How a counterbalance forklift truck works

A counterbalance forklift truck is a seated vehicle with a counterweight at the rear. It lifts loads without support legs beneath the forks. This makes a forklift truck suitable for loading lorries, longer runs in the warehouse and outdoor yard work.

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

A counterbalance forklift carries its load on forks that extend in front of the front wheels. The weight at the rear of the machine balances the load, so there are no support legs under the forks. This allows the truck to pick up pallets directly from the floor, from a lorry bed or from a rack beam where support legs would be in the way.

All four machines in this category are seated models. The operator sits and controls the truck using a steering wheel and pedals, which is convenient for longer distances in a warehouse or when loading and unloading lorries.

Walk-behind and stand-on stackers are more suitable for short distances, narrow racking and lighter use. In this category, 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 centre; the XE25A’s specifications are on its product page.

A key feature of a counterbalance forklift is the mast tilt function. The mast tilts back while travelling, so the load rests against the load backrest. When picking up or setting down a pallet, the mast is set upright. A pallet truck does not have mast tilt.

The 3-wheel electric forklift for tight aisles

The 3-wheel electric forklift has a capacity of 1500 kg at a 500 mm load centre. Its single rear wheel both drives and steers, allowing the forklift to turn 360 degrees on the spot. The turning radius is 1348 mm. The aisle width required 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 slides out sideways for quick replacement. The travel speed is 6.5 km/h when loaded and 8.0 km/h when empty. Safety features include automatic speed reduction when the forks are raised 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, making it suitable for aisles where a four-wheel truck would need more space.

Before purchasing, measure your narrowest aisle to ensure the truck will fit. The truck is 917 mm wide and 2590 mm long.

The 24 V / 400 Ah battery slides out sideways, so you can quickly swap in a fully charged spare. With a spare battery ready, the truck can continue working through a second shift.

Electric power steering keeps the steering light. If the battery charge becomes too low, the lift is disabled and the truck can only drive, alerting the operator to return for charging. The display shows both battery charge and operating hours, helping you plan battery changes and breaks.

The battery display on the 3-wheel electric forklift has 10 bars, each representing 10 percent of charge. When the battery drops to 30 percent, a warning symbol appears to indicate charging is needed. At 20 percent, a stop symbol remains on and the lift is disabled. After this, the truck can only drive, and lifting is restored only when the battery is charged to at least 70 percent.

The pump motor for lifting the forks is rated for five minutes of continuous use, so you should pause between lifts. If you continue lifting without a break, the motor may overheat and burn out. If the pump continues running when you are not using the lever, stop the truck and disconnect the battery. The truck will not drive while the parking brake is engaged, as a switch on the brake prevents movement until it is released. Press the red emergency power switch on the dashboard to cut power immediately if the truck becomes uncontrollable or you notice smoke or a burning smell. Once the issue is resolved, turn the switch clockwise to reset. The side-pull battery measures 645 × 292 × 570 mm; ensure there is space for the spare battery and its charger near the working area.

Compare forklift models in the table below

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

To use the table, compare each model’s capacity with your heaviest load at a 500 mm load centre. Check the lift height against your highest racking or stacking point. The turning radius will show if the truck can manoeuvre in your aisles. Choose between battery or diesel power depending on whether you work indoors or outdoors. Where a cell says see the product page, the information 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 up to 4500 mm with a triplex mast. Standard features include an integrated side shifter and a closed cabin with heating.

The XE25A is a seated, battery-powered electric counterbalance forklift. Details of its lifting capacity, maximum lift height and battery specifications can be found on its product page.

The XE4535A can lift 3500 kg at a 500 mm load centre and reaches up to 4500 mm with its triplex mast. A triplex mast has three sections, allowing for high lifts while keeping the overall height low when retracted. The total height of the forklift truck is 2201 mm, which is important for passing through doorways or under low beams.

