Types of Forklifts: A Complete Guide
A forklift is a powered industrial truck built to lift, carry, and stack loads that would otherwise take a full crew and hours of effort. Walk into any warehouse, loading dock, or construction site and you will find a different type of forklift matched to the job at hand, because no single machine handles every material handling task equally well. This guide breaks down the many types of forklifts by design and function, by power source, by tire type, and by the official OSHA forklift classifications so you can see exactly how the industry organizes these machines. Once you know which category fits your operation, PS Janitorial's forklift inventory is a good place to start comparing options.
What Is a Forklift?
At its core, a forklift is a powered industrial truck used to lift and move materials that are too heavy or too bulky to handle by hand. The term covers a broad range of machines built for very different tasks and environments, from compact trucks that squeeze through narrow spaces in a warehouse to rugged rough terrain forklifts that work outdoor job sites in mud and gravel. Some forklift types are designed purely for lifting and stacking pallets, while others are built for towing, reaching high storage racks, or handling oversized loads like lumber and steel. Understanding these differences is the first step toward choosing the right forklift for your operation.
Types of Forklifts by Design and Function
One of the most practical ways to sort through the different types of forklifts is by looking at the job each one is built to do. From general purpose lifting to highly specialized tasks, the following forklift types cover most of what you will encounter in warehouses, storage facilities, and industrial sites.
Counterbalance Forklifts
The counterbalance forklift is the standard forklift most people picture when they hear the word forklift. It uses a rear counterweight to offset the load on the forks, which lets it lift and carry without the need for outrigger arms extending in front of the machine. This design makes the counterbalance forklift one of the most versatile machines on the market, capable of working both indoors and outdoors depending on the tire type it is fitted with. Lift capacities typically range from around 3,000 pounds up to well over 15,000 pounds for heavy duty models, and you will find these forklifts in manufacturing facilities, distribution centers, retail backrooms, and construction sites alike.
Reach Trucks
Reach trucks are electric forklifts built specifically for narrow aisle warehouses where maximizing vertical storage space matters more than outdoor capability. Their extendable mast lets the forks reach forward into the rack while the body of the truck stays in the aisle, which allows for tighter turning and denser shelving layouts. Reach trucks can lift loads to heights of roughly 13 metres, making them a strong fit for high density racking in storage facilities and cold storage facilities where every inch of vertical storage space counts. Because they run on electric power, reach trucks are also a quieter, lower emission option for indoor use.
Order Pickers
An order picker is built for a very specific task: individual item picking rather than moving full pallets. The operator platform rises along with the load, letting the person on board reach items stored at height without climbing a separate ladder. Order pickers are essential in distribution and e commerce warehouses where fast, accurate picking directly affects how efficiently orders go out the door. Safety features like guardrails and harness points are standard on most order pickers, since the operator works from an elevated position throughout the shift.
Pallet Jacks (Pallet Trucks)
Pallet jacks, also called pallet trucks, are used for moving pallets short distances across a warehouse floor or loading dock. Manual pallet jacks rely on the operator to pump the handle and push the load, while electric pallet jacks use a battery powered motor to move heavier loads with less physical strain. Load capacities on pallet jacks commonly range from around 2,000 to 5,500 pounds, and you will see them everywhere from retail stockrooms to large scale storage facilities where unloading pallets from a truck or moving them across a receiving area is a daily task.
Pallet Stackers
Pallet stackers, sometimes called walkie stackers, combine the short distance movement of a pallet jack with the vertical lifting of a mast, allowing them to stack pallets several feet into the air. Available in both electric and manual versions, pallet stackers are a practical fit for smaller warehouses or storage areas that need more storage capacity without investing in a full sized counterbalance forklift. Their compact footprint also makes them easier to maneuver in narrow spaces than larger forklifts.
Side Loaders
Side loaders mount their forks on the side of the machine rather than the front, which lets them carry long materials like lumber, pipe, and steel without the load overhanging awkwardly in front of the operator. This design is especially useful in lumber yards and metal fabrication shops, where standard forklifts would struggle to maneuver oversized materials through narrow spaces between racks or storage bays.
