Without a question, the R&D people at major lift truck suppliers are working overtime these days. During the past year, there have been many new models introduced. The most activity is in counterbalanced trucks with reach trucks, stackers and orderpickers sporting new and improved features too.

As you read through the writeups of 12 newly introduced trucks on the next few pages, you'll see that truck productivity and operator ergonomics are high on the list of improvements.

In some cases, strides have been made in matching engines and transmissions for specific applications. Elsewhere, ease of maneuverability (especially in the AirTrax truck which moves in any direction) and advanced controls contribute to higher productivity.

On the ergonomics side, operator compartments often have a new look and feel with the intention of reducing fatigue. In addition, controls are being laid out differently to make the trucks easier to operate.

New electrics are also in the mix. As would be expected, AC power figures in some, continuing to offer its lineup of operating advantages to users. Meanwhile, internal combustion trucks are ever mindful of emission levels.

What's new:Workhorse pneumatic tire counterbalanced lift trucks are designed to maximize operator comfort while moving loads of 3,000 to 7,000 pounds. These compact trucks come in nine models and three fuel configurations. Travel and lift speeds are rapid. Unintended movement is prevented by the S.T.O.P. (System for Tracking Operator Presence) feature. An on-board diagnostic system simplifies troubleshooting of various systems. A full suspension seat and non-cinching seat belt reduce operator fatigue. A tilt steering feature offers infinite adjustability within a 12 degree range of movement to accommodate a range of operators. For LP models, a single-motion, swing-down bracket reduces operator effort required to change the gas cylinder.

What's new:This new addition to the order picker line-up features a 24 volt electric power system that delivers efficient power for maximum performance and long work cycles. The Separately Excited (SepEx) drive motor offers excellent acceleration and top travel speed both with and without loads. The SepEx transistor control system with MOSFET delivers smooth speed control for precise positioning and higher operator efficiency. Maximum fork heights up to 20 feet offer the ability to pick cases up to 25 feet, for increased selectivity. A low step height of 7.75 inches eases frequent entry and exit, reducing operator fatigue.

What's new: These ergonomically designed trucks with lifting capacities of 3,000 to 6,000 pounds offer the operator an excellent view of the instrument panel while making it simple to control the truck. Simultaneous control of travel direction and speed, lift, lower, tilt, side-shift and other hydraulic functions is possible with one hand. The other hand controls the electronic tiller steering with MOSFET drive controller providing ease of maneuverability and driving performance. Features include full electronic power steering and dual steer tires.

What's new: Modular manufacturing allows each truck to be tailored to the application, maximizing productivity on the job. The 4,000- to 7,000-pound counterbalanced trucks have three engine options, four transmissions and a variety of ergonomic features. Each engine has a closed loop emission control system. All transmissions feature electronic inching, electric shift control and anti-restart protection. Electrohydraulic controls are mounted in the operator's right-side armrest, allowing superior ergonomic actuation. A single pedal controls both inching and braking. Auto-motive-style pedal arrangement features large, single inch/brake pedal.

What's new:Available with either pneumatic or cushion tires, these counterbalanced trucks have lift capacities of 3,000, 3,500 and 4,000 pounds. They can be used in manufacturing as well as warehousing applications. Upright options include standard, triple stage and hi-lo in a wide range of heights. Regardless of the configuration of the upright, visibility for the operator is high. Both LPG and diesel engines are available. A monitoring and shutdown system controls various systems including engine, transmission and cooling components. Brakes are a self energizing, hydraulic-actuated drum and shoe design.

What's new:Both pneumatic and cushion tire models are available in this series of 80 volt electric counterbalanced lift trucks. The 80-volt system is said to provide power equal to Class IV and V internal combustion trucks in both indoor and outdoor use. Advantages over lower voltage power systems include reduced current draw, internal power loss and heat generation. And advanced drive/hydraulics/steering/diagnostics control system controls acceleration without wheel spin and modulates automatic regenerative braking upon release of the accelerator.

What's new:A new generation of low-level orderpickers for first and second levels of warehouse racking combines high productivity with advanced ergonomics and reduced maintenance costs. Two base versions include one with the driver position fixed for first level picking and rising for second levels and even higher in some cases. Both can be rigged with either low- or high-lift forks to suit the picking operation and items picked. The AC motor provides top travel speeds without a load of 7.4 mph and 6.8 mph with a load.

What's new: Added to a line of stackers, the ST 3000 handles loads up to 2,000 pounds and offers four different battery options for various applications. The X10 handle's user friendly features minimize hand and wrist movements, improving operator performance. Tactile and visual differentiation of controls provides a natural, more efficient interface for left-hand and right-hand operation. A brake override feature allows the truck to be maneuvered with the handle in a near vertical position while remaining within the profile of the power unit. Movement of pallets and other loads to heights of 168 inches over even rough floors and through congested work areas is easy.

What's new:A highly unconventional counterbalanced lift truck features omni-directional movement using a patented set of wheels, making it well suited to operating in tight spaces. Each wheel consists of a high-strength steel hub with 12 specially designed polyurethane coated rollers. The rollers rotate freely. That combines with a four-wheel drive system to provide omni-directional movement of the truck based on the speed and direction of each wheel. In addition, the 48-volt AC powered truck can climb obstacles up to 3 inches high and travel through potholes. The truck can rotate 360 degrees in its own footprint with the simple twist of the traction control joystick, which controls movement in all directions. A second joystick controls all hydraulic movements.

What's new: With capacities ranging from 4,000 to 7,000 pounds, the trucks match the engine and transmission to the application at hand, lowering the cost of operations while delivering excellent dependability, productivity and ergonomics. The advanced transmissions offer excellent performance and fuel economy. Both hydraulic and electrical systems have been upgraded for improved reliability. Electrohydraulic controls are integrated into the seat armrest to reduce driver fatigue, increase comfort and enhance the ability to operate lifting functions. Service time requirements have been reduced up to 25% with an electronic and in-dash warning system that reduces daily service task requirements.

What's new: This 24-volt model of reach truck uses AC power technology to deliver more truck uptime, fewer battery changes and lower maintenance costs. An AC drive motor delivers more runtime per battery charge and maintains full performance longer. It uses fewer amps per cycle, saving batteries and chargers will minimizing downtime. To maximize operator performance and productivity, logical, intuitive controls are laid out in a comfortable configuration. The operator compartment accommodates multiple working positions.

What's new: Designed to reduce operating costs in dynamic, fast-moving facilities, these gas and LP cushion tire counterbalanced trucks have capacities from 3,000 to 6,500 pounds. They are said to be the first in the industry equipped at the factory with a wireless scale that is fully integrated into the carriage. The Integrated Presence system ensures that when the operator leaves the normal sitting position, the transmission goes into neutral, and hydraulic functions halt. When the operator is seated properly, systems are reactivated.

Click on the icon to read last year's report. (What's new in lift trucks - May 2004)

Click on the icon to read the report from two years ago. (The latest in lift truck design - May 2003)