Different Types of Forklifts: Guide to Choosing the Right One

Forklifts are essential. They help move, lift, and place heavy stuff fast. In warehouses, construction sites, or retail centers, they save time and boost safety.

But choosing one isn’t simple. It’s not just about picking the biggest. You need to think about a lot of things. How wide are your aisles? Is the ground smooth or rough? How high do you need to lift? How often will it be used? All of these matter. Picking the right one helps you avoid breakdowns and keeps things moving smoothly.

There are many types of forklifts. Electric ones are great indoors. Rugged models work better outside. Some squeeze into tight spaces. Others lift really heavy loads. Each one has a purpose. Using the right one reduces risk, protects your products, and prevents damage to your building.

In this guide, we’ll go over the different types—pallet jacks, reach trucks, order pickers, telehandlers. We’ll talk about what they do best, when to use them, and what to watch out for. We’ll also help you think through your space, workload, and goals.

Want more help? Head to our site. You’ll find guides, comparison charts, and expert advice tailored to your industry.

Understanding Forklifts and Their Core Purpose

What is a Forklift

A forklift is a machine. It moves heavy things. You see it a lot in warehouses, shipping yards, and factories. It helps move stuff faster. It also helps people avoid lifting too much and getting hurt.

A forklift—often referred to as a lift truck—is a motorized industrial machine built to lift, maneuver, and transport heavy materials across short distances with remarkable efficiency. Ubiquitous in warehouses, shipping yards, and manufacturing plants, forklifts play a pivotal role in modern logistics and operations. Their presence not only accelerates workflows but also significantly reduces the physical strain and injury risk typically associated with manual material handling.

At its core, every forklift features a chassis (the base frame), a mast (the vertical assembly for lifting), and two fork arms (prongs that slide under or into loads). Yet despite this fundamental blueprint, forklifts come in an astonishing array of specialized configurations. Electric pallet jacks, for instance, are ideal for indoor use and tight aisles, while counterbalance forklifts offer robust lifting capacity for varied warehouse operations. On the other end of the spectrum, telehandlers and rough terrain forklifts are engineered for heavy-duty performance across uneven or outdoor job sites.

Each model is tailored for specific tasks—whether it’s stacking inventory at high elevations, unloading freight containers, or navigating narrow warehouse corridors. Choosing the right forklift requires a careful evaluation of load type, terrain, lift height, maneuverability, and power source (electric, propane, diesel, or gas).

In today’s fast-paced industrial landscape, understanding the capabilities and limitations of different forklift types is essential for enhancing workplace safety, reducing downtime, and optimizing material flow.

Why Knowing the Types of Forklifts Matters

Forklifts aren’t all the same. That’s not just a detail—it’s a big deal. The kind of forklift you use can affect your costs, safety, and how smoothly your team works every day.

Some forklifts run on gas. Others use batteries. Some turn easily. Others are made for rough outdoor areas. If you pick the wrong one? Problems start showing up fast.

Let’s break it down:

• Broken Stuff: Use the wrong forklift in the wrong spot? You might smash up shelves. Or break expensive gear. Ouch.
• Higher Bills: If the machine burns more fuel or works slower, you’ll see it in your budget.
• Safety Issues: Some forklifts need special training. Some are for outside only. Mess this up and someone could get hurt—or you could get fined.
• Wasted Space: A big machine in a tiny aisle? That’s a traffic jam. Work slows down.

Now, think about all the types out there: counterbalance lifts, pallet jacks, reach trucks, telehandlers. Each one has a job it’s best at. It’s not just about lifting heavy stuff—it’s about doing it right.

In a huge warehouse or a tight one, the right choice means fewer problems. Better safety. Faster work. Happier team.

Classifying Forklifts – The Six Main Categories

Forklifts matter. A lot. They help move things around in warehouses, construction sites, and more. To make sure everything stays safe and organized, OSHA—the U.S. agency for workplace safety—put forklifts into seven main classes. These classes are based on how they’re powered, where they’re used, and what they’re built to do.

