20 Lesser-Known Forklift Facts You Should Know

NO. 1 The predecessor of forklifts was “Lift Trucks”

Invention timeline: Material handling equipment can be traced back earlier, but modern forklifts (equipment with powered lifting and tilting functions) are generally considered to have been invented around 1923 (some say 1924) in the United States.

Early names: In the early days, they were called “Lift Trucks” or “High Lift Trucks.” It was not until after World War II, with the large-scale application of standardized pallets, that forklifts truly became widespread and an indispensable tool in warehouses and factories.

NO.2 Forklifts use “reverse” steering

Rear-wheel steering design: Unlike cars, the vast majority of forklifts (counterbalance forklifts) steer through the rear wheels.

This design allows forklifts to have a very small turning radius and extremely high maneuverability in narrow warehouse aisles, making it easy to enter and exit shelves. This requires operators to have special skills and training, as the operating feel is completely opposite to driving a car.

NO. 3 Forklift load capacity relies entirely on the “counterweight”

The load-bearing principle of a counterbalance forklift is essentially a large “seesaw” principle.

Working principle: A very heavy counterweight (usually a cast iron block) is installed at the rear of the forklift (under the operator cabin). This counterweight must be heavy enough to balance the load lifted at the front and prevent the forklift from tipping forward. This is why counterbalance forklifts are usually much larger and heavier than the loads they lift.

NO. 4 Forklift tires have multiple types and cannot be mixed

Forklift tires are not only divided into pneumatic and solid types; they are generally classified into three main categories:

• Pneumatic tires: inflated like car tires, suitable for rough outdoor ground
• Solid tires: made of solid rubber, puncture-proof, suitable for smooth indoor floors
• Polyurethane tires: commonly used on electric pallet trucks and narrow aisle forklifts, designed for flat warehouse floors

Safety knowledge: Manufacturers design specific tire types for forklifts with different load capacities. They must never be changed arbitrarily, otherwise it will seriously affect the stability and safety of the forklift.

NO.5 The forklift mast can perform “free lift”

When a forklift enters a low-clearance area (such as inside a container or a low doorway), it needs to raise the forks first while the mast itself cannot rise. This function is called free lift.

Application scenario: When stacking goods inside a container, the free lift function allows the operator to stack goods above the first layer without touching the top of the container.

NO.6 The professional name for the forklift lifting frame is “mast”

What we usually call the “forklift lifting frame” or “lifting arm” is officially called the “mast” in the industry and professional training. This name comes from the mast of ships.

Structure composition: A complete mast usually consists of two or three nested steel rails (inner mast, middle mast, outer mast), driven by hydraulic cylinders to achieve lifting of goods.

Professional usage: It is important to remember this term, because when checking forklift specification sheets, manufacturers will list parameters such as “mast height,” “lifting height,” and “free lift height.”

NO.7 The “stability triangle” theory of forklifts

The center of gravity of all counterbalance forklifts moves within an area called the “stability triangle.”

Triangle composition: This triangle is formed by the center points of the two front wheels and the center point of the rear axle pivot (applicable to both single and dual rear wheel designs).

Safety key: When the forklift is loaded, the combined center of gravity of the forklift, load, and operator must always remain within the boundary of this “stability triangle.” Once the center of gravity moves outside this area, the forklift will tip over sideways or forward. This is why operators are strictly prohibited from lifting while turning or driving at high speed.

NO.8 Early forklifts were not designed for pallet handling

When the first “Lift Trucks” appeared in the early 20th century, they were mainly used for handling wooden boxes and stacked raw materials.

World War II drove standardization: It was not until World War II, due to the huge demand for rapid and efficient transportation of materials in military logistics, that standardized wooden pallets were widely adopted.

The widespread use of standardized pallets truly defined the standard size and design of forklifts (and their forks), completely revolutionizing the material handling industry and shaping it into what we know today.

NO.9 The forklift battery is also a “counterweight”

The large-capacity lead-acid battery used in electric forklifts not only provides power but is also an important part of the counterweight design.

Load principle: The battery usually weighs between 700 kg and 1500 kg, acting as a counterweight to keep the entire vehicle stable when lifting goods.

This is why the battery model, capacity, and weight cannot be changed or reduced arbitrarily, otherwise it will damage the balance structure of the whole vehicle, causing unstable lifting, center-of-gravity shift, or even tipping.

NO. 10 Forklifts do not have a “suspension system”

Unlike cars, most counterbalance forklifts do not have traditional front and rear suspension systems.

The lack of suspension is to ensure that the forklift maintains rigidity and stability during turning and lifting, without causing center-of-gravity movement due to suspension compression.

Practical impact: Operators will feel stronger vibrations on uneven surfaces, and the vehicle is more likely to bounce when crossing bumps. This is one of the common causes of driving fatigue and lumbar spine injuries.

