What a counterbalance forklift truck does

A counterbalance forklift truck is a seated machine with a counterweight at the back. It lifts loads without support legs under the forks. This makes a forklift truck suitable for loading trucks, longer runs in the warehouse and work in yards.

Walk-behind and stand-on machines are listed in the walkie stackers category.

A counterbalance forklift carries the load on forks that project in front of the front wheels. The weight of the machine at the back balances the load, so there are no support legs under the forks. This lets the truck pick up pallets directly from the floor, from a truck bed or from a rack beam where support legs would get in the way.

All four machines in this category are seated models. The driver sits and operates the truck with a steering wheel and pedals, which is practical for longer runs in a warehouse or when loading and unloading trucks.

Walk-behind and stand-on stackers are the better choice for short runs, narrow racks and light use. Here, the three electric models (3-wheel electric forklift, XE25A, XE4535A) and the diesel FX3 carry 1500 kg (3-wheel electric forklift) and 3500 kg (XE4535A and FX3) at a 500 mm load center; the XE25A’s figures are on its product page.

A key feature of a counterbalance forklift is the mast tilt function. The mast tilts back while driving, so the load rests against the load backrest. When picking up or setting down a pallet, the mast is set upright. A pallet truck has no mast tilt.

The 3-wheel electric forklift for narrow aisles

The 3-wheel electric forklift has a capacity of 1500 kg at a 500 mm load center. Its single rear wheel both drives and steers, so the forklift turns 360 degrees on the spot. The turning radius is 1348 mm. The aisle width is 2893 mm for 1000 × 1200 mm pallets crossways and 3005 mm for 800 × 1200 mm pallets lengthways.

This forklift uses a 24 V / 400 Ah battery that pulls out sideways for a quick change. The travel speed is 6.5 km/h laden and 8.0 km/h unladen. Safety features include automatic speed reduction when the forks are above 300 mm, a lift cut-off at the top of the mast and a reversing alarm.

It has two front wheels and one rear wheel, so it works in aisles where a four-wheel truck needs more room.

Before ordering, measure your narrowest aisle to check if the truck fits. The truck is 917 mm wide and 2590 mm long.

The 24 V / 400 Ah battery pulls out sideways, so you can swap in a charged spare quickly. With a charged spare battery, the truck keeps working over a second shift.

Electric power steering keeps the steering light. When the battery charge drops too low, the lift is cut off and the truck can only drive, signaling the operator to return for charging. The display shows both the battery charge and the working time, so you can plan battery changes and breaks.

The battery display on the 3-wheel electric forklift shows 10 bars, each for 10 percent of charge. When the battery drops to 30 percent, a Warning mark appears to tell you it is time to charge. At 20 percent, a Stop mark stays on and the lift is cut off. After that the truck can only drive, and the lift works again only when the battery has been charged to at least 70 percent.

The pump motor that lifts the forks is rated for five minutes of work at a time, so you need to leave pauses between lifts. If you keep lifting without a break, the motor overheats and can burn out. If the pump keeps running when you are not moving the lever, stop the truck and pull the battery plug. The truck does not drive while the parking brake is on, because a switch on the brake keeps the drive off until you release it. Press the red emergency power switch on the dashboard to cut the power at once if the truck runs out of control or you notice smoke or a burnt smell. After you find the cause, turn the switch clockwise to reset it. The side-pull battery measures 645 × 292 × 570 mm; plan room for the spare battery and its charger close to where the truck works.

Compare forklift models in the table below

The table below lists all four forklifts in this category. It shows the type, the capacity at a 500 mm load center, the lift height, the power and the turning radius of each forklift.

To use the table, compare the capacity of each model with your heaviest load at a 500 mm load center. Check the lift height against the highest rack or stacking point you need to reach. The turning radius tells you if the truck can turn in your aisles. Choose between battery or diesel power based on whether you work indoors or outdoors. Where a cell says see the product page, the figure is on that forklift’s own page.

Larger electric forklifts: XE4535A and XE25A

The XE4535A is a seated electric counterbalance forklift with a capacity of 3500 kg. It lifts to 4500 mm on a triplex mast. The integrated side shifter and closed cabin with heater are standard features.

