How to Ship a Counterbalance Forklift
Counterbalance forklifts are among the most commonly shipped pieces of industrial equipment in the country — moved between warehouses, dealer lots, auction sites, and job sites every day. While they're not the largest machines on the road, shipping a forklift correctly requires attention to mast height, propane tank handling, tire type, and tie-down requirements. This guide covers everything you need to know.
Counterbalance Forklift Dimensions and Weights
Counterbalance forklifts vary significantly in size depending on their lift capacity and application. Understanding your machine's specs before booking transport is essential for selecting the right trailer and determining permit requirements.
| Capacity Class | Typical Weight | Length (forks retracted) | Width | Mast Height (lowered) |
|---|---|---|---|---|
| 3,000–5,000 lb (standard warehouse) | 7,000–10,000 lbs | 8–9 ft | 42–50 in | 7–8 ft |
| 6,000–10,000 lb (mid-range) | 10,000–15,000 lbs | 9–11 ft | 50–60 in | 7–9 ft |
| 15,000–30,000 lb (heavy industrial) | 20,000–40,000 lbs | 11–14 ft | 60–80 in | 8–10 ft |
| 40,000–80,000 lb (port/container handler) | 50,000–100,000+ lbs | 14–20 ft | 80–120 in | 10–14 ft |
The mast configuration (simplex, duplex, triplex, or quad) significantly affects the collapsed height. Always lower the mast fully before transport and verify the collapsed height against your trailer's deck height and any bridge clearances on the route.
Trailer Selection for Forklift Transport
Most standard warehouse forklifts (under 15,000 lbs, under 8'6" wide, under 8'6" tall with mast lowered) can be shipped on a flatbed or step-deck without an oversize permit. Larger industrial forklifts require more specialized equipment:
- Flatbed (48' or 53'): Best for standard forklifts under 8'6" wide and under 8'6" tall. The forklift is driven onto the trailer via ramps or loaded by crane. Forks should be removed or secured flat.
- Step-Deck (Drop Deck): Used when the forklift is taller than 8'6" with mast lowered but under 10'. The lower deck (34–36 inches off the ground) provides additional height clearance.
- Lowboy: Required for very heavy industrial forklifts (30,000+ lbs) or port container handlers. The ultra-low deck (18–24 inches) accommodates tall masts and heavy machines.
- RGN (Removable Gooseneck): Used for the largest port forklifts and reach stackers that need to drive on/off under their own power.
Pre-Transport Preparation
Proper preparation prevents damage and ensures compliance with DOT securement rules:
- Lower the mast fully: The mast must be in its lowest position for transport. Verify the collapsed height and document it for the carrier.
- Tilt the mast back: Tilt the mast to its full rearward position to reduce the forward overhang and lower the center of gravity.
- Remove or secure the forks: Forks should be removed and shipped separately, or secured flat against the carriage with chains. Loose forks are a serious safety hazard.
- Propane tanks: LPG tanks must be removed from the forklift before transport per DOT regulations. Ship the tank separately or have it emptied and purged.
- Drain fluids if required: For long-distance moves or ocean shipping, some carriers require hydraulic fluid levels to be reduced. Confirm with your carrier.
- Secure the parking brake: Engage the parking brake and chock the wheels before loading.
Tie-Down and Securement Requirements
DOT regulations (49 CFR Part 393) require that forklifts be secured with a minimum of four tie-down points — two at the front and two at the rear. Chains (3/8" Grade 70 or Grade 80) are the standard securement method. The working load limit (WLL) of all tie-downs combined must equal at least 50% of the forklift's weight. Tie-down points are typically the forklift's frame rails, tow hooks, or designated anchor points — never the mast, carriage, or hydraulic cylinders.
Permit Thresholds
Most standard forklifts ship without an oversize permit. Permit requirements are triggered when:
- Width exceeds 8'6" (102 inches)
- Height exceeds 13'6" (with mast lowered and loaded on trailer)
- GVW of truck + trailer + forklift exceeds 80,000 lbs
Large industrial forklifts (30,000+ lbs) and port container handlers almost always require oversize/overweight permits and may require pilot cars.
Need to ship a forklift? IronHaul Logistics handles counterbalance forklifts of all sizes — from standard warehouse units to heavy industrial port machines. Call (208) 495-2260, email [email protected], or get a quote online today.
Common questions
Do I need to remove the forks before shipping a forklift?
It's strongly recommended. Forks should be removed and shipped separately, or secured flat against the carriage with chains. Loose forks are a safety hazard and may violate DOT securement rules. Confirm with your carrier.
Can a standard forklift be shipped on a flatbed without a permit?
Yes, if the forklift is under 8'6" wide, under 8'6" tall (with mast fully lowered), and the total GVW of the truck, trailer, and forklift is under 80,000 lbs. Most standard 3,000–10,000 lb warehouse forklifts meet these criteria.
What happens to the propane tank when shipping an LPG forklift?
DOT regulations require that LPG tanks be removed from the forklift before transport. The tank must be shipped separately or emptied and purged. Your carrier can advise on the specific requirements for your move.
How is a forklift secured on a flatbed trailer?
Forklifts are secured with a minimum of four chain tie-downs (3/8" Grade 70 or Grade 80) — two at the front and two at the rear. Tie-downs attach to the frame rails or designated anchor points, never the mast or hydraulic cylinders.
What trailer do I need for a 40,000 lb industrial forklift?
A lowboy or RGN trailer is required for forklifts in the 30,000–80,000 lb range. The low deck height (18–24 inches) accommodates the machine's weight and height. An oversize/overweight permit will also be required.
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