Telehandlers (Telescopic Handlers)
A telehandler functions as something between a crane and a forklift, using an extendable boom to reach heights and distances a standard forklift simply cannot match. Telehandlers can lift loads to heights of around 55 feet depending on the model, and their attachment options, including buckets, winches, and pallet forks, make them adaptable across construction and agriculture applications. Their lifting capacity and reach make them a common sight on construction sites where materials need to move both up and outward.
Rough Terrain Forklifts
Rough terrain forklift trucks are built with large tractor style tires and reinforced frames to handle uneven terrain that would stall a standard warehouse forklift. These machines are designed for outdoor work on rough outdoor terrain, and you will typically find rough terrain forklifts at construction sites, lumber yards, and other outdoor job sites where the ground is anything but level.
Very Narrow Aisle (VNA) Trucks
Very narrow aisles present a unique challenge: how do you maximize storage capacity without sacrificing access? VNA trucks solve this with a rising operator cabin that travels up with the load, allowing the truck to work in aisles too tight for a standard reach truck or counterbalance forklift. This forklift type is popular in storage facilities that prioritize vertical storage space above nearly everything else.
Tow Tractors
Not every material handling task involves lifting. Tow tractors are designed to pull loads on wheeled carts rather than raise them off the ground, and they run on either electric or internal combustion engines depending on the setting. You will commonly find tow tractors at airports moving luggage carts and on assembly lines where components need to move steadily between stations without the need for lift capacity at all.
Types of Forklifts by Power Source
Beyond design and function, forklifts are also grouped by what powers them. This distinction, electric versus internal combustion, often matters just as much as the forklift's physical design when it comes to choosing the right machine for your facility.
Electric Forklifts
Electric forklifts run on rechargeable batteries instead of fuel, which gives them a distinct set of advantages for indoor use. They operate quietly, produce zero direct emissions, and tend to have lower maintenance costs than internal combustion engines because there is no engine oil, spark plugs, or exhaust system to service. The tradeoff is charging time and battery management, since an electric forklift needs access to a charging station and, in some operations, a spare battery to avoid downtime during long shifts. For manufacturing facilities and warehouses focused on air quality and noise levels, electric forklifts are usually the preferred choice.
Internal Combustion (IC) Forklifts
Internal combustion engine trucks are powered by propane, diesel, or gasoline, and they offer a level of power output and refueling speed that electric forklifts cannot always match. Propane forklifts can operate indoors with proper ventilation, while diesel forklifts are generally reserved for outdoor environments due to their higher emissions. There is no recharge downtime with an IC forklift; you simply refuel and get back to work, which makes these forklift types a strong fit for outdoor job sites, construction sites, and any operation that runs heavy loads across long shifts.
Types of Forklifts by Tire Type
Tire type is another factor that determines where a forklift can operate, and it often works hand in hand with power source to define a machine's ideal environment.
Cushion Tire Forklifts
Cushion tires are made of solid rubber molded directly onto a metal core, giving these forklifts a smaller footprint and a lower center of gravity. This makes cushion tire forklifts well suited to smooth indoor surfaces like warehouse floors and manufacturing facilities, where their compact size helps them maneuver through narrow spaces between racks and equipment.
Pneumatic Tire Forklifts
Pneumatic tires, whether air filled or solid pneumatic, are built to handle rough or uneven outdoor terrain. Their larger size and deeper tread provide better traction and greater ground clearance than cushion tires, which is why pneumatic tire forklifts are the standard choice for lumber yards, construction sites, and other outdoor job sites where the surface underfoot is unpredictable.
The 7 OSHA Forklift Classifications
Beyond the informal categories above, OSHA and the Industrial Truck Association group all forklifts into seven official classes based on power source, design, and operating environment. Knowing these forklift classifications matters for training requirements and compliance, since operator certification is tied to the specific class of equipment being used.
Class I: Electric Motor Rider Trucks
Class I covers electric motor rider trucks, available in both sit down forklifts and stand up forklifts configurations. These machines are ideal for indoor use, running quietly and without emissions, which makes them a natural fit for warehouses and manufacturing facilities focused on air quality.
Class II: Electric Motor Narrow Aisle Trucks
Class II is made up of electric motor narrow aisle trucks, a category that includes reach trucks and order pickers. These forklifts are built for high density racking and very narrow aisles, helping facilities get the most out of limited floor space.
