How Many Types of Forklifts Are There

How Many Types of Forklifts Are There? A Complete Guide to Forklift Classifications

Modern industries have flourished with the use of forklifts. Starting from shipping docks and warehouses to retail distribution centers, and construction sites, forklifts are the ones that do all the heavy work. However, if you are in the thought that every forklift is the same, better chase away those thoughts.

There are not only a few, but dozens of different forklift types, each with a different purpose for the application and the environment in which they are used. So how many types of forklifts are available? It’s not just a number that can be straightforwardly answered. It’s a broad range of machines which get created particularly for multiple applications and operational locations.

Knowing the different types of forklifts is a good way to get the right tool needed for a task. It contributes to the safety of the working area, increases productivity, and in the long run, saves money. Irrespective of whether you are handling a big warehouse with a high level of activity or a retail inventory system, the fact that you have a clear idea about forklifts is a must.

This comprehensive guide section by section, gives an account of all the points informed—from class classifications to special designs. Let’s closely look at all the types of forklifts, which are available in full and how each one of them can be put to its unique purpose.

Understanding the Basics of Forklifts

What Is a Forklift?

A powered industrial truck is often referred to as a forklift which is designed to lift and transfer materials over short distances. In general, forklifts are equipped with two forks (or tines) at the front which can be manually positioned under pallets or other bulky objects thus allowing the operator to lift and move them to a new location. Their primary purpose is to simplify, enhance safety, and expedite the process of lifting heavy loads.

Without forklifts, those sectors that require bulky, heavy, or multiple loads of transportation, such as logistics, storage, construction, and manufacturing, would be unable to carry on their operations. These vehicles are not only powerful but they are also made for safe, accurate load movement and controlled usage in limited spaces and rough terrains.

Brief History and Evolution

The forklift concept has quite old origins originating back to the early 20th century. A few decades later, the first prototypes of the factory gear began you come to light in time to be useful for the needs of the military during World War I. In the 1920s, firms such as Clark and Yale made the first transition to mechanical power by inventing powered lift trucks that operated via hydraulic lifts.

With newer technology, lifts changed from simple manual carts into machines with electric or internal combustion engines, advanced hydraulics, ergonomic controls, and smart technology. The forklift that we see currently is not only not the same machines but it is also a highly specific tool with several options which can satisfy almost every work need.

The Main Classification of Forklifts

Class I to Class VII Forklifts Overview

In the U.S., forklifts are primarily classified into seven major types by the Occupational Safety and Health Administration (OSHA), ranging from Class I (electric motor riders) to Class VII (rough terrain forklifts). These classes are based on the forklift’s power source and its intended operational environment.

Here’s a quick breakdown:

Forklift Class	Type of Forklift	Power Source	Ideal Use Case
Class I	Electric Motor Rider Trucks	Electric	Indoor use, low emissions
Class II	Electric Narrow Aisle Trucks	Electric	Tight warehouse spaces
Class III	Electric Hand Trucks or Hand/Rider	Electric	Small warehouses, retail
Class IV	IC Engine Trucks (Cushion Tires)	Diesel, LPG	Indoor use on smooth surfaces
Class V	IC Engine Trucks (Pneumatic Tires)	Diesel, LPG	Indoor/outdoor versatility
Class VI	Electric and IC Engine Tractors	Electric, Diesel	Towing loads
Class VII	Rough Terrain Forklifts	Diesel	Construction, outdoor terrain

Internal Combustion vs. Electric Forklifts

Forklifts generally run on either internal combustion engines (ICE) or electric power:

Electric Forklifts: Ideal for indoor use; quiet, clean, and require charging stations.
ICE Forklifts: Powered by diesel, propane (LPG), or gasoline; more power and suitable for outdoor or heavy-duty tasks.

Choosing between electric and internal combustion often comes down to the work environment, lifting capacity needs, and long-term operating costs.

Class I Forklifts – Electric Motor Riders

These are some of the most commonly used forklifts in indoor environments like warehouses and distribution centers.