If you understand these classes, you’ll know which forklift fits your needs. Whether you’re in a tight warehouse or on a muddy job site, choosing the right machine makes a big difference.

Class I – Electric Motor Rider Trucks

These run on batteries.

Where they work best: Indoors. Clean, closed spaces like warehouses or retail storage areas.

Common types: Sit-down models. Stand-up riders.

Why people like them:

• No emissions.
• Quiet.
• Cheaper to run over time.

Downsides? You’ll need to stop to charge the battery. And they don’t do well outside in wet or rough conditions.

Class II – Electric Motor Narrow Aisle Trucks

Also battery-powered.

Made for places where space is tight. Think: narrow warehouse aisles.

Examples: Reach trucks. Order pickers. Turret trucks.

They’re built to move around in small spaces. If space is money for you, these are gold.

Class III – Electric Motor Hand or Hand/Rider Trucks

Still electric. Still simple.

How they work: Walk-behind or ride-on.

What they are: Pallet jacks. Walkie stackers.

These are for moving things across short distances. Perfect for loading docks and small warehouse areas. Usually, they’re the first step in getting a product from one place to another.

Class IV – Internal Combustion Engine Trucks (Cushion Tires)

These use gas, diesel, or LPG.

Use them inside—but only on smooth floors.

Why? They’re strong and compact. The cushion tires help them turn well in tight indoor spots.

Caution: They produce exhaust. So, good ventilation is a must.

Class V – Internal Combustion Engine Trucks (Pneumatic Tires)

Same fuel as Class IV: gas, diesel, or LPG.

But they’re made for the outdoors. Think rough ground—construction sites, yards, etc.

Pneumatic tires give better grip. Better shock absorption. And more clearance off the ground.

If you’re working outside? Start here.

Class VI – Electric and Internal Combustion Engine Tractors

These don’t lift. They pull.

Power: Electric or combustion engines.

Where you’ll see them: Airports. Big factories. Mail centers.

They tow heavy stuff across long distances. No forks, no lifting—just hauling.

Class VII – Rough Terrain Forklifts

Toughest of them all.

Usually diesel. Always rugged.

Made for: Farms, job sites, and rough land.

They come with big tires. Strong suspension. High clearance. And loads of power.

Mud? Gravel? Steep slopes? No problem. These machines go where others can’t.

Common Forklift Types and Their Applications

Understanding forklift classifications is just the beginning. Now let’s break down the most common types of forklifts you’ll encounter across industries. Each of these machines fits into one of the previously mentioned classes but has its own specialized design and operational purpose.

1. Counterbalance Forklifts

Counterbalance forklifts are the go-to machines in warehouses and loading docks. Why? Because they’re simple, efficient, and powerful. The big weight in the back—called the counterweight—keeps the whole thing balanced when lifting heavy loads up front. No arms sticking out. No extra legs for support. Just lift and go.

When to Use Them

• Moving standard pallets in and out, quick and clean
• Carrying stuff short distances indoors
• Great for smooth floors—whether inside or outside
• Handy across industries: retail, shipping, even manufacturing

Main Features

• Easy to drive: Controls are simple. Most folks can pick it up fast.
• Flexible power options:
  • Electric? Quiet and perfect for inside.
  • Diesel? Tough and ready for the outdoors.
  • LPG? A solid all-rounder.
• Steering to match your space:
  • Three wheels = tight turns.
  • Four wheels = more stable, better for bumpy spots.

Why People Like Them

• Works almost anywhere: Inside a warehouse, outside by a truck—no problem.
• Simple lifting: Up, down, repeat. Great for everyday jobs.
• Good across the board: Retail, logistics, factories—they all use them.

What to Watch Out For

• Bigger turns: They need more space to turn.
• Doesn’t love rough ground: Unless you upgrade the tires, keep it on smooth surfaces.
• A bit bulky: Not ideal if your space is super tight.

2. Reach Trucks

Reach trucks are built for one thing—getting into tight spots and going way up. They’re different from regular forklifts. Why? Their forks extend forward. That’s how they “reach” into deep pallet racks. Super useful when space is tight and shelves go sky-high.

