When most people hear "Versa-Lift," they think of aerial bucket trucks for utility workers. Versalift with an "a" is indeed a major manufacturer of truck-mounted aerial lifts, serving the electric utility and tree care industries for over sixty years . But the Versa-Lift forklift, spelled with a capital "V" and a hyphen, is something entirely different. It is a specialized heavy-duty forklift designed to solve a problem that conventional forklifts cannot handle. Moving massive loads through doorways that are barely wider than the load itself.
The manufacturer behind this unique machine is Custom Mobile Equipment, based in Baldwin City, Kansas. Founded in 1993, the company has been building Versa-Lift forklifts for over thirty years . They are not a household name in material handling. They do not compete with Toyota or Hyster in the standard forklift market. They occupy a narrow but vital niche: moving extremely heavy machinery and equipment in spaces where standard forklifts simply cannot fit.
The key innovation that sets the Versa-Lift apart is the extendable counterweight. A standard forklift carries a fixed counterweight at the rear to balance loads on the forks. The counterweight makes the forklift long and heavy, which limits maneuverability in tight spaces. The Versa-Lift uses a counterweight that extends backward hydraulically when lifting a heavy load, and retracts when traveling or maneuvering in confined areas . When the counterweight is retracted, the forklift is surprisingly compact. It can fit through standard industrial doorways and navigate tight spaces inside buildings or ships. When the load is positioned and lifting begins, the counterweight extends to provide the necessary balance for lifting tens of thousands of pounds.
The result is a machine that can move loads that would otherwise require a crane or a much larger forklift, but in spaces that could never accommodate either.
The Versa-Lift product line includes several models based on lifting capacity. The Model 40/60 is the entry point into serious heavy lifting. It can handle loads up to 60,000 pounds, which is 27.2 metric tons . Its total gross weight is approximately 25.85 tons, with a removable counterweight of 6.8 tons. The Model 60/80 steps up to 80,000 pounds or 45.4 metric tons . It weighs 36.3 tons total with a 13.6 ton removable counterweight. Even larger models exist. The Model 100/140 handles up to 140,000 pounds. The Model 17/25 is the smallest in the line, designed for lighter applications .
Power comes from General Motors V6 engines running on LPG. The 40/60 uses a GM 3.0 liter engine. The 60/80 uses a 4.3 liter version . LPG provides clean burning operation suitable for indoor use while delivering the power needed for heavy lifts. The hydraulic system is extensive, powering not just the lift and tilt functions but also the extendable counterweight and an optional removable hydraulic boom.
The boom attachment transforms the Versa-Lift from a forklift into a mobile crane. The boom can extend the machine's reach significantly, with maximum extension heights around 7.9 to 8.2 meters . The fork lift height from the base position is approximately 2.5 meters. The mast tilt ranges from 10 to 12 degrees forward and 7 degrees backward depending on the model.
Applications for the Versa-Lift are specialized but critical. The manufacturer's literature specifically mentions working inside buildings or ships, where door heights and widths can restrict the use of other larger equipment . Consider a manufacturing plant that needs to move a 40,000 pound stamping press from one bay to another. The doorway is only eight feet wide. A standard forklift with enough capacity to lift 40,000 pounds would be enormous, too wide to fit through the door, too long to maneuver inside the building. A crane could lift the press but cannot drive it through the plant. The Versa-Lift solves this problem. It fits through the door with the counterweight retracted, positions itself under the press, extends the counterweight, lifts the load, and drives it to the new location.
Rigging companies are the primary users of these machines. Firms like Allelys in the UK offer Versa-Lift 40/60 and 60/80 units for hire, using them specifically for moving heavy machinery smoothly and safely on solid surfaces . The machines are designed for riggers, by riggers, with an understanding that heavy equipment moves do not happen in wide open spaces. They happen in crowded factories, tight ship compartments, and aging industrial buildings where every inch of clearance matters.
The used market for Versa-Lift forklifts reflects their specialized nature. A 2012 Versa-Lift 40/60 counterbalance forklift with only 734 hours on the meter was recently listed for sale . The low hours indicate that these machines are not daily workhorses. They are called into service for specific heavy moves, then parked until the next job. The original paint was intact. The machine was fully serviced. The two-stage mast stands 124 inches when lowered and reaches a fork height of 122 inches or 354 inches with the boom attachment. The 60,000 pound capacity was the headline feature.
A used Versa-Lift 40/60 with 734 hours represents an almost new machine. At 734 hours, a standard forklift might be just broken in. For a Versa-Lift, it is practically unused. The price reflects the specialization. A used unit can cost as much as a new standard forklift, but for the company that needs to move 60,000 pound loads through eight foot doorways, there is no alternative. You either buy the Versa-Lift or you do not do the job.
The distinction between Versa-Lift (the forklift) and Versalift (the aerial lift) is important to avoid confusion. Versalift with an "a" is a Texas-based manufacturer of bucket trucks and aerial devices, founded in 1965 and celebrating sixty years in 2025 . They make truck-mounted lifts for linemen and tree trimmers, with working heights up to 75 feet and platform capacities of 450 to 800 pounds . They are a completely different company serving a completely different industry. Versa-Lift with a capital V and a hyphen is the Kansas-built heavy forklift.
The Versa-Lift forklift is not for every warehouse. It is not for loading docks or pallet racking. It is for the heavy lift, the impossible move, the job that makes project managers lose sleep. When a 50,000 pound transformer needs to go through a doorway that seems too small, when a printing press must be relocated across a plant floor that was not designed for heavy equipment, when a ship's engine room requires maintenance that seems physically impossible, the Versa-Lift is the tool that makes it happen. It is a machine built for the edge cases. But in the world of heavy rigging, edge cases are everyday business. And the Versa-Lift has no competition.