Class III: Electric Motor Hand Trucks / Pallet Jacks
Class III comprises electric motor hand trucks, commonly called pallet jacks, along with walkie stackers. These are pedestrian operated machines designed for short distances, making them a practical choice for loading docks and retail environments where full sized forklifts would be overkill.
Class IV: Internal Combustion Engine Trucks, Cushion Tires
Class IV forklifts use internal combustion engines paired with cushion tires, and they are intended for indoor use on smooth surfaces. Powered by LP gas, diesel, or gasoline, class IV forklifts bring the power of an internal combustion engine into facilities that still need a compact, indoor friendly footprint.
Class V: Internal Combustion Engine Trucks, Pneumatic Tires
Class V forklifts pair internal combustion engines with pneumatic tires for outdoor use on uneven terrain. With higher ground clearance than their cushion tire counterparts, class V forklifts handle rougher surfaces while still delivering the power that internal combustion engines provide.
Class VI: Electric and Internal Combustion Engine Tractors
Class VI includes both electric and internal combustion engine tractors, and unlike the other classes, these machines are designed for towing rather than lifting. Tow tractors in this category are common in airports and distribution centers where moving carts efficiently matters more than raising a load off the ground.
Class VII: Rough Terrain Forklifts
Class VII features rough terrain forklifts fitted with large tractor tires and built for outdoor use on uneven ground. Construction sites and lumber yards rely on class VII forklifts when the working surface is too unpredictable for a standard warehouse machine.
How to Choose the Right Forklift
With so many forklift types and forklift classifications available, narrowing down the right forklift for your operation comes down to a handful of practical questions.
Start with the load capacity you need on a regular basis, since underestimating this can lead to safety issues and equipment strain over time. Consider whether your operation is primarily indoor or outdoor, as this will point you toward cushion or pneumatic tires and help determine whether electric forklifts or internal combustion engine trucks make more sense. Aisle width matters too: standard forklifts need more room to turn than reach trucks or VNA trucks, so measure your storage layout before committing to a design. Think about load center and the shape of what you are lifting, since long or oversized materials may call for a side loader rather than a standard forklift. Fuel type, maintenance needs, and budget round out the decision, along with how often the machine will run and for how long each shift. If you are still weighing your options, our new forklifts and refurbished forklift inventory gives you a range of models to compare side by side.
Frequently Asked Questions
What are the 7 types of forklifts?
The seven official forklift classifications set by OSHA and the Industrial Truck Association are Class I electric motor rider trucks, Class II electric motor narrow aisle trucks, Class III electric motor hand trucks or pallet jacks, Class IV internal combustion engine trucks with cushion tires, Class V internal combustion engine trucks with pneumatic tires, Class VI electric and internal combustion engine tractors, and Class VII rough terrain forklifts.
What is the most common type of forklift?
The counterbalance forklift is the most common type thanks to its versatility. Its rear counterweight design allows it to work in a wide range of settings without the specialized limitations of narrow aisle or rough terrain equipment.
Which forklifts work best in narrow aisles?
Reach trucks, order pickers, VNA trucks, and pallet stackers are all built for narrow spaces and high density storage, making them the better choice over standard counterbalance forklifts when aisle width is limited.
What is the difference between a reach truck and a counterbalance forklift?
A reach truck is an electric machine designed specifically for indoor, narrow aisle work with an extendable mast, while a counterbalance forklift is a more versatile machine that can operate both indoors and outdoors and typically offers a wider range of power source and tire options.
Are electric forklifts better than gas powered forklifts?
It depends on your use case. Electric forklifts are better suited to indoor work where quiet operation, zero emissions, and lower maintenance are priorities, while internal combustion engines are often the better fit for outdoor work, heavy loads, and operations that cannot afford recharge downtime.
Do you need a license to operate a forklift?
You do not need a government issued license, but OSHA does require operator training and certification specific to the class of forklift being used. This certification confirms the operator has the knowledge and hands on skills to run the equipment safely.
Find the Right Forklift for Your Operation
Whether you need a compact pallet jack for a loading dock or a rough terrain forklift for an outdoor job site, understanding the different forklift types and classifications puts you in a better position to choose equipment that will operate efficiently for years to come. Browse PS Janitorial's forklift and used forklift category to see what is currently available, or reach out to our team if you would like help narrowing down the right model for your material handling needs.