The XE25A is a seated, battery-powered electric counterbalance forklift. Its capacity, lift height and battery details are on its product page.

The XE4535A lifts 3500 kg at a 500 mm load center and reaches up to 4500 mm on a triplex mast. A triplex mast has three stages, so it can lift high while staying low when lowered. The overall height of the truck is 2201 mm, which is important when passing through doors or under low beams.

With the side shifter, the driver lines up the forks with a pallet or rack position without moving the whole truck. For example, if a pallet is not centered in a rack, the driver can shift the forks sideways to pick it up cleanly, saving time and reducing the risk of damaging racks or loads.

The closed cabin with a heater keeps the driver warm in winter, on docks or in cold stores. The seat belt is worn at all times and the parking brake is set before leaving the seat. It lifts at 370 mm/s unladen and 220 mm/s laden. On-board diagnostics show battery charge, motor temperature and hydraulic pressure, so the operator can spot issues early.

The FX3 diesel forklift for outdoor work

The FX3 diesel forklift has a capacity of 3500 kg at a 500 mm load centre. It is powered by a 40 kW diesel engine. Drive is through a torque converter and a power-shift transmission. The travel speed is up to 20 km/h.

The mast tilts 6 degrees forward and 12 degrees back, with 170 mm free lift. The overall width is 1240 mm and the overall height is 2130 mm.

Refueling takes only a few minutes, so the truck can work through multiple shifts without long stops.

With the torque converter and the power-shift transmission, the driver selects the direction and the truck pulls away smoothly, even with a heavy load on the forks.

The FX3 reaches travel speeds up to 20 km/h, which is useful for long runs across a yard or between loading points. With the mast tilted back, the load rests against the fork carriage while driving.

The forks are 1070 × 125 × 50 mm. Check its width and height against your gates and storage areas. As a diesel machine, the FX3 is made for outdoor yards and loading places with smooth, hard ground.

When starting the FX3, use the starter for no longer than 15 seconds at a time and wait at least 2 minutes between attempts. If the engine does not start after three tries, check the fuel and the electrics before trying again. After starting, let the engine idle for about 5 minutes and only put on full load when the coolant temperature reaches about 65 °C.

With the power-shift transmission, always select reverse only after the truck has slowed down safely. Changing direction at speed damages the drive parts. Refuel with the engine off and nobody on the truck. Fill the tank after the day’s work so that moisture does not condense into water in the fuel overnight. If the water lamp of the fuel filter lights, drain the water and close the drain again.

Electric or diesel: choosing the right forklift

Electric forklifts give off no exhaust at the place of work, so they suit closed halls and cold stores. The diesel FX3 is for outdoor work. The 3-wheel electric forklift uses a 24 V / 400 Ah battery. The XE4535A has a lead-acid traction battery charged by an external charger.

An electric truck needs charging time, which must be planned between shifts or covered with a charged spare battery.

Charge a lead-acid battery fully after the shift and never leave it discharged. For a flooded battery, check the electrolyte level and top up with distilled water as needed. Always charge in a dry, ventilated place with the correct charger, because lead-acid batteries give off hydrogen while charging. No open flame or smoking is allowed in the charging area.

The FX3 maker’s manual forbids running the diesel engine in closed rooms, because the exhaust can suffocate the operator. This is why the FX3 is for outdoor work only.

For the 3-wheel electric forklift, recharge the battery within 24 hours of running it down. Waiting longer damages the battery. In cold weather, charging outdoors may not work, so the battery is charged indoors. The manual warns against overcharging, deep discharge, fast charging and charging only halfway. It also asks for an equalising charge once a month. Never drive and lift at the same time, as this draws a large current from the battery. Store and charge the battery at least 2 m from anything flammable, in a ventilated place with a fire extinguisher. Battery acid is toxic and corrosive: wear work clothes and protective glasses, and rinse any splash with plenty of clean water.

What to measure before choosing a forklift

Before selecting a forklift, measure the heaviest load you need to lift and its size. The load center is the distance from the fork back to the load’s center of gravity. The rated capacities of the 3-wheel electric forklift, the XE4535A and the FX3 apply at a 500 mm load center. If your load is longer or top-heavy, the forklift may carry less than its rated capacity.