The side shifter enables the operator to align the forks with a pallet or racking position without moving the entire forklift. For instance, if a pallet is not centred in a rack, the forks can be shifted sideways to pick it up accurately, saving time and reducing the risk of damaging racks or goods.

A closed cabin with heating keeps the operator comfortable in cold weather, on loading docks or in chilled storage. The seat belt must be worn at all times and the parking brake applied before leaving the seat. Lifting speed is 370 mm/s when empty and 220 mm/s when loaded. On-board diagnostics display battery charge, motor temperature and hydraulic pressure, helping the operator to identify any issues early.

The FX3 diesel forklift truck for outdoor use

The FX3 diesel forklift truck offers a capacity of 3500 kg at a 500 mm load centre. It is fitted with a 40 kW diesel engine. The drive system uses a torque converter and power-shift transmission. Maximum travel speed is 20 km/h.

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

Refuelling takes just a few minutes, allowing the forklift truck to operate through several shifts without lengthy interruptions.

With the torque converter and power-shift transmission, the operator selects the direction and the forklift moves off smoothly, even when carrying a heavy load.

The FX3 can travel at speeds up to 20 km/h, which is useful for longer distances across yards or between loading points. When the mast is tilted back, the load rests securely against the fork carriage during travel.

The forks measure 1070 × 125 × 50 mm. Check these dimensions against your gates and storage areas. As a diesel forklift, the FX3 is designed for outdoor yards and loading areas with level, hard surfaces.

When starting the FX3, use the starter for no more 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 supply and electrics before trying again. After starting, allow the engine to idle for around 5 minutes and only apply full load once the coolant temperature reaches approximately 65 °C.

With the power-shift transmission, always select reverse only after the forklift has slowed down safely. Changing direction while moving can damage the drive components. Refuel only with the engine switched off and no one on the truck. Fill the tank at the end of the working day to prevent moisture forming in the fuel overnight. If the water warning light on the fuel filter comes on, drain the water and close the drain again.

Electric or diesel: selecting the right forklift

Electric forklifts produce no exhaust at the workplace, making them suitable for enclosed warehouses and cold stores. The FX3 diesel forklift truck is intended for outdoor use. The 3-wheel electric forklift operates with a 24 V / 400 Ah battery. The XE4535A uses a lead-acid traction battery, which is charged using an external charger.

An electric forklift requires charging time, which must be planned between shifts or managed with a fully charged spare battery.

Always fully charge a lead-acid battery after each shift and never leave it discharged. For flooded batteries, check the electrolyte level and top up with distilled water as needed. Charging must be done in a dry, well-ventilated area with the correct charger, as lead-acid batteries emit hydrogen during charging. No open flames or smoking are permitted in the charging area.

The FX3 manufacturer’s manual prohibits running the diesel engine indoors, because the exhaust can suffocate the operator. For this reason, the FX3 is for outdoor use only.

For the 3-wheel electric forklift, recharge the battery within 24 hours of discharge. Delaying this can damage the battery. In cold weather, charging should take place indoors, as outdoor charging may not be effective. The manual warns against overcharging, deep discharge, rapid charging and partial charging. It also recommends an equalising charge once a month. Never drive and lift simultaneously, as this places a high demand on the battery. Store and charge the battery at least 2 m from flammable materials, in a ventilated area with a fire extinguisher. Battery acid is toxic and corrosive: wear protective clothing and goggles, and rinse any splashes with plenty of clean water.

What to measure before choosing your forklift

Before selecting a forklift, measure the heaviest load you need to lift and its dimensions. The load centre is the distance from the back of the forks to the centre of gravity of the load. The rated capacities of the 3-wheel electric forklift, XE4535A and FX3 are based on a 500 mm load centre. If your load is longer or top-heavy, the forklift may not be able to lift its full rated capacity.

Lifting capacity at height is also important. As the forks are raised, the maximum lifting capacity decreases. Always check the load chart and the capacity plate on the forklift for the height you require.