Features and Uses

Class I forklifts are run by industrial batteries and fitted with transistor motor controllers. They’re available in both types of three-wheel and four-wheel models so that the user can be mobile and give the right capacity. They are driven by an electric motor that, in addition to being incredibly quiet and fuel-efficient, does not produce harmful emissions , therefore, they are suitable for clean indoor environments such as warehouses (for food and pharma products) etc.

Common Applications and Industries

Warehouses
Retail distribution centers
Manufacturing facilities
Clean room environments

Because of their zero-emission nature and compact size, Class I forklifts are especially popular in industries where environmental conditions and space are key considerations.

Class II Forklift—Electricc Narrow Aisle Trucks

These forklifts are specifically designed to operate in narrow aisles, giving warehouses the ability to maximize storage space without sacrificing maneuverability.

Unique Design for Tight Spaces

Class II forklifts include reach trucks, order pickers, and turret trucks. They have a compact design and can make tight turns, allowing them to operate in aisles as narrow as 8–10 feet. Their precision and control make them indispensable in facilities where every square foot counts.

Efficiency in Warehousing

Narrow aisle forklifts are game-changers in high-density storage. With adjustable forks and mast configurations, these machines can reach higher shelving units without the need for wide turning radii. They also contribute to lower energy consumption and improved workflow efficiency.

Class III Forklift—Electricc Hand Trucks or Hand/Rider Trucks

Class III forklifts are compact, user-friendly, and perfect for lighter tasks. These are often referred to as pallet jacks or walkie stackers and are typically used for moving materials over short distances, especially in retail environments or small warehouses.

Low-Capacity Pallet Handling

These forklifts are electrically powered and designed for operators to walk behind (or occasionally ride on). They’re not meant for high lifting but are incredibly efficient for horizontal pallet transportation. Their maximum capacity generally ranges from 2,000 to 8,000 pounds, and they come in several sub-types, such as:

Walkie pallet trucks
Walkie stackers
Rider pallet trucks

Their intuitive controls and lightweight build make them ideal for indoor use where space is limited.

Perfect for Retail and Small Warehouses

If you run a retail store, small-scale distribution center, or grocery warehouse, Class III forklifts are likely your go-to equipment. They’re extremely cost-effective, require minimal training to operate, and are ideal for day-to-day operations like restocking shelves or unloading small shipments.

Additionally, their battery-powered motors emit no emissions, ensuring their safety in environments that require air quality maintenance. However, they are limited in height and weight capacity compared to higher classes.

Class IV Forklift—Internall Combustion Engine with Cushion Tires

Class IV forklifts are indoor powerhouses. Equipped with internal combustion engines and cushion tires, these forklifts are perfect for environments that require high lifting power but don’t need off-road mobility.

For Indoor Industrial Use

These forklifts run on diesel, gasoline, or LPG and are designed to be used on smooth surfaces like concrete. Cushion tires are made from solid rubber and provide better maneuverability in tight indoor areas. Class IV forklifts offer a higher lifting capacity than Classes I–III, making them perfect for heavy pallet handling and large industrial applications.

Benefits and Limitations

Pros:

High lifting power (up to 15,000 lbs or more)
Great for loading/unloading large items
Long operational life with proper maintenance

Cons:

Not suitable for uneven or outdoor surfaces
Requires ventilation due to exhaust emissions

Industries such as automotive manufacturing, metal fabrication, and appliance warehousing often depend on Class IV forklifts for their power and efficiency.

Class V Forklifts – Internal Combustion Engine with Pneumatic Tires

Think of Class V forklifts as the rugged cousins of Class IV. These heavy-duty machines come with pneumatic (air-filled) tires, allowing them to handle rough or uneven surfaces both indoors and outdoors.

Versatility in Indoor and Outdoor Use

Class V forklifts are incredibly versatile. They’re commonly powered by diesel, LPG, or gasoline and come in a wide range of sizes and load capacities. The pneumatic tires give them excellent traction, making them suitable for construction sites, lumber yards, and ports.

Whether you’re transporting large steel coils or moving goods across a loading dock, Class V forklifts deliver top-notch performance under demanding conditions.

