The Pros and Cons of Different Types of Forklifts Explained

Forklifts are essential in warehouses, construction sites, manufacturing plants, and distribution centers across the United States. With so many different types of forklifts available, choosing the right one can feel overwhelming. Each forklift class and design has unique strengths and limitations, making it critical to understand which model fits your specific operations.

This guide breaks down forklift classifications, explains the pros and cons of each, and helps you decide which forklift is best for your work environment.

Overview of Forklift Classification

Forklifts, also known as fork trucks or powered industrial trucks, are grouped into categories defined by the Industrial Truck Association (ITA) and OSHA. These forklift classifications are based on power source, tire type, and intended use.

There are seven different classes of forklifts, ranging from compact electric motor hand trucks to heavy-duty rough terrain forklifts.

What Are Forklift Classes?

Forklift classes (1–7) standardize the types of forklifts used across industries:

• Class 1: Electric Motor Rider Trucks

• Class 2: Electric Motor Narrow Aisle Trucks

• Class 3: Electric Motor Hand Trucks

• Class 4: Internal Combustion Engine with Cushion Tires

• Class 5: Internal Combustion Engine with Pneumatic Tires

• Class 6: Electric and Internal Combustion Tractors

• Class 7: Rough Terrain Trucks

Let’s take a closer look at the most common forklift classes, their advantages, and their drawbacks.

Types of Forklifts and Their Categories

Class 1 Forklift: Electric Motor Rider Trucks

Pros:

• Zero emissions, safe for indoor use

• Quiet operation

• Lower long-term operating costs

• Excellent maneuverability in tight spaces

Cons:

• Higher upfront cost

• Requires charging and battery maintenance

• Limited outdoor performance

Class 2 Forklift: Electric Motor Narrow Aisle Trucks

Pros:

• Ideal for narrow warehouse aisles

• Energy efficient

• Increases storage capacity

Cons:

• Not designed for heavy-duty outdoor use

• Specialized parts may require higher maintenance

• Lower load capacity than larger forklifts

Class 3 Forklift: Electric Motor Hand Trucks

Pros:

• Compact and easy to maneuver

• Cost-effective for short distances

• Useful in loading docks and retail spaces

Cons:

• Limited lift height and weight capacity

• Not suitable for outdoor or heavy-duty jobs

Class 4 Forklift: Internal Combustion Engine with Cushion Tires

Pros:

• High lifting capacity

• Excellent for smooth indoor surfaces

• Quick refueling with LPG, diesel, or gas

Cons:

• Produces emissions, unsuitable for air-sensitive environments

• Cannot handle uneven outdoor terrain

• Higher fuel costs than electric forklifts

Class 5 Forklift: Internal Combustion Engine with Pneumatic Tires

Pros:

• Designed for rough, uneven surfaces

• Handles heavy loads easily

• Available in wide capacity ranges

Cons:

• Higher operating costs

• Produces emissions

• Requires more maneuvering space

Class 7 Forklift: Rough Terrain Trucks

Pros:

• Built for construction and agricultural sites

• Exceptional performance on dirt, gravel, and uneven ground

• High lifting capacities

Cons:

• Expensive to purchase and maintain

• Not designed for indoor use

• Large footprint requires more storage space

3 Types of Extended Lift Forklifts

Some operations require forklifts with specialized reach. Common examples include:

• Telescopic Forklifts (Telehandlers): Extendable boom for extreme reach.

  • Pros: Great height capabilities.

  • Cons: Requires skilled operators, higher cost.

• Order Pickers: Lift operators with the load for warehouse picking.

  • Pros: Increases warehouse efficiency.

  • Cons: Limited load capacity.

• Reach Trucks: Forks extend beyond stabilizers for tall racking.

  • Pros: Perfect for indoor warehouses.

  • Cons: Indoor use only.

Conclusion: How to Choose the Right Forklift

When evaluating different types of forklifts, focus on your environment, workload, and long-term budget:

• For indoor warehouses, Classes 1–3 electric forklifts are quiet, efficient, and emission-free.

• For outdoor heavy-duty work, Classes 5 and 7 provide strength and durability.

• For specialized reach needs, telehandlers, order pickers, and reach trucks are ideal.

By weighing the pros and cons of each forklift type, you’ll be able to choose a machine that balances performance, cost, and safety—ensuring smooth operations across your facility.

👉 Want to explore forklift safety and efficiency further? Listen to Forklift Attachments and Safety Essentials: A Deep Dive Conversation and learn how attachments can enhance productivity while keeping operations safe.