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 under the forks, making it suitable for loading trucks, longer warehouse runs, and yard work.

Walk-behind and stand-on models are included in the walkie stackers category.

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

All four forklifts in this category are seated models. The operator sits and drives using a steering wheel and pedals, which is ideal for longer warehouse runs or loading and unloading trucks.

Walk-behind and stand-on stackers are better for short distances, narrow aisles, and lighter tasks. The three electric models (3-wheel electric forklift, XE25A, XE4535A) and the diesel FX3 handle 1500 kg (3-wheel electric forklift) and 3500 kg (XE4535A and FX3) at a 500 mm load center. The XE25A’s specifications are on its product page.

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

3-Wheel Electric Forklift for Tight Aisles

The 3-wheel electric forklift has a 1500 kg capacity at a 500 mm load center. Its single rear wheel drives and steers, allowing the forklift to turn 360 degrees in place. The turning radius is 1348 mm. The aisle width is 2893 mm for 1000 × 1200 mm pallets crosswise and 3005 mm for 800 × 1200 mm pallets lengthwise.

This forklift uses a 24 V / 400 Ah battery that slides out sideways for quick changes. 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 above 300 mm, lift cut-off at the top of the mast, and a reverse alarm.

With two front wheels and one rear wheel, this forklift works in aisles where a four-wheel model would need more space.

Before you order, measure your narrowest aisle to ensure the forklift 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 charged spare. With a spare battery ready, the forklift can keep running for a second shift.

Electric power steering makes steering easy. When the battery charge gets too low, the lift is disabled and the forklift can only drive, signaling the operator to return for charging. The display shows both battery charge and working hours, helping you plan battery changes and breaks.

The battery display on the 3-wheel electric forklift shows 10 bars, each representing 10 percent of charge. When the battery drops to 30 percent, a warning appears to let you know it’s time to charge. At 20 percent, a stop mark stays on and the lift is disabled. After that, the forklift can only drive, and lifting is enabled again only when the battery is charged to at least 70 percent.

The pump motor for lifting is rated for five minutes of continuous use, so you should pause between lifts. Continuous lifting without breaks can overheat and damage the motor. If the pump keeps running when you are not using the lever, stop the forklift and unplug the battery. The forklift will not drive while the parking brake is engaged, as a switch on the brake disables the drive until released. Use the red emergency power switch on the dashboard to cut power immediately if the forklift runs out of control or you notice smoke or a burning smell. After resolving the issue, turn the switch clockwise to reset. The side-pull battery measures 645 × 292 × 570 mm; make sure you have space for the spare battery and charger near where the forklift operates.

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 center, 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 center. Check the lift height against your highest rack or stacking point. The turning radius tells you if the forklift can turn in your aisles. Choose between battery or diesel power depending on whether you work indoors or outdoors. If a cell says see the product page, the information is on that forklift’s 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 a heater.

The XE25A is a sit-down, battery-powered electric counterbalance forklift. Details on its capacity, lift height, and battery are listed on its product page.

The XE4535A can lift 3,500 kg at a 500 mm load center and reaches up to 4,500 mm with its triplex mast. A triplex mast has three stages, letting the forklift lift high while keeping its lowered height compact. The truck’s overall height is 2,201 mm, which is important for passing under low beams or through doorways.

With a side shifter, the operator can move the forks left or right without moving the whole forklift truck. For example, if a pallet is off-center in a rack, the driver can shift the forks sideways to pick it up straight, saving time and reducing the risk of damaging racks or goods.

The closed cabin with a heater keeps the operator warm during winter, on loading docks, or in cold storage. The seat belt must always be worn, and the parking brake set before leaving the seat. The XE4535A lifts at 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 spot problems early.

The FX3 diesel forklift truck for outdoor use

The FX3 diesel forklift has a capacity of 3,500 kg at a 500 mm load center. It uses a 40 kW diesel engine. Power is delivered through a torque converter and a power-shift transmission. The forklift can travel up to 20 km/h.

The mast tilts 6 degrees forward and 12 degrees back, with 170 mm of free lift. The overall width is 1,240 mm and the overall height is 2,130 mm.

Refueling takes just a few minutes, so the forklift can work through several shifts without long stops.

Thanks to the torque converter and power-shift transmission, the operator selects the direction and the forklift moves off smoothly, even with a heavy load.

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

The forks measure 1,070 × 125 × 50 mm. Be sure to check the forklift’s width and height against your gates and storage areas. As a diesel model, the FX3 is designed for outdoor yards and loading areas with smooth, 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 and electrical system before trying again. After starting, let the engine idle for about 5 minutes and only apply full load when the coolant temperature reaches about 65 °C.

With a power-shift transmission, always select reverse only after the forklift has slowed down safely. Changing direction while moving can damage the drive system. Refuel only with the engine off and no one on the forklift. Fill the tank at the end of the day to prevent moisture from condensing in the fuel overnight. If the fuel filter’s water lamp comes on, drain the water and close the drain again.

Electric or diesel: how to choose your forklift

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

Electric forklifts require charging time, which should 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. Charge only in a dry, well-ventilated area using the correct charger, since lead-acid batteries release hydrogen during charging. No open flames or smoking are allowed 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 running it down. Waiting longer can damage 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, or partial charging. It also recommends an equalizing charge once a month. Never drive and lift at the same time, as this puts a heavy load on the battery. Store and charge the battery at least 2 meters from anything flammable, in a ventilated area with a fire extinguisher nearby. Battery acid is toxic and corrosive: wear protective clothing and safety glasses, and rinse any splashes with plenty of clean water.

