Material handling and lifting equipment are crucial in various industries, from construction to warehousing. Among the most used machines are telehandlers and forklifts. While these two may appear similar at first glance, their functionalities, applications, and operational requirements differ significantly.  

Understanding these differences is essential for safety, efficiency, and compliance with industry regulations. In this comprehensive guide, we will explore the key distinctions between them, ensuring every worker knows which machine is best suited for their tasks. 

What is a Telehandler? 

A telehandler, short for telescopic handler, is a versatile lifting machine equipped with a telescopic boom. This boom can extend both forward and upwards, allowing the telehandler to function similarly to a crane. Attachments such as buckets, pallet forks, muck grabs, or winches can be fitted to the boom, enhancing its adaptability across various tasks. Manufacturers like JCB, Merlo, and Manitou are renowned for producing reliable telehandlers.  

What is a Forklift? 

A forklift is a compact material-handling vehicle designed to lift and transport heavy loads over short distances. It features two forks at the front that slide under pallets and other materials to lift them. Forklifts come in several varieties, such as counterbalance, reach truck, and rough terrain models. They are commonly used in warehouses, factories, and distribution centres due to their manoeuvrability and efficiency in tight spaces. 

Key Differences Between a Telehandler and a Forklift 

1. Design and Reach Capabilities

Telehandlers are equipped with a telescopic boom that allows for both vertical and horizontal extension. This design enables them to reach over obstacles and place loads at significant heights and distances. For instance, certain telehandler models can extend their booms up to 56 feet outward and reach a 700 angle. This capability makes them ideal for tasks requiring extended reach, such as placing materials on rooftops or over obstacles.  

A forklift, on the other hand, is designed primarily for vertical lifting and has limited reach beyond its mast height. They lack the telescopic boom found in telehandlers, restricting their ability to handle tasks that require reaching over obstacles or accessing elevated positions without moving the base machine. 

2. Terrain Adaptability

Telehandlers are built for versatility in various terrains. Their robust design and four-wheel drive capabilities allow them to operate effectively on uneven, sloped, and rough terrains, making them indispensable on construction sites and agricultural fields. Their ability to navigate challenging landscapes provides a significant advantage over standard forklifts in outdoor settings. 

Forklifts are compact and highly manoeuvrable, making them ideal for indoor environments with narrow aisles and tight spaces. However, standard forklifts are not well-suited for uneven or rough terrains. While rough terrain forklifts exist, they are primarily designed for level surfaces like dirt or asphalt. 

3. Attachment Versatility

What truly sets telehandlers apart is their compatibility with a wide range of attachments. Beyond standard pallet forks, they can be equipped with buckets, grapples, truss booms, and more, allowing them to perform tasks such as lifting, scooping, and even light excavation. This versatility makes telehandlers akin to multi-functional tools on job sites. 

Forklifts, while primarily designed for lifting pallets, can also accommodate various attachments like rotators, booms, and clamps. However, their range of compatible attachments is generally more limited compared to telehandlers, focusing mainly on lifting and transporting materials within warehouses or storage facilities.​ 

4. Lifting Capacity and Height

Telehandlers typically have higher lifting capacities and reach greater heights than forklifts. Some telehandler models can lift 24,000 lbs, making them suitable for heavy-duty lifting tasks. Additionally, their telescopic booms allow them to place materials at significant heights. 

Forklifts, while available in different sizes, generally have lower lifting capacities. Most forklifts have a maximum lifting capacity of 10,000 lbs and are limited to lower heights compared to telehandlers. This makes them ideal for stacking pallets and transporting loads within controlled spaces. 

5. Operator Training and Certification Requirements

Operating both telehandlers and forklifts requires proper training and certification to ensure safety and compliance. In New Zealand, specific requirements are set for each:​ 

• Forklift Training and Certification 

Forklift operators must obtain a forklift licence NZ or an F endorsement for public road usage. This licensing system requires completing training programs such as forklift training Auckland and national forklift training that teach operators the necessary skills to handle these machines safely. Completing a recognised forklift certification course ensures compliance with safety regulations. 

• Telehandler Operator Training 

Telehandler operators are required to have specific telehandler operator training due to the machine's versatility and complexity. A current driver's license with the correct class for the telehandler's weight is necessary, along with a W endorsement for special-type vehicles that run on wheels. Additionally, operators should complete the telehandler licence NZQA Unit Standard 23637, which covers general telehandler operation. 

6. Maintenance and Operational Costs

Due to their complex structures and multiple attachments, telehandlers generally have higher maintenance costs than forklifts. Regular inspections and maintenance are necessary to keep them in optimal condition, especially when operating in rough terrains. 

Forklifts, particularly electric models, have lower maintenance costs. They contain fewer moving parts, which reduces the likelihood of mechanical issues. Forklifts used indoors also experience less wear and tear than telehandlers, making them more cost-effective in warehouse environments. 

Which Machine Should You Choose? 

The decision between a telehandler and a forklift depends on the specific needs of your work environment. Here is a quick comparison: 

If you require a machine for construction, farming, or rough outdoor conditions, a telehandler is the better choice. However, if your work involves lifting materials in a warehouse or a factory setting, a forklift is more suitable. 

Embrace the knowledge, invest in your training, and let the right machinery propel your career forward—one lift at a time. 

ACT Safety – Telehandler Operator Training by Industry Experts 

At ACT Safety, we specialise in telehandler operator training delivered by industry professionals. Our courses are designed to provide hands-on experience, ensuring operators gain the skills and confidence needed to handle telehandlers safely and efficiently. With nationally recognised telehandler certification, you can advance your career and meet industry compliance standards with ease. For those looking to expand their expertise, we also offer health and safety training NZ, helping you stay compliant and enhance workplace safety. 

Contact ACT Safety and get certified today!