7 Forklift Types & Classes – Selection Chart

Choosing the right forklift type isn’t just about lifting loads—it’s about maximizing uptime, safety, and productivity across material handling operations. From electric counterbalance models to rough terrain and narrow aisle forklifts, each type is engineered for specific environments and load demands.

This guide provides actionable insights for warehouse managers, procurement officers, and operations professionals looking to align equipment choice with technical requirements and ROI goals. With a detailed breakdown of specifications, advantages, and best-use scenarios, you’ll gain clarity on the optimal forklift solution for your operational context.

The main types of forklifts include counterbalance forklifts, reach trucks, pallet jacks, order pickers, rough terrain forklifts, and side loaders. Counterbalance forklifts are common in warehouses. Reach trucks handle high shelving. Pallet jacks are ideal for short distances, while rough terrain forklifts work on uneven ground.

Why Forklift Selection Actually Matters

“Just get whatever’s cheapest” – words typically spoken by someone who’s never had to explain why productivity is down or why worker comp claims are up.

The truth is, your forklift fleet directly impacts everything from picking efficiency to space utilization. Those KPIs your boss keeps mentioning? Yep, the right forklift can make or break them.

Think of it this way: material handling challenges like navigating tight spaces, optimizing vertical storage, and moving awkward loads safely aren’t just daily annoyances – they’re profit-killers when multiplied across thousands of movements. A forklift that can’t reach your top rack or maneuver your aisles without doing a 17-point turn isn’t just frustrating; it’s actively costing you money.

And let’s not forget safety. Nothing tanks operational efficiency quite like an accident report and OSHA investigation.

Forklift Basics: Not Just “Big Orange Machines”

Before diving into the nitty-gritty, let’s establish what we’re talking about. OSHA formally calls them “Powered Industrial Trucks” (PITs), but everyone else just calls them forklifts. They’re power-driven vehicles designed to lift, carry, push, pull, stack or tier materials.

The standard forklift consists of:

• A truck frame (the base)
• A power source (engine or battery)
• The mast (vertical assembly that goes up and down)
• The forks (those two metal prongs that do the heavy lifting, literally)
• A counterweight (often the battery in electric models)
• An operator cab with all the controls and safety features

But here’s where things get interesting – not all forklifts are created equal, and there’s a surprisingly wide variety of specialized machines out there.

The Forklift Family: More Diverse Than You Think

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    IV[Class IV<br>IC Engine Trucks<br>Cushion Tires]:::classIV
    V[Class V<br>IC Engine Trucks<br>Pneumatic Tires]:::classV
    VI[Class VI<br>Electric & IC<br>Tow Tractors]:::classVI
    VII[Class VII<br>Rough Terrain<br>Forklift Trucks]:::classVII
    
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    I --> I2[4-Wheel Electric<br>Counterbalance]:::classI
    I --> I3[Stand-Up Rider]:::classI
    
    II --> II1[Reach Trucks]:::classII
    II --> II2[Order Pickers]:::classII
    II --> II3[Turret Trucks<br>Very Narrow Aisle]:::classII
    
    III --> III1[Walkie Pallet Jack]:::classIII
    III --> III2[Walkie Stacker]:::classIII
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    VI --> VI1[Tow Tractors]:::classVI
    VI --> VI2[Baggage Tugs]:::classVI
    
    VII --> VII1[Straight Mast<br>Rough Terrain]:::classVII
    VII --> VII2[Telehandlers<br>Extended Reach]:::classVII

If you thought a forklift was just a forklift, buckle up. OSHA actually classifies them into seven distinct categories, and knowing the difference matters. Here’s the family breakdown:

Class I: Electric Motor Rider Trucks

These battery-powered counterbalance trucks are the darlings of indoor warehouses. Zero emissions, relatively quiet, and they don’t leave you with a splitting headache from exhaust fumes. Operators sit down (or sometimes stand), and they typically run on cushion or pneumatic tires.