They’re made for environments that are all about height and precision. You can steer them around narrow aisles with ease. No need for wide-open spaces. Want to grab something 30 feet in the air? No problem.

Best For:

• Warehouses with skinny aisles
• Facilities stacking inventory above the norm
• Indoor operations that need clean, quiet machines

Key Features:

• Reach That Impresses: They go high—really high. Thirty feet or more isn’t out of the question.
• Tight Turning: These things spin on a dime. Great for places where space is scarce.
• Extra Support: Outriggers keep the truck steady, even when it’s lifting heavy loads up high.

Advantages:

• More Room, Same Space: Want to pack in more inventory? Just look up. Reach trucks make full use of vertical space.
• Faster Workflow: No need to reposition constantly. Operators can go up, grab, and move on. Quick and efficient.
• Quiet and Clean: Most are electric. That means lower noise, no emissions, and cheaper to run in the long term.

Limitations:

• Not for Outside: Small wheels. Low clearance. Bumpy outdoor surfaces? Forget it.
• Needs Smooth Floors: Best on flat, polished warehouse floors. Anything rough or sloped will cause problems.

3. Pallet Jacks (Manual and Electric)

Pallet jacks—also called pallet trucks—are basic tools used in places like warehouses, backrooms, and shipping areas. They help move loads on pallets from one spot to another. Simple, but very useful. There are two main types: manual and electric. Manual jacks rely on people pushing or pulling. Electric ones do most of the work for you with motors.

Best For:

• Moving light or medium loads over short, flat distances.
• Getting through tight spots like narrow store aisles or cramped storerooms.
• Companies that want an affordable and easy material handling tool.

Key Features:

• Low Cost: Manual jacks are especially cheap, perfect for small businesses.
• Small Size: Their compact shape helps them fit through tight areas.
• Just Enough Lift: They only raise loads slightly—just off the ground, nothing more.

Advantages:

• Easy to Use: Anyone can learn fast. No deep training needed.
• Low Maintenance: Fewer parts means fewer problems. They last.
• Great for Tight Spaces: Where forklifts can’t go, pallet jacks can.
• Electric = Less Strain: No more pushing or pulling heavy stuff by hand.

Limitations:

• Low Lift: They don’t go high. Not made for shelving.
• Weight Limits: Don’t expect them to carry really heavy stuff.
• No Stacking: They move things forward, not upward.

4. Telehandlers (Telescopic Handlers)

A telehandler is like a mix between a forklift and a crane. It has a long boom arm that stretches both up and out. This means it can lift things very high and reach out far, even into tricky spots. It’s made to handle heavy loads that normal forklifts can’t manage—especially when height or distance matters.

Best For:

• Farmers who need to stack bales or move grain up high
• Construction workers lifting bricks or tools to roofs or scaffolding
• Landscapers placing big trees or rocks where it’s hard to reach

Key Features:

• All-Terrain Mobility: It drives over mud, rocks, or rough ground without a problem.
• Telescopic Boom Arm: The arm stretches far—both up and out.
• Versatile Attachments: Forks, buckets, winches, and jibs can be swapped in and out.

Advantages:

• Great Reach: It goes high. Very high. You can access rooftops, second floors, or deep corners.
• Flexible on the Job Site: One machine, many uses. It handles all kinds of ground and tasks.
• Multi-Tool Machine: Need a crane? A loader? An aerial lift? Add the right attachment, and it becomes that.

Limitations:

• Takes Training: It’s not as simple as jump in and go. You need to know how to handle it—especially at height.
• Cost: More expensive than a regular forklift. But if reach and versatility matter? It’s worth every dollar.

5. Side Loaders

Side loaders are forklifts. But they don’t lift from the front—they lift from the side. That’s the key difference. This sideways loading is very useful. Especially in tight spaces. Imagine long steel beams in a narrow aisle—side loaders shine in that setting. Operators can drive right next to shelves. No need to twist or spin big loads. It’s smoother. Faster. More efficient.

Best For:

Think of long, heavy stuff. Steel rods. Timber beams. Pipes—PVC or metal. These machines thrive there.