Ideal Industries

Construction
Shipping and logistics
Agriculture
Warehousing and heavy manufacturing

Their all-terrain capability and lifting capacity (often up to 36,000 lbs) make them a favorite for companies dealing with heavy, awkward, or oversized materials. If your operations span both indoor and outdoor settings, Class V forklifts offer the perfect blend of durability, power, and flexibility.

Class VI Forklifts – Electric and Internal Combustion Tractors

Class VI forklifts, also known as tuggers or tow tractors, are not for lifting but towing. These are specialized machines used to pull loads on trailers or carts, commonly seen in airports, manufacturing plants, and large-scale distribution centers.

Tuggers and Tow Tractors

These forklifts may not have forks at all. Instead, they feature towing mechanisms that can haul several tons of cargo in one trip. They come in both electric and internal combustion engine models, allowing businesses to choose based on indoor or outdoor needs.

Electric models are used indoors for things like mailroom carts, baggage handling, or assembly line components, while diesel-powered versions handle outdoor tasks like hauling airplane luggage or moving pallets between warehouses.

Specialized Applications

Airport luggage transport
Auto manufacturing parts delivery
Hospital supply distribution
Warehousing systems using towable carts

Tow tractors are invaluable in lean manufacturing systems that rely on just-in-time inventory movement. They help streamline material flow and reduce the number of lift trucks required on-site.

Class VII Forklifts – Rough Terrain Forklifts

When it comes to heavy-duty performance in the harshest environments, Class VII forklifts lead the pack. These are built for outdoor use and excel on rocky, muddy, or uneven terrain.

Built for the Outdoors

Rough terrain forklifts are equipped with large pneumatic tires, higher ground clearance, and powerful diesel engines. These machines are engineered for strength, stability, and reliability, often used in areas where a standard forklift would get stuck or break down.

They can lift heavy loads like lumber, steel beams, concrete blocks, and even large construction equipment. Their design often includes four-wheel drive and high-lift capabilities, making them extremely capable under pressure.

Construction and Agricultural Uses

Common environments include:

Building construction sites
Logging operations
Mining areas
Farms and agricultural supply yards

Class VII forklifts are a staple in industries where the ground is unstable, the loads are heavy, and the conditions are rough. Their robustness and safety features make them a top pick for operators who need reliability and strength above all else.

Specialized Forklifts Beyond the Classes

While Classes I–VII cover the standard forklift spectrum, many operations require equipment that goes beyond these general categories. These are often known as specialty or niche forklifts, and they’re engineered for very specific roles in logistics, construction, or warehousing.

Telescopic Handlers (Telehandlers)

Telehandlers are hybrid machines, part forklift, part crane. Equipped with a telescoping boom, they can reach upwards and forwards—something a standard forklift can’t do. These are ideal for lifting pallets onto high scaffolding, moving materials over obstacles, or accessing difficult-to-reach locations.

Key industries:

Construction
Agriculture
Military operations

Side Loaders and Reach Trucks

Side loaders are designed for handling long, awkward loads like pipes, timber, or steel rods. They lift from the side rather than the front, which allows operators to easily navigate narrow aisles without turning.

Reach trucks are a type of narrow-aisle forklift that features extendable forks to reach deep into racking systems. They’re incredibly popular in high-density warehouses where space is at a premium.

Order Pickers and Articulated Forklifts

Order pickers are designed for manual product picking at high shelves. Instead of lifting pallets, they lift the operator alongside the load, making it easier to grab individual items.

Articulated forklifts feature a jointed mast that can pivot, allowing them to access narrow aisles without sacrificing lifting height. They combine the agility of a Class II forklift with the reach of a much larger machine.

These specialized forklifts prove that one size doesn’t fit all. Depending on your needs, they could significantly improve both safety and efficiency in your workflow.

Forklift Power Sources and Fuel Types

Understanding how a forklift is powered can make a world of difference in terms of efficiency, operating cost, and suitability. Forklifts today come with a range of power options—each with its own pros and cons.

Electric Forklifts

Powered by rechargeable industrial batteries, electric forklifts are ideal for indoor use. They’re:

Quiet
Emission-free
Low-maintenance

However, they do require downtime for charging (typically 8 hours) and may not perform well in wet or uneven outdoor terrain.

