A forklift makes hundreds of short decisions a day: raise the mast to this level, stop the carriage here, warn the pedestrian around that corner. Behind each of those decisions sits a small control device — a position switch on the mast, a micro switch in the control handle, a buzzer that sounds before the truck moves. In a warehouse, these components work in dust, vibration and constant stop-start duty, and they are expected to work every single time.
A forklift at work in a warehouse — KACON limit and micro switches sense its mast and travel positions, while tower lights, buzzers and voice alarms provide status indication and pedestrian warning.
KACON has manufactured industrial control components in Korea since 1955. This solution combines our compact limit switches, micro switches, tower lights, buzzers and alarms and relays into a control package for forklift and warehouse-truck builders, fleet workshops and retrofit projects.
Position sensing in very tight spaces. Mast height, carriage position, tilt and travel limits must be detected by switches small enough to fit inside mast profiles and chassis cavities — and tough enough to stay accurate under vibration.
Pedestrian safety in noisy warehouses. Trucks share aisles with people. A reversing or start-up warning that cannot be heard, or a status light that cannot be seen, is an accident waiting to happen.
Stop-start electrical duty. Electric trucks switch control circuits constantly. Contacts face frequent operation, inrush currents and long service intervals, so contact material and mechanism design decide service life.
Harsh, dirty environment. Dust, moisture from cold-store condensation and pressure washing all attack unsealed components.
The ZXG series miniature limit switch is a compact horizontal switch rated 10A with a 1NO+1NC contact, sealed to IP65 and offered with 14 actuator types — levers, roller levers, plungers and spring wires — so one family covers mast height steps, carriage end positions and travel limits. Its mechanical life of at least 10 million operations suits high-cycle warehouse duty. Where a position signal feeds a safety-related function, the KXM miniature limit switch adds a positive-opening NC contact, 24K gold-plated contacts for stable low-level switching, a 6A 250VAC rating and IP67 sealing for trucks that work outdoors or in cold stores.
KACON ZXG-301 miniature limit switch
Inside control handles, seat interlocks and brake linkages, KACON snap-action micro switches provide the compact, fast switching that position levers and presence detection need. Specifying them alongside the mast limit switches keeps the whole sensing chain on one contact technology family, with consistent actuation feel for the operator.
KHS and KTD series tower lights give a truck or its charging station a clear status readout — in service, charging, or fault — visible across the aisle. For audible warning, KSP multi-tone alarms (16 tones on the KSP-6, 4 tones on the KSP-4) and KMB buzzers cover travel and reversing alerts, while the KSV programmable voice alarm replaces an anonymous beep with a spoken message pedestrians actually react to.
KACON KHS / KTD Series LED tower light with buzzer
KACON KSP-4 multi-tone buzzer
KACON general-purpose and slim relays handle the auxiliary control circuits behind the scenes — interlocking, signal conversion and load switching between the truck's controller and its lamps, alarms and contactors — in standard, socket-mount formats that fleet workshops can service quickly.
KACON KXM miniature limit switch
| Application point | KACON device | Role | Key data |
|---|---|---|---|
| Mast height and carriage position | ZXG limit switch | Compact position and end-limit sensing | 10A, 1NO+1NC, IP65, 14 actuator types, ≥10M mechanical operations |
| Safety-related position signals | KXM limit switch | Positive-opening position detection | 6A 250VAC, IP67, positive-opening NC, 24K gold-plated contacts |
| Handles, seat and brake interlocks | Micro switches (V series / Z15G) | Compact snap-action switching | Snap-action micro switch range |
| Truck and charger status | KHS / KTD tower lights | In-service, charging and fault indication | LED tower light range |
| Travel and reversing warning | KSP alarms / KMB buzzers / KSV voice alarm | Audible pedestrian warning | 16 / 4 selectable tones; programmable voice messages |
| Auxiliary control circuits | General-purpose and slim relays | Interlock and signal switching | Socket-mount relay range |
Safer aisles. Distinct, selectable warning tones, spoken voice alerts and clear status lights attack the most common warehouse accident pattern — a truck and a pedestrian who never noticed each other.
Longer service intervals. Gold-plated contacts, positive-opening mechanisms and mechanical life measured in tens of millions of operations mean position switches keep their accuracy between scheduled services instead of drifting out of adjustment.
One supplier for the control layer. Limit switches, micro switches, signalling and relays from a single manufacturer simplify the bill of materials for truck OEMs and the spare-parts shelf for fleet workshops.
Proven, certified range. KACON products carry international certifications including CE, UL, CSA, TUV, VDE, CCC and CQC, backed by more than 160 patents.
Put compact ZXG switches where space is tight and cycle counts are high; step up to KXM with positive-opening contacts where the signal has a safety function.
Choose IP67-sealed models for outdoor yards, cold stores and washdown areas; IP65 is sufficient for dry indoor aisles.
Give each warning function its own tone — travel, reverse and fault — and train crews on the set, so the sound itself carries the message.
Tell us your truck type and the control points you need to cover — mast sensing, interlocks, signalling or control relays — and our team will help you specify the matching components or adapt standard models to your design. Contact KACON or browse the full Solution Proposal section for more application ideas.