They also work great in tight spots. Warehouses with narrow aisles? Perfect match.

Outside yards too. Or big, indoor spaces where saving room matters.

Key Features:

• They load from the side. That’s their thing.
• Drivers can move right along the racks. No sharp turns needed.
• Many have enclosed cabins. That keeps out rain, wind, and dust.
• Some can even steer in different directions. Makes things easier.

Advantages:

• Handling long stuff is easy. No reversing. No awkward U-turns.
• They save space. A lot of it. Aisles don’t need to be wide.
• Repetitive tasks go quicker. Time saved is money saved.

Limitations:

• They’re not for everything. If you don’t move long items, you might not need one.
• Turning can be tricky. Not as nimble as smaller forklifts—unless moving sideways.
• They cost more. And they don’t sell as easily later. Niche gear comes with niche trade-offs.

6. Rough Terrain Forklifts

Rough terrain forklifts don’t care about paved roads. They’re tough. Built to handle dirt, rocks, and the wild outdoors, these machines use big, bouncy tires and strong diesel engines to move loads where regular forklifts give up. Got mud? No problem. Hills? Bring it on. These beasts were made for rugged work.

Best For:

• Bumpy construction sites
• Farms and orchards
• Logging and lumber yards
• Outdoor events or emergency zones

Key Features:

• Big Pneumatic Tires: They soak up bumps and grip loose ground.
• Diesel Engines: Strong and reliable. Plenty of power for heavy lifting.
• Four-Wheel Drive: Moves steadily over rough areas.
• High Ground Clearance: Keeps the undercarriage safe from rocks and roots.
• Optional Enclosed Cabins: For comfort in heat, cold, or rain.

Advantages:

They shine where others fail. Muddy roads? They power through. Loose gravel? No worries. These machines carry heavy stuff with ease. Need to lift logs or equipment way out in the field? Done. They also don’t need fancy roads or indoor storage. Just drop them in and go.

Limitations:

They’re big. Sometimes too big. Tight indoor spaces? Not ideal. And that diesel engine? Loud. Also, not the greenest option. Maintenance can cost more too—thanks to their rugged build and all that bouncing around.

7. Order Pickers

Order pickers aren’t your average forklifts. They’re made for something more specific. Instead of lifting entire pallets, these machines take the operator up with the load. That way, the operator can grab individual items from shelves—even from way up high. It’s all about speed and precision. You’ll mostly see them in busy warehouses, especially those in eCommerce or retail. Places where every second counts and every order is different.

Best For:

• Picking single items from tall shelves
• Fulfilling mixed-SKU orders
• Fast-moving setups with limited walking space

Key Features:

The platform lifts the operator to shelf level. That means direct access to each bin or product slot. Most models run on electricity. Quiet. Clean. Perfect for indoor use. Their turning radius is tight—really tight. That helps in narrow aisles. Safety? Built in. Think harness points, sensors, and guardrails.

Advantages:

You don’t waste time walking. Or climbing. That speeds things up. It’s better for your back too. Fewer injuries, more comfort. Want to keep inventory lean? These machines help you pick only what’s needed—fast. Plus, they’re quiet. Clean. Ideal for inside jobs.

Limitations:

They can’t move big pallets. If you need to carry a lot, look elsewhere. They run on batteries, so you’ll need charging space—and a schedule. Training is a must. Especially if you’re working in tight spots or going high up. Oh, and uneven ground? Not their thing.

8. Industrial Forklift (Large Capacity Forklift)

Big jobs need big machines. That’s where industrial forklifts—also called large capacity or heavy-duty forklifts—step in. These are not your average warehouse lifts. They’re built tough. Real tough. You’ll see them working hard in places like steel factories, ports, and giant manufacturing sites. Their purpose? Lifting very heavy stuff. And doing it without breaking a sweat.

