): an 8-hour shift at medium use.

• Lead-acid 48V/500Ah: about 5 hours. You would need a battery change, or a larger battery.
• Lead-acid 48V/725Ah: about 7 hours. This is close to a full shift.
• Lithium 80V/175Ah: about 3 hours, plus roughly 1.5 hours from top-ups on a 100A charger at two smokos and lunch. That suits lighter work or shorter shifts.
• Lithium with about twice the capacity: about 6 hours, plus top-ups. That is a full medium-use shift with no battery swaps.

The right choice is the battery that fits your hours and workload. JAC lithium forklifts are available with larger battery options, and we can work out the size you need from how you run your site.

What does each one cost to run per hour?

These are estimates for a 2.5–3.5 tonne forklift at medium use. All figures exclude GST.

• Diesel: 2–4 litres per hour at about $2.77 per litre excl GST (national average of about $3.19 incl GST, late October 2026) comes to about $5.50–$11 per hour.
• LPG: an 18 kg bottle lasting 6–8 hours works out at roughly 2.3–3 kg per hour. Multiply by your gas supplier’s price per kg, as bottle exchange prices vary by supplier and region.
• Lead-acid electric: about 4.8 kWh used per hour, plus roughly 20% lost while charging, is about 6 kWh from the wall. At about 23c per kWh, that is about $1.40 per hour.
• Lithium electric: about 4.7 kWh per hour with very little charging loss, about 4.9 kWh from the wall. That is about $1.15 per hour.

Fuel and power prices change, so treat these as a guide and use your own rates. Electric forklifts usually cost more up front than an equivalent LPG or diesel machine, but cost much less per hour to run.

Working indoors: exhaust and air quality

LPG, petrol and diesel forklifts all produce carbon monoxide, an odourless and colourless gas. WorkSafe New Zealand identifies switching to electric forklifts as the most effective way to eliminate the risk in enclosed spaces. If you run LPG or diesel indoors, you need good ventilation, regular engine tuning and carbon monoxide monitoring. See WorkSafe’s guidance on forklifts and carbon monoxide.

Servicing differences

All forklifts need regular servicing, but what is involved differs by power type:

• LPG and diesel: engine oil, oil filter and air filter at each service. On LPG models, we also check spark plugs, ignition leads and distributor caps. Transmission oil is usually changed around 1,000 hours and hydraulic oil around 2,000 hours, depending on condition.
• Lead-acid electric: check and top up battery water with distilled water, clean the electrical compartments, check motor brushes (where fitted), and check the brakes, hydraulic motor, pump and oil. Hydraulic oil is usually replaced around 2,000 hours.
• Lithium electric: similar to lead-acid, but the battery is sealed and needs no watering or internal maintenance. We inspect the battery’s electrical components for damage.

For every type, we grease the lubrication points and inspect the mast chains, rollers, hydraulic cylinders, brakes, tyres and forks. For how often to service, see our guide to forklift service intervals in NZ.

Battery life

Lead-acid: “9,000–13,000 hours is possible with proper maintenance, but not guaranteed. It depends on how well operators look after it,” says Rohit. Under-watering, deep discharging and opportunity charging a standard lead-acid battery all shorten its life.

Lithium: needs much less routine care and suits top-up charging. The battery management system (BMS) inside the pack is an important part to have supported by your dealer, so buy from a supplier with local service backup.

Which should you choose?

• Mostly outdoors, rough ground or heavy loads: diesel.
• Indoors and outdoors, or more than one shift a day: LPG, or lithium with top-up charging.
• Indoors, one shift, regular hours: lead-acid or lithium electric.
• Food, cold stores or anywhere exhaust is a problem: electric, ideally lithium.
• You want low running costs and little day-to-day maintenance: lithium.

Whatever you choose, size it for where your business will be in 3–5 years, not just today. See 6 forklift buying mistakes to avoid.

Frequently asked questions

Is a lithium forklift worth the extra cost?

Often, yes, when the machine works most days. It costs a fraction of diesel per hour to run, needs no battery watering, and can top up on breaks. For occasional use, LPG or lead-acid can be the better value.

How long does an 18 kg LPG bottle last on a forklift?

About 6–8 hours of typical use, in our technician’s experience. Heavy lifting and long travel distances shorten that.

How much diesel does a forklift use?

A 2.5–3.5 tonne diesel forklift typically uses about 2–4 litres per hour, depending on the work.

Can I charge a lithium forklift battery during breaks?

Yes. Lithium batteries are designed for top-up charging. A 100A charger adds about 19% to an 80V/175Ah battery in 20 minutes.

Talk to us

Power Forklifts is the exclusive New Zealand distributor of JAC Forklifts. Browse our lithium forklifts, LPG forklifts, diesel forklifts and new forklifts in stock. Or call 09 838 0023 and we’ll help you choose the right power type and battery size for your site.