Class II: Electric Motor Narrow Aisle Trucks

When warehouse real estate gets expensive, these skinny specialists come into play. Reach trucks, order pickers, and turret trucks all fall into this category, designed specifically for tight spaces where standard forklifts would need to perform a 12-point turn.

Class III: Electric Motor Hand/Rider Trucks

Think of these as the entry-level forklifts. They include electric pallet jacks and walkie stackers, where the operator either walks behind or stands on a small platform. Perfect for short distances and lower-level work.

Class IV: Internal Combustion Engine Trucks (Cushion Tires)

These gas-guzzlers run on LPG, gasoline, CNG, or diesel and sport solid cushion tires. They’re built for smooth indoor surfaces like warehouse floors and loading docks.

Class V: Internal Combustion Engine Trucks (Pneumatic Tires)

Same combustion engines as Class IV, but equipped with pneumatic tires that can handle rougher outdoor terrain. If you’ve seen forklifts working in lumberyards or construction sites, they were probably Class V.

Class VI: Electric and IC Engine Tow Tractors

These tow tractors or “tuggers” are primarily for pulling loads rather than lifting them. Think airport baggage handling or assembly lines.

Class VII: Rough Terrain Forklift Trucks

The off-road enthusiasts of the forklift world. With their big tractor-style tires and robust construction, they’re built specifically for unpaved surfaces and construction sites.

Beyond these formal classifications, there are specific types you’ll hear mentioned:

• Counterbalance Forklifts: The classic design with forks in front and weight in back.
• Reach Trucks: Specialists at, well, reaching deep into racking systems.
• Pallet Jacks: The humble workhorses of retail backrooms and loading docks.
• Order Pickers: Lifts the operator up to pick individual items from shelves.
• Telehandlers: Think of them as forklift-crane hybrids with telescopic booms.
• Side Loaders: Forks mounted perpendicular to direction of travel for long loads.
• Turret Trucks: High-end specialists for very narrow aisle warehouses.

Each type exists because someone, somewhere, had a specific material handling problem that standard forklifts couldn’t solve efficiently.

The Critical Features That Actually Matter

Let’s talk about what separates a good forklift from a great one for your specific operation.

Power Source: Electric vs. Combustion

The eternal debate. Here’s what no salesperson will tell you straight:

Electric Pros: Quieter, zero tailpipe emissions (crucial for food and pharma), typically lower maintenance costs, and often better maneuverability.

Electric Cons: Higher upfront cost, you’ll need charging infrastructure, and battery management becomes part of your daily operations.

IC Engine Pros: Generally more powerful, can run continuously with quick refueling, and tend to handle outdoor conditions better.

IC Engine Cons: Emissions (hope you have good ventilation), noisier operation, and typically higher fuel and maintenance costs.

The industry has been trending electric for years, but IC engines still have their place, especially in outdoor applications or when power demands are extremely high.

Tire Types: More Important Than You Think

Cushion Tires: Solid rubber molded onto wheels. Best for smooth indoor surfaces. Lower ground clearance means smaller turning radius, which is great for tight spaces. They’re puncture-proof but offer poor traction when wet.

Pneumatic Tires: Either air-filled or solid rubber with tread patterns. Essential for outdoor use, uneven surfaces, or wet conditions. They provide better stability and a smoother ride but increase the turning radius.

Putting cushion tires on outdoor terrain is like wearing dress shoes to hike a mountain – technically possible but a terrible idea that will end badly.

Load Capacity and Lift Height

This seems straightforward but gets tricky fast. A forklift rated for 5,000 lbs doesn’t mean it can safely lift 5,000 lbs in all situations. That rating is typically based on a standard load center (usually 24 inches), and capacity decreases as:

• The load center moves further out
• The lift height increases
• The mast tilts forward

Always check the data plate and never play games with these limits unless you enjoy impromptu workplace safety demonstrations.

Mast Types: The Vertical Elevator

Different masts offer varying lift heights and collapsed heights:

• Standard (Simplex): Two sections, limited free lift.
• Duplex: Two sections with significant free lift before mast extends.
• Triplex: Three sections, most common, good balance of lift height and collapsed height.
• Quad: Four sections for maximum height, but taller collapsed height.