Capacity at height is another key point. As the forks go higher, the lifting capacity drops. Always read the load chart and the capacity plate on the truck for the height you need.

When measuring lift height, measure to the top of the highest rack beam and add enough space to lift the pallet over it and set it down. This avoids damage to the load and the racking.

Free lift and overall height matter in tight spaces. Free lift tells you how far the forks can rise before the mast itself gets taller. This is important in containers, trailers or under low ceilings. Compare the overall height of the truck with the lowest door or ceiling on your route.

A counterbalance truck needs room to turn with the load. The 3-wheel electric forklift’s product page gives the aisle width for two pallet sizes. Measure your narrowest aisle and compare it to these figures.

When planning stacking at right angles, allow enough space for the truck to turn with a load. The FX3 maker’s manual gives a minimum right-angle stacking aisle of 4260 mm for its 3.5 t model. This is far more than the 3-wheel electric forklift needs.

Do not measure only the weight of your loads. The height of the load matters as well. The FX3 maker’s manual limits the load height to the height of the load backrest, because taller goods can slide back towards the driver.

Check that the floor, dock board or goods lift on your route can carry the weight of the truck and its load together. The 3-wheel electric forklift manual states that a goods lift is used only if its capacity is enough for both. When using a goods lift, the truck drives in first, people enter after it and leave before the truck. Also, count the number of lifts per hour as well as the loads moved. With the 3-wheel electric forklift, plan work that mixes driving and lifting rather than long periods of continuous lifting.

Floors, slopes, indoors and outdoors

The floor surface affects which forklift suits your site. Polyurethane (PU) tires are made for smooth, hard floors. Potholes, gravel or high door sills slow the forklift and can shake the load. For outdoor yards, the FX3 diesel forklift is the machine in this category.

If you work on slopes, check the gradeability of the forklift. Diesel forklifts give off exhaust and belong outdoors.

The 3-wheel electric forklift runs on polyurethane tires.

When driving on a slope, always go forward uphill and backward downhill with a load. Never turn on a slope, as this can tip the truck.

The XE4535A has a closed, heated cabin, which keeps the driver working in winter yards, on loading docks or in cold stores.

The 3-wheel electric forklift has a ground clearance of 128 mm at the middle of the wheelbase and less under the mast. Before choosing this truck, measure the height of door sills, cable covers and the edges of ramps on your route. If these are higher than the clearance, the truck may get stuck or damage its underbody when crossing.

The FX3 maker’s manual allows the truck only on smooth, hard ground, with oil and grease wiped off the floor to prevent slipping. Outdoors, the manual warns, wind affects the stability of the truck. On wet or slippery ground, the manual asks the driver to slow down, especially before turning, to avoid losing control.

The FX3 maker’s manual gives a maximum gradeability of 20 percent for its 3.5 t model. When crossing dock boards or temporary plates, drive slowly and straight, and only if the plate can carry the truck and its load.

What affects the price of a forklift

The price of a forklift depends on whether it is electric or diesel, its capacity, lift height, mast type, cabin and side shifter, and the battery. Running costs include electricity or diesel, battery care, tires and service. The price for each forklift is shown on its product card.

Service covers the brakes, chains, mast and hydraulics. The product cards have a Get offer button for a quote, such as for a truck with a certain lift height, and an Add to inquiry button that collects several products into one request.

Service costs depend on how many hours the truck works. The 3-wheel electric forklift’s manual calls for a service every 50 working hours, at least weekly, then at 500 hours or three months, 1000 hours or six months, and 2000 hours or twelve months for one shift a day. If you work in dust, with large temperature changes or more than one shift, service intervals are shorter.

On the 3-wheel electric forklift, the first check after 50–100 hours or two months tightens the wheel nuts, looks for hydraulic leaks and replaces the hydraulic filter. Its gear box oil is changed every 1000 hours and its hydraulic hoses every 6 years. On the FX3, the fuel system is serviced every 100 hours, and the fuel filter is replaced and the fuel tank cleaned every 600 hours. The XE4535A page asks for weekly lubrication of the mast rollers and chain pins, and greasing of the side-shifter rails every 250 operating hours.