Internal Combustion (IC) Forklifts

These forklifts can run on a variety of fuels:

Diesel: Ideal for outdoor use and heavy loads. High power but emits fumes.
LPG (Propane): Cleaner than diesel and can be used indoors with proper ventilation.
Gasoline: Similar to diesel but less common.
CNG (Compressed Natural Gas): Less common but eco-friendlier than traditional fuels.

How to Choose Based on Work Environment

Fuel Type	Best For	Pros	Cons
Electric	Indoors	Clean, quiet, low maintenance	Long charge time, higher upfront cost
Diesel	Outdoors	Powerful, long run-time	High emissions, noisy
LPG	Indoor/Outdoor	Flexible, quick refueling	Emissions still present
CNG	Outdoor	Cleaner than diesel	Limited availability

Choosing the right fuel type depends on your usage pattern, site conditions, and sustainability goals. Electric models may have higher upfront costs, but they often pay off with reduced maintenance and fuel expenses.

How to Choose the Right Type of Forklift

Picking the right forklift is about more than just horsepower and lifting capacity. It’s about making a strategic decision that supports your operational needs, safety goals, and budget constraints.

Factors to Consider

Load Requirements:
- Weight and dimensions of the materials you’ll move.
- Typical pallet sizes.
Environment:
- Indoor vs. outdoor use.
- Terrain type (smooth, gravel, inclined, wet).
Aisle Widths:
- Narrow aisles may require compact or articulated models.
Lift Height Needs:
- Standard vs. high-lift racking systems.
Run Time and Downtime:
- Consider electric models if shifts are short and intermittent.
- IC models are better for continuous use without breaks.

Cost Efficiency and Safety

Forklifts are long-term investments. Maintenance, fuel, operator training, and regulatory compliance all factor into your total cost of ownership. Safety should also be a top priority. Choosing a forklift with built-in stability systems, ergonomic controls, and safety sensors can save lives and protect assets.

Also, consider aftermarket support. Is the brand known for its service network? Are replacement parts easy to source? These are the real-world factors that will determine the forklift’s effectiveness over time.

Forklift Safety and Regulations

Safety isn’t just a best practice—it’s a legal requirement. Forklifts are powerful machines, and mishandling them can result in serious injury or death. That’s why regulatory bodies like OSHA (Occupational Safety and Health Administration) have established detailed safety guidelines.

OSHA Classifications and Standards

OSHA categorizes powered industrial trucks by their class and outlines required training and safety procedures. All forklift operators in the U.S. must:

Be at least 18 years old
Complete certified training
Be evaluated every three years

Key Safety Tips

Always wear a seatbelt
Don’t exceed load limits
Avoid uneven surfaces with inappropriate tires
Conduct pre-operation checks daily
Never allow unauthorized persons to operate machinery

Certifications and Training

OSHA mandates that all forklift operators must complete a formal training and evaluation process, which includes:

Classroom instruction
Practical training
Hands-on evaluation

Failure to comply can result in heavy fines and accidents. Investing in proper training is not only legally required—it’s smart business practice.

Top Brands and Manufacturers of Forklifts

When it comes to reliability and performance, the brand you choose matters. The top forklift manufacturers have decades of experience and proven records for safety, innovation, and service.

Leading Forklift Brands

Toyota – World leader in forklift manufacturing, known for reliability and advanced safety systems.
Crown Equipment – Exceptional in electric forklifts and ergonomic design.
Hyster-Yale – Offers a wide range of IC and electric forklifts with strong dealer support.
Komatsu – Durable machines with a strong presence in heavy industries.
Mitsubishi/UniCarriers – Known for affordability and mid-range reliability.
Clark – One of the oldest names in the industry, known for budget-friendly models.

What Sets Them Apart?

Toyota is often praised for its System of Active Stability (SAS), reducing the chance of tip-overs.
Crown invests heavily in design and ergonomics, improving operator comfort.
Hyster offers a wide global service network, making parts and service accessible worldwide.

Choosing a trusted brand means better performance, reduced downtime, and excellent resale value. Always consider dealer support, warranty, and parts availability when picking a brand.

How Many Types of Forklifts Are There