Key measurements before selecting a forklift

Before choosing a forklift, measure the heaviest load you need to lift and its dimensions. The load center is the distance from the back of the forks to the center of gravity of the load. The rated capacities for the 3-wheel electric forklift, XE4535A, and FX3 are based on a 500 mm load center. If your load is longer or top-heavy, the forklift may handle less than its rated capacity.

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

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

Free lift and overall height are important in tight spaces. Free lift is how far the forks can rise before the mast itself gets taller. This matters in containers, trailers, or under low ceilings. Compare the forklift’s overall height to the lowest door or ceiling on your route.

A counterbalance forklift needs enough space to turn with a 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, make sure there is enough space for the forklift to turn with a load. The FX3 manufacturer’s manual gives a minimum right-angle stacking aisle of 4,260 mm for its 3.5 t model. This is much more than the 3-wheel electric forklift requires.

Do not just measure the weight of your loads. The height of the load is also important. The FX3 manual limits load height to the height of the load backrest, since taller items can slide back toward the operator.

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

Floors, slopes, indoor and outdoor use

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

If you work on slopes, check the forklift’s gradeability. Diesel forklifts produce exhaust and are for outdoor use.

The 3-wheel electric forklift uses polyurethane tires.

When driving on a slope, always drive forward uphill and reverse downhill with 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 working in winter yards, on loading docks, or in cold storage.

The 3-wheel electric forklift offers a ground clearance of 128 mm at the center of the wheelbase, with less clearance under the mast. Before selecting this forklift truck, measure the height of door thresholds, cable protectors, and ramp edges along your route. If any of these are higher than the clearance, the forklift could get 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, and any oil or grease should be cleaned 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 manual states that the maximum gradeability for its 3.5 t model is 20 percent. When crossing dock boards or temporary plates, drive slowly and straight, and only if the plate can support both the forklift and its load.

Factors That Influence Forklift Prices

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

Service includes maintenance of the brakes, chains, mast, and hydraulic system. Each product card features a Get offer button for requesting a quote, for example, for a forklift truck with a specific lift height, and an Add to inquiry button to combine several products in one request.

Service costs depend on the number of hours the forklift operates. The 3-wheel electric forklift manual recommends servicing every 50 working hours, at least once a week, then at 500 hours or three months, 1000 hours or six months, and 2000 hours or twelve months for single-shift use. For dusty environments, large temperature changes, or multi-shift operation, service intervals should be shorter.

For the 3-wheel electric forklift, the first 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 are replaced 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 the side-shifter rails every 250 operating hours.

Safe Operation of Forklifts

Safe operation of a forklift requires trained and authorized personnel. Before each shift, inspect the brakes, steering, horn, lights, tires, forks, chains, mast, hydraulic system for leaks, and battery charge or fuel level. Always wear the seat belt.

Keep the load low and tilt the mast back. No one should stand under raised forks or ride on them. On slopes, drive a loaded forklift forward uphill and backward downhill, and never turn on a slope. When parking, lower the forks to the ground, set the parking brake, and remove the key.

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

Adjust the forks to fit the load so both forks support the weight evenly. Never lift with just one fork. Push the forks in until the load touches them.

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

If a large load blocks your forward view, drive in reverse. If you cannot see behind, have a second person walk ahead to guide you. If the forklift starts to tip, stay seated, hold the steering wheel with both hands, and lean away from the direction of the tip. Never jump off. For the FX3, check at idle before work: 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 tire pressure must match the label. For the 3-wheel electric forklift, never fully depress the accelerator when starting. The FX3 operator should enter and exit from the left side.

Checklist Before You Order

Before ordering, confirm the weight and size of your loads, the highest lift point needed, and the aisle width. Determine if you need free lift for containers or low ceilings.

Decide if you require features like a closed cabin or side shifter. The table above shows which forklift matches your needs. Check the product pages for lift height, battery information, and other technical details.

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

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

Provide protective equipment for the operator. The FX3 manual recommends safety shoes, 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. Install an extinguisher before use as advised.

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 engaged, and wheels chocked. The FX3 should be stored with the mast fully lowered, parking brake on, and wheel chocks in place. Set up a service schedule based on hours worked: record working hours from the display or hour meter to ensure maintenance is done on time.

Forklifts: Frequently Asked Questions

What is the difference between a forklift and a walkie stacker?

A forklift is a counterbalance truck with a seated operator and no support legs under the load. It is used for loading vehicles, longer travel distances, and yard work. Walkie stackers have support legs under the forks and are operated by walking behind or riding standing; they are listed under the walkie stackers category.

Which forklift can be used outside?

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

Which forklift is best for narrow aisles?

The 3-wheel electric forklift can turn 360 degrees in place and has a turning radius of 1348 mm, making it 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 do you charge and maintain an electric forklift battery?

The 3-wheel electric forklift uses a 24 V / 400 Ah battery that slides out sideways for quick replacement. The XE4535A is equipped with a lead-acid traction battery charged with an external charger. Always fully charge a lead-acid battery after use in a dry, ventilated area with the correct charger, and never leave it discharged.