When selecting the correct materials handling equipment (MHE), understanding forklift classifications is essential. Forklift trucks are separated into 5 main classifications based on their power source, design and intended application.
In this blog, we’ll go through the different forklift classes as well as examples of where these fit into real world situations.
What is a Class 1 Forklift?
Class 1 – Electric Counterbalance Trucks
Class 1 forklifts are versatile electric counterbalance forklift trucks powered by lead-acid or lithium-ion batteries. They can be three or four wheeled and equipped with cushion or pneumatic tyres. This makes them ideal for a multitude of applications including warehouse and distribution environments.
Typical areas include:
Warehouses – moving pallets in storage aisles and loading areas
Distribution centres – loading and unloading goods
Food & beverage facilities – where it is important to have low emissions
Logistics hubs – moving freight between storage locations and loading bays
Retail stockrooms – handling palletised stock deliveries
Example truck:
These trucks are often found in areas where emissions and noise pollution need to be lower and conditions are more favourable. For outdoor applications utilising pneumatic tyres would improve their capabilities.
What is a Class 2 Forklift?
Class 2 – Rider Warehouse Trucks
Class 2 forklift trucks also utilise lead-acid or lithium-ion batteries. The key difference with class 2 forklifts is they are specifically designed for warehouse operations. Equipment includes order pickers, reach trucks and very narrow aisle (VNA) variations.
Typical areas include:
Warehouses – order picking from warehouse racking
Distribution centres – VNA where counterbalance forklifts cannot operate
Retail distribution hubs – putting pallets away into high level racking
Cold storage facilities – handling loads in cold stores where space is limited
E-commerce fulfilment centres – with dense storage layouts
Example truck:
Class 2 forklift trucks are designed for smaller areas where class 1 forklifts would not have room to manoeuvre. These are designed for indoor use in VNA and to help maximise warehouse storage capacity.
What is a Class 3 Forklift?
Class 3 – Electric Pallet Trucks & Stackers (Pedestrian Warehouse)
Class 3 forklift trucks are easy to identify as they are walk behind or stand-on MHE. Again, powered by lead-acid or lithium-ion batteries, they are focused on short-distance warehouse operations.
Typical Areas Include:
Warehouses – moving pallets around warehouse
Retail facilities – replenishing stock
E-commerce – order picking activities
Distribution centres – stacking pallets at lower heights
Supermarkets – transporting stock from goods-in to storage areas
Example truck:
Moving palletised loads over a short distance is where Class 3 forklifts are the best option. As electric trucks they are ideal for warehouses, stockrooms and supermarket environments.
What is a Class 4 Forklift?
Class 4 – Engine Counterbalance – Cushion Tyres Only
Class 4 forklifts are engine-powered counterbalance trucks powered by LPG or diesel with compact cushioned tyres. These trucks are designed for indoor use on smooth, solid surfaces.
Typical Areas Include:
Manufacturing plants – transportation of heavy materials
Freight areas – working on loading bays and indoor freight areas
Distribution – loading and unloading lorries
Warehouses – transporting palletised goods around warehouses
Automotive manufacturing – transportation of components and finished goods
Example truck:
As fuel powered (LPG or Diesel) counterbalance forklift trucks, Class 4 forklifts are suited to indoor industrial environments where the loads are heavier, but the floor is smooth.
What is a Class 5 Forklift?
Class 5 – Engine Counterbalance – Pneumatic Tyres Only
Class 5 forklift trucks are slightly different to class 4 as these have pneumatic tyres. They are still engine counterbalance trucks powered by LPG or diesel but are more versatile as they are suited to both indoor and outdoor environments.
Typical areas include:
Builders’ merchants – where the ground is often rough and the loads are heavier
Ports and docks – loading and unloading ships and containers
Recycling facilities – moving and stacking large bales
Outdoor storage compounds – moving goods around a facility
Manufacturing plants – handling raw materials and finished products
Example trucks:
Class 5 forklift trucks are fuel-powered counterbalance trucks with pneumatic tyres. These are designed for both indoor and outdoor use where the ground may be uneven or rough.
Forklift Classification Comparison Table
| Class | Type | Power Source | Typical Uses | Advantages | Disadvantages |
| Class 1 | Electric Counterbalance Forklift | Battery Electric | Loading/unloading vehicles, pallet handling, stacking racking | Zero emissions, versatile
| Limited on rough terrain
|
| Class 2 | Narrow Aisle Trucks | Battery Electric | High-level racking, order picking, stock replenishment | Maximises storage space | Mainly indoor use only
|
| Class 3 | Electric Pallet Trucks & Stackers | Battery Electric | Moving pallets over short distances, low-level stacking | Compact and easy to use | Limited lift height and capacity |
| Class 4 | Counterbalance Forklift with Cushion Tyres | Diesel or LPG | Loading, unloading, manufacturing operations | Powerful and manoeuvrable indoors | Cushion tyres unsuitable for rough ground |
| Class 5 | Counterbalance Forklift with Pneumatic Tyres | Diesel or LPG | Yards, depots, builders’ merchants, warehouses | Handles rough and uneven surfaces | Produces emissions and requires ventilation indoors |
Classifications of forklift trucks can help maximise productivity, safety and efficiency. Each classification is suited to different environments, namely Class 1, 2 and 3 are suited to warehouse environments whereas class 4 and 5 are designed to be involved in more robust industrial applications. By understanding the different types of forklift trucks, you can select the correct materials handling equipment for your application.
Frequently Asked Questions
What are the different forklift classes?
Forklift trucks can be separated into 5 different class types. Class 1 electric counterbalance trucks, Class 2 warehouse trucks, Class 3 electric pallet trucks and stackers, Class 4 engine-powered counterbalance forklifts with cushioned tyres and Class 5 engine-powered counterbalance forklifts with pneumatic tyres.
Which forklift class is best for warehouse use?
The best forklift truck for warehouse use is dependent on a multitude of factors including warehouse function. The most common forklift classifications used within a warehouse are Class 1, Class 2 and Class 3 forklifts.
What is the difference between Class 4 and Class 5 Forklifts?
The key difference between Class 4 and Class 5 is tyre type. Both are engine-powered forklift trucks however Class 4 has cushioned tyres suited to indoor smooth applications and Class 5 has Pneumatic tyres suited to the outdoors or uneven surface applications.
Which forklift class is best for narrow aisles?
Reach Trucks and very narrow aisle (VNA) trucks are specifically designed for narrow warehouse aisles. These come under class 2 forklifts and allow businesses to maximise storage density.
Can electric forklifts be used outdoors?
Yes, electric forklifts can be fitted with pneumatic tyres, this makes them suitable for use outdoors. They do need to be charged however so these facilities must be available. They perform well on maintained surfaces so when used outdoors it is essential that the aera is well maintained.
How do I choose the right forklift for my business?
Choosing the right forklift type comes down to a few key factors:
- Load weight
- Lift height
- Aisle width
- Operating environment
- Duty cycle
Analysing your environment and requirements will help determine which forklift is suitable for your application. Contact us for assistance.