Safe work with forklifts

Safe use of a forklift requires trained and authorized operators. Before each shift, check brakes, steering, horn, lights, tires, forks, chains, mast, hydraulic leaks and battery charge or fuel. The seat belt must be worn at all times.

Carry the load low and tilt the mast back. Nobody should stand under raised forks or ride on them. On slopes, a laden forklift drives forward uphill and backward downhill, never turning on the slope. When parked, lower the forks to the floor, set the parking brake and remove the key.

Lift only at the rack or stacking point, and do not drive or turn with the load raised.

Set the forks to match the size of the load so that both forks carry the same weight. Never lift with only one fork. Push the forks in until the load touches them.

Drive with the forks low: the 3-wheel electric forklift manual asks for them to be raised about 10 cm before driving off, and the FX3 manual recommends 200–300 mm, with the mast tilted back. Always load and unload with the mast upright and the truck braked. Brake before tilting the mast, and do not drive or turn with the forks raised.

When a bulky load blocks the view forward, drive in reverse. If the view backward is blocked, a second person walks ahead and guides the driver. If the truck starts to tip over, stay in the seat, hold the steering wheel with both hands and lean away from the fall. Never jump off. On the FX3, check at idle before work: the gauges, the lift, lowering, tilt, steering and brakes. The fully applied parking brake must hold the empty truck on a 15 percent slope, the brake pedal clearance must be at least 20 mm, and the tire pressure must match the tire label. On the 3-wheel electric forklift, never press the accelerator pedal to the end when pulling away. The FX3 driver gets on and off on the left side.

Checklist before ordering

Before ordering, confirm the load weight and size, the highest lift point, and the aisle width. Check if you need free lift for containers or low ceilings.

Decide if you need features such as a closed cabin or side shifter. The table above shows which forklift fits your requirements. Check the product pages for lift height, battery details and other specifications.

Also write down the lowest door and ceiling on the route, the floor type and any slopes, whether you work indoors or outdoors, and the hours of use per day.

Plan the energy supply: a charging place in a dry, ventilated room for an electric model, or diesel storage and refueling for the FX3. For work over more than one shift, plan for a charged spare battery or charging during breaks for electric trucks.

Plan for protective equipment for the driver. The FX3 maker’s manual asks for protective shoes, a helmet, protective clothes and glasses. For fire safety, the 3-wheel electric forklift has a bracket for a fire extinguisher at the back of the overhead guard. The page asks you to fit an extinguisher before use.

Decide where the truck will stand when not in use. The 3-wheel electric forklift is parked in a dry, ventilated room with the key switched off, the battery plug pulled, the parking brake on and the wheels chocked. The FX3 is stored with the mast fully lowered, the parking brake on and wedges under the wheels. Set up a service plan by the hours: note the working hours from the display or hour meter, so the services in the manual are done on time.

Questions about forklifts

What is the difference between a forklift and a stacker?

A forklift is a seated counterbalance truck with no support legs under the load. It is used for loading trucks, longer runs and yards. Stackers have support legs under the forks and are walked behind or ridden standing; they are in the walkie stackers category.

Which forklift can be used outdoors?

The FX3 diesel forklift is designed for outdoor use in yards. The electric forklifts give off no exhaust at the place of work; the XE4535A’s heated closed cabin keeps the driver working in winter yards and on loading docks, while the 3-wheel electric forklift needs smooth floors.

Which forklift suits narrow aisles?

The 3-wheel electric forklift turns 360 degrees on the spot and has a turning radius of 1348 mm. It is suitable for narrow aisles and tight spaces.

How high do the forklifts lift?

The XE4535A lifts to 4500 mm on a triplex mast. The lift heights for the 3-wheel electric forklift, XE25A and FX3 are listed on their product pages.

How is the battery of an electric forklift charged and maintained?

The 3-wheel electric forklift uses a 24 V / 400 Ah battery that pulls out sideways for quick changes. The XE4535A has a lead-acid traction battery charged by an external charger. Charge a lead-acid battery fully after work in a dry, ventilated place with the charger made for it, and never leave it discharged.