Best Used For:

• Loads over 15,000 lbs (about 6,800 kg). That’s a lot.
• Places that move massive materials every day:
  • Steel plants
  • Warehouses with large machines or parts
  • Shipyards, ports, and even aerospace work zones

Main Features:

• Thick, tough frames. Built to stay strong under pressure.
• Powerful hydraulics. Smooth and steady lifts.
• Engines that run on diesel or gas. Lots of torque. Long shifts.
• Big tires—air-filled or solid—for bumpy ground.
• Weather-ready cabins. Great for working outside all day, all year.

Why It’s Great:

These forklifts are beasts. They lift things others can’t. Heavy coils, metal casts, giant crates—they handle it all. With just one of these, you might not need a team of smaller lifts. That means less confusion and more speed. They can even use custom forks or attachments to handle tricky jobs. And yes, they’re ready to work around the clock, even in tough conditions.

Things to Keep in Mind:

• They’re expensive. Both to buy and to keep running.
• You need trained pros to drive them. Safety matters.
• They’re big. Not easy to squeeze through tight aisles.
• Floors might need reinforcing. These machines are heavy—and they spread that weight around.

Choosing the Right Forklift for Your Needs

After understanding the different types of forklifts and their unique strengths, the next step is selecting the right one for your specific operational requirements. With dozens of models and configurations available, here’s a step-by-step framework to help guide your decision-making process.

1. Assess Your Operational Environment

Indoor or Outdoor?

Start by figuring out where the forklift will be used. Inside a building? Outside? Maybe both?

• Inside Workspaces: If you’re mostly working indoors—like in warehouses—electric forklifts are your best bet. They don’t create fumes, which keeps the air clean. They’re also quiet, so there’s less noise for your team to deal with. Use cushion tires—they’re made from solid rubber and perfect for smooth floors. They also help with tight turns and tight spaces.
• Outside Jobs: Working outside? Then you’ll need something tougher. Forklifts that run on gas, diesel, or LPG have more power. They’re great for steep ramps, heavy stuff, and tricky weather. Use pneumatic tires—they’re filled with air or made solid, and they handle bumps, mud, and gravel like a champ.

Think About Your Space

How your space is set up matters a lot—just as much as the type of ground you’re working on.

• Narrow Aisles: Got skinny aisles in your warehouse? Look into reach trucks or order pickers. They’re built for tight places. Super nimble. Super accurate. They’ll help your team stay safe and move faster.
• Wide-Open Areas: Have lots of room? Then go for standard forklifts or rough terrain models. They’re strong, can carry big loads, and are easy to drive around. Great for big yards, ports, or construction zones.

2. Understand Your Load Requirements

Weight Capacity

Think about weight first. It’s important. Your forklift needs to lift more than just your usual load. Go beyond average. What’s the heaviest load you might lift? Plan for that. Don’t cut it close. Too much weight can break the machine. It can hurt someone. It can also wear the forklift out faster. To be safe, go at least 15–20% above your typical max load. That buffer gives you room to work without risk.

Load Dimensions

Weight isn’t everything. Shape matters too. A lot. Imagine a long metal pipe or a wide wooden beam. Forklifts don’t like weird shapes. Balance becomes tricky. Loads can tip. That’s dangerous. In these cases, try a side loader. Or maybe a multi-directional model. Those machines can move sideways. They handle long items better, especially in tight spots.

But if most of your stuff comes on pallets—standard ones like 48″x40″—you’re in luck. A counterbalance forklift works great. So does a pallet jack. These tools are made for smooth, quick movement. They glide through warehouse aisles. They load and unload trucks. Fast. Easy. No stress.

3. Consider Lifting Height and Reach

If your warehouse uses multi-level racking, your choice of forklift matters a lot. It’s not just about what’s easy — it affects how well your operations run and how safe they are.

Reach trucks and telehandlers are built for this. They’re made to move through tight spaces. They lift pallets high. That makes them perfect for these kinds of storage systems.

But here’s something people often miss: lift height. It’s not enough to say, “This forklift goes high.” You need to be sure. Really sure. Can it reach your tallest rack? And then some? There should be room to spare — for the operator to see clearly, for the pallet to settle in safely.

If not, you’re taking risks. You might slow things down. You could cause accidents. Worst of all, you might need new equipment sooner than expected.