Choosing the right mast depends on your maximum needed lift height and any overhead clearance restrictions like doorways.

Real Benefits That Impact Your Bottom Line

Let’s talk straight about what these machines actually do for your operation:

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    I3["Reduced worker injury claims"]:::impact
    I4["Lower workers' compensation costs"]:::impact
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    I6["Delayed facility expansion costs"]:::impact
    I7["Staff reassignment to value-add tasks"]:::impact
    I8["Lower labor cost per unit moved"]:::impact
    I9["Decreased inventory shrinkage"]:::impact
    I10["Fewer product returns"]:::impact
    I11["Multiple tasks with one machine"]:::impact
    I12["Reduced equipment fleet size"]:::impact
    
    Benefits --> B1 & B2 & B3 & B4 & B5 & B6
    
    B1 --> I1 & I2
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    B4 --> I7 & I8
    B5 --> I9 & I10
    B6 --> I11 & I12

Productivity Boosts

Tasks that would take a team of workers hours to complete manually can be done in minutes with the right forklift. Loading/unloading trailers, moving pallets, and stacking inventory all happen faster, allowing you to handle higher volumes with the same workforce.

Safety Improvements

One of the biggest benefits is reducing manual handling injuries. Back strains, sprains, and fatigue from manual lifting are among the most common workplace injuries. Forklifts drastically reduce these risks, though they introduce different safety considerations.

Space Optimization

Vertical storage is the cheapest expansion you can make. A good forklift lets you stack higher, maximizing your existing footprint and potentially delaying or avoiding costly physical expansions.

Labor Optimization

Automating material handling means fewer people dedicated to just moving stuff around. This lets you reallocate labor to more value-added activities.

Reduced Product Damage

Precise control during lifting and stacking means less dropped, crushed, or otherwise damaged inventory.

Versatility Through Attachments

Modern forklifts can be equipped with specialized attachments (clamps, rotators, booms) to handle almost any load type, essentially turning one machine into several.

Matching Forklifts to Real-World Applications

Different environments demand different equipment. Here’s where specific types shine:

Warehousing & Distribution

• General Tasks: Standard counterbalance forklifts handle loading/unloading and general pallet movement.
• High-Density Storage: Reach trucks, turret trucks, and VNA articulated forklifts maximize vertical space.
• Order Fulfillment: E-commerce relies heavily on order pickers for retrieving individual items.
• Short-Distance Transport: Pallet jacks move loads from receiving to staging.

Retail

Smaller electric counterbalance trucks, pallet jacks, and walkie stackers dominate backroom storage and inventory management.

Construction Sites

Rough terrain forklifts and telehandlers with their uneven-terrain capabilities are essential for moving building materials around sites.

Manufacturing

Counterbalance forklifts and side loaders (for long materials) keep production flowing with raw materials and finished goods.

Special Material Handling

• Lumber/Steel/Pipes: Side loaders efficiently handle long, awkward loads.
• Agriculture: Rough terrain forklifts and telehandlers move hay bales and equipment on unpaved farm terrain.
• Loading Docks/Ports: High-traffic areas use counterbalance forklifts for loading/unloading while pallet jacks work within containers.

Making the Right Choice: What to Actually Consider

When it’s time to pull the trigger on a forklift purchase or lease, here’s what really matters:

Load Requirements

• Maximum Weight: Don’t just consider average loads – what’s the heaviest thing you’ll lift? Add a safety margin.
• Load Characteristics: Dimensions, shape, and weight distribution all affect stability and might require specialized equipment.

Lift Height Requirements

• Maximum Fork Height: Determined by your highest shelf.
• Overhead Clearance: The lowest point the forklift must pass under.
• Free Lift: Essential if you’re lifting in areas with low overhead clearance.

Operating Environment

• Location: Indoor, outdoor, or mixed use? This drives power source and tire selection.
• Surface Conditions: Smooth concrete vs. gravel vs. mud all require different equipment.
• Special Conditions: Temperature extremes, hazardous atmospheres, etc.

