Forklifts can be classified in several ways: by their OSHA/ITA class (which defines their power source and primary application), by their power source (electric vs. internal combustion), or by their specific type and design for specialized tasks.
The OSHA/ITA Classification System
The most standardized way to categorize forklifts is through the seven classes established by the Occupational Safety and Health Administration (OSHA) and the Industrial Truck Association (ITA). This system groups trucks by their power source, tires, and primary operating environment.
Class Name Power Source Key Features & Common Types Primary Use
I Electric Motor Rider Trucks Electric Battery Sit-down or stand-up riders; often counterbalanced. Examples: Electric counterbalance, 3-wheel electric forklifts. Indoor warehouses, distribution centers, manufacturing with smooth floors
II Electric Motor Narrow Aisle Trucks Electric Battery Designed for tight spaces and high-reach. Examples: Reach trucks, order pickers, turret trucks. High-density warehouses with narrow aisles and tall racking
III Electric Motor Hand or Hand/Rider Trucks Electric Battery Walk-behind or stand-on operation. Examples: Electric pallet jacks, walkie stackers. Loading docks, retail stockrooms, short-distance moves
IV Internal Combustion Engine Trucks (Cushion Tires) IC Engine (LPG, Gasoline, Diesel) Solid, smooth "cushion" tires for indoor surfaces. Indoor use on smooth, paved surfaces like warehouses
V Internal Combustion Engine Trucks (Pneumatic Tires) IC Engine (Diesel, LPG, Gasoline) Air-filled, treaded tires for traction indoors and outdoors. Versatile for lumberyards, construction sites, and mixed indoor/outdoor use
VI Electric and Internal Combustion Engine Tractors Electric or IC Engine Designed for towing, not lifting. Airports, assembly lines, large warehouses for towing trailers
VII Rough Terrain Forklift Trucks IC Engine (Usually Diesel) Large pneumatic tires, 4WD, high ground clearance. Construction sites, lumber yards, agricultural fields
By Power Source
Electric Forklifts (Classes I, II, III)
Powered by industrial batteries (lead-acid or lithium-ion). They produce zero emissions, operate quietly, and have lower operating costs than internal combustion models. Best for indoor use where air quality and noise are concerns. Lithium-ion models offer fast charging and opportunity charging during breaks.
Internal Combustion (IC) Forklifts (Classes IV, V, VII)
Powered by diesel, LPG (propane), or gasoline. They offer higher power and torque for heavy loads and can operate continuously without battery charging downtime. Best for outdoor use and heavy-duty applications. Diesel provides maximum torque; LPG is cleaner than diesel; gasoline is less common.
By Specific Type and Application
Type Description Key Applications
Counterbalance Forklift The most common type; uses a rear counterweight to balance the load. Available in electric, LPG, and diesel. General warehousing, loading docks, manufacturing
Reach Truck Designed for narrow aisles with extended reach forks. Electric Class II truck. High-bay racking in narrow aisles (warehouses)
Order Picker Allows the operator to pick individual items from racking. Electric Class II truck. Order fulfillment in distribution centers
Pallet Jack (Walkie) Manual or electric; used for moving pallets across short distances. Electric versions are Class III. Loading docks, retail stockrooms, short-distance transport
Rough Terrain Forklift Designed for outdoor, uneven surfaces. Large pneumatic tires, 4WD. Typically diesel. Construction sites, lumber yards, farms
Telehandler (Telescopic Handler) Combines forklift and crane functionality with a telescopic boom. Available in diesel. Construction, agriculture, placing loads at height
Sideloader Carries long loads (timber, steel) along the side of the truck. Available in electric and diesel. Steel service centers, timber yards, long-load transport
Very Narrow Aisle (VNA) Truck Specialized electric trucks (turret trucks, swing-mast) for ultra-narrow aisles (as narrow as 56 inches). High-density warehousing
Multi-Directional Forklift Moves in any direction (forward, sideways, diagonally). Combilift is a leading example. Long loads in narrow aisles (timber, steel, pipes)
Walkie Stacker A compact electric stacker for low-height stacking. Operator walks behind. Small warehouses, retail backrooms, light-duty stacking
Truck-Mounted Forklift Forklift mounted on a truck for delivery operations. Picks up from the truck bed. Delivery operations, job-site unloading
Summary
Forklift trucks are classified by OSHA/ITA into seven classes based on power source, tires, and application. Class I–III are electric, suitable for indoor use; Class IV–V are internal combustion, for indoor/outdoor mixed use; Class VI are tractors; Class VII are rough terrain. Specific types include counterbalance (most common), reach trucks (narrow aisles), order pickers (order fulfillment), rough terrain (construction), telehandlers (extended reach), sideloaders (long loads), VNA trucks (ultra-narrow aisles), multi-directional (Combilift), walkie stackers (light stacking), and truck-mounted forklifts (delivery). When selecting a forklift, consider your operating environment, load capacity, lift height, aisle width, and duty cycle to match the right type to your application.