4. Evaluate Fuel Type and Efficiency

Choosing a forklift’s fuel type matters. It’s not just about the engine—it affects your costs, how long you can run, and even your environmental impact.

Electric Forklifts

Electric forklifts are great for working indoors. They make sense if you want clean, quiet machines that don’t cost much to run.

• They don’t need fuel. Fewer moving parts mean fewer repairs.
• No emissions. That’s good for food storage, indoor warehouses, or tight spaces.
• They’re quiet. Operators like that. Less noise makes a better work environment.
• But—they need charging. That takes time unless you swap batteries or plan charging breaks.

Electric models are smart if you value quiet, clean energy and indoor safety. Just remember: they need a good charging setup and schedule.

Internal Combustion (IC) Forklifts

If the job is tough, long, or outside, IC forklifts might be better. They use diesel, gas, or LPG. Here’s what they bring:

• Fast refueling. Fill up and get back to work.
• Strong engines. More torque. Great for rough or outdoor areas.
• But—more emissions. And they’re noisy. That’s not ideal for indoor spaces.
• More maintenance too. Their engines are more complex.

IC forklifts are powerful. They’re built for tough jobs. But they cost more to maintain and aren’t as green.

5. Budget and Total Cost of Ownership (TCO)

It’s easy to focus on the price tag. But that’s just the beginning. What really matters is the total cost over time—known as the total cost of ownership (TCO). You need to look beyond what you pay upfront. Think about how much it will cost you over the machine’s life.

Let’s break it down:

• Maintenance and Repairs: Will it need regular fixes? Are parts easy to get? Is it hard to find someone who can work on it?
• Fuel or Energy: Diesel and LPG models use a lot of fuel. Electric ones are cheaper to run—but you may need to add charging stations.
• Training Costs: Some machines are more complex. That means more training—and more money.
• Long-Term Durability: Will it last in your conditions? Hot, cold, dusty, wet—some machines break down faster in tough spots.

Here’s an example: Electric forklifts cost more at first. But they’re cheaper over time. They don’t need as many repairs. They use less energy. Over five or ten years, the savings add up. That extra spend in the beginning? It can pay off.

6. Operator Experience and Safety

A forklift doesn’t run itself. The person driving it matters. A lot. If the machine is hard to use, people get tired. Or worse, they get hurt. That’s bad for everyone.

Here’s what to look for:

• Easy Controls: Simple layouts. Comfortable grips. Less shaking. That means less strain on the driver.
• Good Visibility: Can they see clearly? That’s key—especially in tight spots or busy areas.
• Safety Tech: Features like auto-braking or tilt control aren’t just nice—they prevent accidents.
• OSHA Compliance: Some machines help you follow safety rules automatically. That’s a big plus.

And remember: Even the best machine is risky if the driver isn’t trained. Get the right people. Or offer solid training. You can also work with vendors that provide onboarding. It’s worth it.

Conclusion

Let’s quickly summarize what we’ve covered in this comprehensive guide to the different types of forklifts:

• Forklifts come in various classes based on power type and design, from electric motor trucks to rough terrain behemoths.
• Common forklift types include counterbalance trucks, reach trucks, pallet jacks, telehandlers, side loaders, and more—each suited for specific environments and use cases.
• Choosing the right forklift depends on factors like load weight, terrain, aisle width, lift height, power preference, and total cost of ownership.

Selecting the correct forklift isn’t just about moving materials—it’s about improving efficiency, enhancing workplace safety, and aligning your equipment with your operational strategy.

Investing in the right forklift means taking a detailed look at your business operations and making informed decisions that promote safety, performance, and long-term value. The wrong choice can hinder productivity and raise operational costs, while the right one can streamline your entire workflow.

Whether you manage a warehouse, a construction site, a retail distribution hub, or a manufacturing plant, understanding the types of forklifts available empowers you to make smarter, more efficient decisions.

If you’re ready to explore forklift solutions tailored to your business, we invite you to visit our website for expert advice, product recommendations, and a complete range of material handling equipment.

Let us help you lift your productivity—safely, efficiently, and affordably.