Space Constraints

• Aisle Width: Critical for choosing between standard, narrow aisle, or very narrow aisle equipment.
• Maneuverability: Tight turns require specific turning radius capabilities.

Power/Fuel Considerations

Balance electric vs. IC based on environment, usage intensity, and infrastructure availability.

Total Cost of Ownership

• Initial Cost: Just the tip of the iceberg.
• Ongoing Expenses: Fuel/energy, maintenance, repairs, parts, training.
• Electric tends to have higher upfront costs but lower TCO due to reduced maintenance and energy costs.

Maintenance and Support

• Dealer Proximity: Local support matters when downtime costs money.
• Parts Availability: How quickly can you get replacement parts?

Operator Considerations

• Training Requirements: Some machines require more specialized training.
• Ergonomics: Operator comfort directly impacts productivity and reduces fatigue.

Attachment Needs

Identify specialized attachments required for specific loads and ensure compatibility.

Safety: Non-Negotiable Considerations

Forklifts are powerful tools that demand respect. Here’s what you absolutely must consider from a safety perspective:

Operator Training and Certification

OSHA requires comprehensive training and certification for all operators. This isn’t just a legal box to check – it’s fundamental to safe operation. Training must cover:

• Equipment-specific operation
• Workplace-specific hazards
• Load handling techniques
• Stability principles
• Inspection procedures

Recertification is required every three years, with additional training after accidents or when switching to different forklift types.

Pre-Operation Inspections

These are mandatory before each shift and should include:

• Visual checks (tires, forks, mast, chains, overhead guard, hydraulics, fluid levels)
• Operational checks (gauges, brakes, steering, horn, controls, alarms)

Any defects require immediate removal from service until repairs are completed.

Understanding Stability

Operators must understand the “stability triangle” concept – an imaginary area formed by the front wheels and rear axle pivot point. The forklift remains stable only when the combined center of gravity stays within this triangle.

Factors affecting stability include load weight and distribution, lift height, tilt angle, speed, turns, and ramp grades.

Safe Load Handling

• Always adhere to rated capacity
• Center loads on forks
• Keep loads low during travel
• Insert forks fully under loads
• Use load backrest extensions when needed

Pedestrian Safety

This is where accidents often happen. Best practices include:

• Separating pedestrian traffic from forklift routes
• Maintaining operator vigilance
• Using horns at intersections and blind spots
• Installing mirrors at blind corners
• Prohibiting anyone from standing under raised forks

The Value Factor: What Equipment Appraisers Know About Forklift Selection

Here’s something you won’t hear from the dealer trying to move that shiny new Toyota off the lot: the most expensive forklift isn’t the one with the highest price tag—it’s the one collecting dust in the corner of your warehouse because it can’t navigate your 8-foot aisles or handle your specific load requirements.

We’ve appraised thousands of forklifts over the years, and let me tell you, the value patterns are crystal clear. Those specialized turret trucks and order pickers? They hold value like gold when they’re actually matched to their applications. Meanwhile, that “great deal” on a standard counterbalance truck often turns into a depreciation nightmare when it’s forced to do jobs it wasn’t built for.

The numbers don’t lie. We consistently see 15-20% higher residual values in purpose-matched equipment versus the “close enough” approach. It’s like watching the same movie play out with different companies—the ones who paid attention to the selection process we’ve outlined above end up with assets that maintain value, while the price-shoppers are back in the market years before they planned to be.

Conclusion

Let’s cut to the chase: picking a forklift is a lot like hiring a key employee. Get it right, and you’ve got a productive team member that makes everyone’s job easier. Get it wrong, and you’re looking at frustrated operators, maintenance headaches, and money burning a hole in your budget.

The most successful operations treat forklift selection as what it actually is: a strategic decision that directly impacts your bottom line. They match the machine to the mission, prioritize operator training, and consider the total cost of ownership instead of just the sticker price.

Remember, that bargain-basement deal often comes with premium-priced problems down the road. Your future self will thank you for spending the time now to select a forklift that actually fits your operation, not just your initial budget.

FAQ