When measuring lift height, measure to the top of your highest racking beam and add enough clearance to lift the pallet over it and lower it safely. This helps prevent damage to goods and racking.

Free lift and overall height are important in confined spaces. Free lift indicates how far the forks can rise before the mast extends upwards. This is relevant in containers, lorries or under low ceilings. Compare the overall height of the forklift with the lowest doorway or ceiling on your route.

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

When planning right-angle stacking, ensure there is enough space for the forklift to turn with a load. According to the FX3 manufacturer’s manual, the minimum right-angle stacking aisle for the 3.5 t model is 4260 mm, which is much more than the 3-wheel electric forklift requires.

Do not only measure the weight of your loads. The height of the load is also important. The FX3 manufacturer’s manual limits the load height to the height of the load backrest, as taller items could slide back towards the operator.

Check that the floor, dock board or goods lift on your route can support the combined weight of the forklift and its load. The 3-wheel electric forklift manual states that a goods lift should only be used if its capacity is sufficient for both. When using a goods lift, the forklift enters first, people enter afterwards and exit before the forklift. Also consider the number of lifts per hour as well as the number of loads handled. With the 3-wheel electric forklift, plan work to alternate between driving and lifting, rather than continuous lifting.

Floor conditions, gradients, indoor and outdoor use

The type of floor surface affects which forklift is suitable for your site. Polyurethane (PU) tyres are designed for smooth, hard floors. Potholes, gravel or high door thresholds slow down the forklift and may destabilise the load. For outdoor yards, the FX3 diesel forklift truck is the model in this category.

If your site includes slopes, check the gradeability of the forklift. Diesel forklift trucks emit exhaust and are intended for outdoor use.

The 3-wheel electric forklift is fitted with polyurethane tyres.

When driving on a slope, always travel forwards uphill and reverse downhill when carrying a load. Never turn on a slope, as this can cause the forklift to tip over.

The XE4535A features a closed, heated cabin, keeping the operator comfortable when working in winter conditions, on loading docks or in cold storage.

The 3-wheel electric forklift offers a ground clearance of 128 mm at the centre of the wheelbase, with less clearance beneath the mast. Before selecting this forklift, measure the height of any door thresholds, cable covers and ramp edges along your route. If these are higher than the clearance, the forklift may become stuck or suffer underbody damage when crossing.

According to the FX3 manufacturer’s manual, this forklift truck should only be used on smooth, hard surfaces, with any oil or grease removed from the floor to prevent slipping. Outdoors, the manual notes that wind can affect the stability of the forklift. On wet or slippery surfaces, drivers are advised to reduce speed, especially before turning, to maintain control.

The FX3 manufacturer’s manual states a maximum gradeability of 20 percent for the 3.5 t model. When crossing dock boards or temporary plates, drive slowly and straight, ensuring the plate can support both the forklift and its load.

Factors influencing the price of a forklift

The price of a forklift depends on whether it is electric or diesel, its lifting capacity, maximum lift height, mast design, cabin features, side shifter, and the battery. Ongoing costs include electricity or diesel, battery maintenance, tyres and servicing. Each forklift’s price is displayed on its product card.

Servicing covers brakes, chains, mast and hydraulics. Each product card includes a Get offer button for a tailored quote, for example for a forklift with a specific lift height, and an Add to inquiry button to group several products into one request.

Service costs are determined by the number of hours the forklift is used. The 3-wheel electric forklift’s manual recommends servicing every 50 working hours, at least weekly, then at 500 hours or every three months, 1000 hours or every six months, and 2000 hours or every twelve months for single-shift operation. In dusty environments, with large temperature changes or multiple shifts, service intervals should be shorter.

For the 3-wheel electric forklift, the initial inspection after 50–100 hours or two months includes tightening wheel nuts, checking for hydraulic leaks and replacing the hydraulic filter. Gearbox oil is changed every 1000 hours, and hydraulic hoses every 6 years. For the FX3, the fuel system is serviced every 100 hours, with the fuel filter replaced and the tank cleaned every 600 hours. The XE4535A requires weekly lubrication of mast rollers and chain pins, and greasing of side-shifter rails every 250 operating hours.

