Curious about the different forklift fuel types powering today's lift trucks?
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Then you're in the right place.
Because in this post, you'll learn everything you need to know, including:
Let's dive in!
What Fuels Do Forklifts Run On?Let's answer the question right away'
Forklift fuels include:
Of these, electric and LPG are the most popular.
Forklift Fuel Types: Everything You Need to KnowElectric forklifts are available in a variety of models and styles, including:
What each has in common is each is powered by electricity through a battery. That battery, however, can be one of two types: lead-acid or lithium-ion. Each of these technologies is different and offers different advantages and disadvantages. Let's go through each type in more detail.
Lead-acid is the most common type of battery chemistry in use today. These batteries rely on a chemical reaction between lead plates and sulfuric acid to produce electricity.
The typical lift capacity of lead-acid electric forklifts is 1,500 to 12,000 lbs. But there are larger models with 20,000 lbs. capacity.
Generally, electric forklifts with lead-acid batteries are more expensive than gas or diesel-powered forklifts.
Depending on the manufacturer, model, lifting capacity, and features, a new electric forklift can cost anywhere from $20,000 to $600,000 or more for the most specialized models.
Buying or leasing used electric forklifts can be purchased for less, with prices ranging from $5,000 to $100,000, depending on the age and condition of the equipment.
Many people are used to lithium-ion batteries, since many smartphones are powered by them. Now, they've made their way to powering forklifts. Much like their smaller counterparts, Li-ion forklift batteries offer longer run times and shorter charging cycles, while also lasting longer than lead-acid batteries.
Lithium-ion batteries are available in practically any size that lead-acid batteries are. If a battery size isn't immediately available, the manufacturer can often build one to your specification.
Forklifts powered by lithium-ion batteries have the same advantages as their lead-acid counterparts. But also Li-ion offers benefits that lead-acid batteries do not, like:
Lithium-ion forklift batteries can cost twice as much as their lead-acid equivalents. Fortunately, most forklift chassis don't require any modification to accept a lithium-ion battery.
All internal combustion (IC) forklifts use an engine and combustible fuel for power. That said, they can be powered by a variety of fuel types. Let's discuss each in more detail.
LPG has long been the chosen forklift fuel because of its wide availability, inexpensiveness, and ability to be used indoors
Liquefied petroleum gas (LPG) forklifts, also known as propane forklifts, are a popular type of material handling equipment powered by propane gas.
LPG forklifts are available with both cushion and pneumatic tires and can be great for indoor and outdoor operations.
Propane forklifts offer the advantage of being able to be used in a greater variety of environments and operations than electrics do.
LPG forklifts are designed to lift and move heavy loads over short to medium distances.
Their lifting capacity range is typically from 3,000 lbs. to 15,000 lbs. Some LPG forklifts extend to 20,000 lbs.
LPG forklifts are used in a wide range of applications, including:
Liquid petroleum gas (LPG) is ideal for locations that do not have gasoline, diesel, or CNG refilling stations readily available.
Generally, LPG forklifts are less expensive than their equivalent electric and diesel-powered models.
For example, a new LPG forklift can cost anywhere from $15,000 to $50,000 or more. On the other hand, used LPG forklifts can be purchased for less. Their prices can range from $5,000 to $20,000, depending on the age and condition.
Gasoline-powered forklifts are rare due to the popularity of electric and LPG forklifts and the more cumbersome refueling requirements.
This is why they're preferred by operators with refueling stations readily available, conveniently placed, and able to accommodate the size of their fleet.
Gasoline forklifts have lifting capacities ranging from 3,000 to 15,500 lbs.
Overall, gasoline forklifts shouldn't be used indoors, making them better for outdoor applications like
The price of gasoline forklifts varies based on the model, lifting capacity, and features.
Lighter gasoline forklifts can cost anywhere from $10,000 to $20,000, while heavy-duty models can cost upwards of $50,000.
In addition to the initial purchase price, companies will also need to factor in ongoing fuel and maintenance costs when considering the total cost of ownership for a gasoline forklift.
