Counterbalance Forklift Trucks: The Complete 2024 Guide
Counterbalance forklifts move 80% of all palletised goods in Australian warehouses and construction sites. This guide explains exactly how they work, when to use them, and how they compare to other forklift types—with 2024 safety standards and cost comparisons.
How Counterbalance Forklifts Work Physics Explained)
The counterbalance principle uses rear weight to offset front loads, allowing operation without outriggers. Here’s the science:
Weight Distribution
60% rear counterweight
40% front load capacity
(Toyota Engineering Standards 2024)
Stability Triangle
Three anchor points:
1. Front wheels
2. Rear wheels
3. Load centre
Mast Types
- Simplex (3m max)
- Duplex (6m)
- Triplex (9m)
- Quad (12m+)
Counterbalance Forklift Types & Capacities (2024 Models)
| Type | Capacity Range | Best For | Price Range (AUD) |
|---|---|---|---|
| Electric Counterbalance | 1-8 tonnes | Indoor warehouses | $25,000-$65,000 |
| LPG Counterbalance | 1.5-5 tonnes | Mixed indoor/outdoor | $35,000-$75,000 |
| Diesel Counterbalance | 3-25 tonnes | Construction sites | $50,000-$120,000 |
| Three-Wheel Electric | 1-2.5 tonnes | Tight spaces | $28,000-$45,000 |
Industry Insight: The 2024 Toyota Traigo 80 now offers 8-tonne capacity in electric models—previously only possible with diesel.
Counterbalance vs Reach Trucks >(Which Wins?)
| Feature | Counterbalance Forklift | Reach Truck |
|---|---|---|
| Operation Area | Open yards, docks | Narrow aisles (2-3m) |
| Max Lift Height | 6m standard | 12m+ |
| Load Capacity | Up to 25 tonnes | Max 2.5 tonnes |
| Maneuverability | 3-4m turning radius | 1.5m radius |
| Fuel Efficiency | 15-20% less efficient | Electric models dominate |
Rule of Thumb: Choose counterbalance forklifts for loading docks and construction sites, but switch to reach trucks for high-bay warehousing.
2024 Safety Features (New Standards)
Mandatory Features
- Load Moment Indicators (LMI)
- Seat-Operated Hydraulics
- Blue LED Safety Lights
Advanced Options
- 360° Camera Systems (+$3,500)
- AI Obstacle Detection
- Automatic Speed Reduction
Safety Fact: New AS 2359.2-2024 standards require all counterbalance forklifts sold in Australia to have tilt sensors and automatic parking brakes.
Counterbalance Forklift Buying Guide (2024 Update)
- Determine Your Needs
• Maximum load weight
• Lift height requirements
• Indoor/outdoor use ratio - Fuel Type Decision
• Electric: $0.18/km
• LPG: $0.32/km
• Diesel: $0.45/km (Source: Forklift Association AU) - New vs Used
• New: 5-7 year warranty
• Used: 30-50% cheaper
• Consider forklift financing options - Supplier Checklist
• Local service centres
• Parts availability
• Operator training included
Counterbalance Forklift FAQs
Can counterbalance forklifts operate on slopes?
Yes, but with strict limits:
• Loaded: Max 5% gradient
• Unloaded: Max 10% gradient
Always drive with the load uphill (WorkSafe Australia Regulation 2024).
How often should counterweights be inspected?
Monthly visual checks for cracks/rust
Annual load testing (AS 2359.1 standard)
Replace if damage exceeds 5% of surface area.
What maintenance do counterbalance forklifts need?
Daily: Fluid checks
Weekly: Tire pressure
Monthly: Brake inspection
Yearly: Full service ($800-$1,200)
Are electric counterbalance forklifts powerful enough?
Modern electric models now match diesel performance:
• 48V systems = 3-5 tonne capacity
• 80V systems = 5-8 tonne capacity
(Raymond Electric Forklifts 2024)
What licence do I need?
All counterbalance forklifts require:
• LF licence (under 15 tonnes)
• LO licence (order pickers)
See our forklift licence guide for details.