Safe operation of forklifts

Safe use of a forklift requires trained and authorised operators. Before each shift, inspect the brakes, steering, horn, lights, tyres, forks, chains, mast, hydraulic system and battery charge or fuel level. The seat belt must always be worn.

Carry loads low and tilt the mast back. No one should stand beneath raised forks or ride on them. On slopes, a loaded forklift drives uphill forwards and downhill in reverse, never turning on the slope. When parked, lower the forks to the floor, apply the parking brake and remove the key.

Only lift at the racking or stacking point, and do not drive or turn with the load raised.

Adjust the forks to suit the load size so both forks support the weight evenly. Never lift with a single fork. Insert the forks fully until the load is against them.

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

If a large load blocks the forward view, drive in reverse. If the rear view is also blocked, a second person should walk ahead to guide the driver. If the forklift starts to tip, remain seated, hold the steering wheel with both hands and lean away from the direction of the fall. Never jump off. For the FX3, check at idle before starting work: the gauges, lift, lowering, tilt, steering and brakes. The fully engaged parking brake must hold the empty forklift on a 15 percent slope, brake pedal clearance must be at least 20 mm, and tyre pressure must match the label. With the 3-wheel electric forklift, never fully depress the accelerator when setting off. The FX3 operator mounts and dismounts from the left side.

Checklist before purchasing

Before purchasing, confirm the weight and dimensions of your loads, the highest lift point required, and the aisle width. Check if you need free lift for containers or low ceilings.

Decide if you require features such as a closed cabin or side shifter. The table above indicates which forklift matches your needs. Refer to the product pages for lift height, battery information and other details.

Also note the lowest door and ceiling heights along the route, the floor type and any slopes, whether you operate indoors or outdoors, and the number of hours used per day.

Plan the energy supply: a charging area in a dry, ventilated room for electric models, or diesel storage and refuelling for the FX3. For multi-shift work, arrange for a charged spare battery or charging during breaks for electric forklifts.

Provide protective equipment for the operator. The FX3 manufacturer’s manual specifies protective footwear, a helmet, protective clothing and safety glasses. For fire safety, the 3-wheel electric forklift has a bracket for a fire extinguisher at the rear of the overhead guard. The page recommends fitting an extinguisher before use.

Decide where the forklift will be parked when not in use. The 3-wheel electric forklift should be stored in a dry, ventilated area with the key off, battery plug disconnected, parking brake applied and wheels chocked. The FX3 is stored with the mast fully lowered, parking brake on and wheel chocks in place. Set up a service schedule based on hours worked: record the hours from the display or hour meter to ensure servicing is carried out as specified in the manual.

Questions about forklifts

What is the difference between a forklift and a stacker?

A forklift is a counterbalance truck with a seated operator and no support legs under the load. It is used for loading lorries, longer distances and yard work. Stackers have support legs beneath the forks and are operated by walking behind or standing on the machine; these are found in the walkie stackers category.

Which forklift can be used outdoors?

The FX3 diesel forklift is designed for outdoor use in yards. Electric forklifts produce no exhaust at the workplace; the XE4535A’s heated, enclosed cabin allows the operator to work in winter yards and on loading docks, while the 3-wheel electric forklift requires smooth flooring.

Which forklift is suitable for narrow aisles?

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

How high can the forklifts lift?

The XE4535A can lift up to 4500 mm with a triplex mast. Lift heights for the 3-wheel electric forklift, XE25A and FX3 are listed on their respective 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 slides out sideways for quick replacement. The XE4535A is fitted with a lead-acid traction battery charged by an external charger. Always fully charge a lead-acid battery after use in a dry, ventilated area with the charger designed for it, and never leave it discharged.