NO. 11 Forklift lifting capacity is “rated under a specific load center distance”

The rated lifting capacity (such as 3 tons) of a forklift cannot be achieved under all conditions.

Load center: All rated loads are measured at a specified load center distance, such as 500 mm or 600 mm.

As long as the load center moves slightly forward—for example, when the forks are not fully inserted, when handling long loads, or when the load shape is irregular—the actual lifting capacity will drop significantly, sometimes to only half of the rated value.

This is one of the reasons why the “load center” must be marked on the forklift nameplate.

NO. 12 Air quality inside containers can be “worse than construction sites”

Using internal combustion forklifts in enclosed spaces (such as containers, cold storage, or underground warehouses) will rapidly accumulate exhaust gases.

Gasoline and diesel forklifts produce CO (carbon monoxide), which can easily reach dangerous concentrations in a short time.

Occupational safety requirement: Most countries require electric forklifts to be used in enclosed spaces and regular air quality testing. This is one of the key reasons why electric forklifts are becoming increasingly popular in modern logistics.

NO. 13 The blue light on forklifts is not for lighting but a “pedestrian warning light”

The blue light is often mistaken as illumination, but its real purpose is to tell pedestrians: the forklift is behind or turning.

Working principle: The blue light projects a bright spot on the ground, appearing ahead of the forklift’s path to provide early warning in low-visibility warehouse environments.

Effect advantage: Compared with sound alarms, visual warnings are less likely to be ignored, especially in noisy factories. Blue lights are widely regarded globally as an effective “collision prevention assist device.”

NO. 14 The chamfer design of fork tips is to “make pallet insertion easier”

The front end of the forks is not flat-cut but designed with an angle.

Purpose:

• Reduce friction between forks and pallets
• Allow smoother insertion into pallet slots
• Avoid damaging packaging or pallet boards

NO.15 Forklift horn volume must meet specific standards

In many countries (including the EU and the United States), safety regulations require industrial vehicle horns to reach a minimum decibel level (usually above 93 dBA) to ensure they can effectively warn pedestrians or nearby vehicles in noisy warehouse environments.

This is not only for convenience but also part of mandatory occupational safety and health requirements aimed at reducing workplace collision accidents.

NO.16 The overhead guard is not mainly for head protection

The strong protective frame above the forklift is often thought to protect the operator’s head.

Actual purpose: It does provide some protection, but it is mainly designed to protect the operator from small falling debris (such as pallet fragments or light goods). It cannot withstand the impact of a full heavy load (such as an entire pallet), otherwise the guard itself may deform or collapse.

NO. 17 Rear wheels have very little traction under heavy load

When a forklift carries heavy loads, almost all the weight is concentrated on the front axle, causing a sharp decrease in traction on the rear wheels (steering wheels).

Safety hazard: Due to low rear-wheel traction, if the operator brakes hard during high-speed turns or operates on slippery surfaces, the rear of the forklift can easily skid, leading to loss of control or tipping risk.

NO. 18 Forklifts are more likely to tip during “sharp turns without load” than when carrying heavy loads

No-load characteristic: When unloaded or lightly loaded, the effective combined center of gravity of the forklift is relatively high and tends to shift toward the rear (especially for models without heavy batteries or counterweights).

Cause analysis: During sharp turns, lateral centrifugal force causes the combined center of gravity to shift sideways. When it moves outside or close to the boundary of the stability triangle, the risk of tipping increases significantly. In contrast, when carrying heavy loads, the load and counterweight usually lower and move the center of gravity forward, temporarily improving lateral stability.

Note: This does not mean heavy loads are safer—other risks still exist.

Safety tips:

• Avoid high-speed or sharp turns when unloaded
• Lower the fork height and slow down before turning
• Include “no-load driving risks” in training procedures and simulations

NO. 19 The operator’s visibility is always a “blind zone”

The operator’s field of vision is not as open as in a car. When the forklift lifts goods, the load itself can completely block forward visibility.

Operation requirement: Industry regulations require that when carrying tall loads that obstruct vision, the operator must drive in reverse, using the rear steering characteristics and open rear visibility for safe operation. Although reversing is slower, it greatly improves safety.

NO.20 “Three-point steering” and “two-point steering” of forklifts

Most counterbalance forklifts use rear-wheel steering, which gives them a very small turning radius and allows them to pivot around the front axle. This is called three-point steering, where the rear wheel acts as the center and the front wheels form the support points.

Operational advantage: In contrast, large heavy-duty forklifts or side loaders (used for handling long materials) may use traditional front-wheel steering, which has poorer maneuverability. Three-point steering is a key feature for efficient operation in narrow aisles.

Conclusion

These 20 facts highlight the hidden engineering and safety principles behind forklift operation. Understanding them helps improve safety and efficiency in real-world applications.