Dual-fuel forklifts are those equipped with both LPG (propane) and gasoline fuel systems. They can be run on either of the fuel types but not at the same time.
Dual-fuel forklifts are available in various styles and lifting capacities to meet different industries' needs, with indoor and outdoor models. This makes them versatile enough to handle various applications.
Most dual-fuel forklifts are designed to lift loads ranging from 3,000 to 15,000 lbs. But larger models are available for heavier lifting applications.
Dual-fuel forklifts are especially useful in applications that require flexibility in fuel choices and where emission reductions are a concern.
Dual-fuel forklifts typically cost more than traditional gasoline-only forklifts. Prices can range from $20,000 to $60,000 depending on the model, capacity, and features.
Given the fuel savings and extended lifespan, these savings may offset the higher initial cost in the long run.
Generally, diesel lift trucks are only available with pneumatic-type tires and are designed for outdoor use. This is mainly because they are louder machines and produce more emissions than LP or gas-powered forklifts.
The sturdy designs of diesel forklifts allow for power and versatility in many industries, from construction and agriculture to recycling and transportation.
Diesel forklifts are available in a wide range of models and styles, with lifting capacities that range from around 3,000 lbs. up to over 40,000 lbs.
There are also heavier-capacity diesel forklifts capable of lifting over 125,000 lbs., like this Toyota High-Capacity IC Pneumatic Diesel Forklift.
Diesel forklifts are known for their high torque, which allows them to handle heavy loads and operate on rough terrain.
On average, new diesel forklifts can cost between $20,000 and $50,000, depending on weight capacity. Some models can cost more due to advanced features such as GPS tracking, specialized attachments, or ergonomic cabs.
Natural gas forklifts run on compressed natural gas (CNG), which is made of compressed and filtered methane.
These models are becoming increasingly popular as companies seek to reduce their carbon footprint and lower their operating costs. They produce much less carbon monoxide than gasoline or diesel forklifts, which can help companies meet OSHA requirements for indoor air quality.
There are various models and styles of CNG forklifts available on the market, including both counterbalance and narrow aisle models.
The lifting capacity of CNG forklifts ranges from 3,000 to 55,000 lbs.
CNG forklifts are particularly useful in indoor environments, as they produce fewer emissions and are quieter than traditional forklifts.
Expect CNG forklifts to be more expensive than traditional LPG or electric forklifts. Also, be aware of the additional cost of installing a dedicated fueling station.
Hydrogen forklifts are powered by hydrogen fuel cells instead of traditional lead-acid batteries or internal combustion engines.
A forklift hydrogen fuel cell is a cell producing an electric current as a direct result of a chemical reaction. The chemical reaction produces electricity used to power a load which, in this case, is a forklift.
These forklifts have gained popularity in recent years due to their efficiency, lower environmental impact, and lower operating costs.
Hydrogen forklifts are available in a variety of models and styles, ranging from compact models with lifting capacities of 2,000 lbs. to larger models with lifting capacities of up to 33,000 lbs.
They come in stand-up, sit-down, and walkie styles, and some models are designed specifically for narrow aisles and tight spaces.
Hydrogen forklifts are more expensive than electric and other IC forklifts with different fuel types. On average, hydrogen forklift costs can range from $50,000 to $100,000.
What Is the Best Fuel for Forklifts? 6 Questions to Help You DecideDetermining the best fuel for your forklift depends on your application, fuel availability, budget, and more. Let's go through each factor in a bit more detail so you can make an informed decision.
Here's a simple comparison of all the forklift fuel types: electric vs. LPG vs. gasoline vs. diesel vs. CNG vs. hydrogen forklifts:
Criteria Electric LPG Gasoline Diesel CNG Hydrogen Environments Indoor & outdoor Indoor & outdoor Indoor & outdoor Outdoor only Indoor & outdoor Indoor (preferably) Lifting capacities Small to medium Small to medium Small to medium Heavy Small to medium Small to medium Emissions None Low Low High Low None Noise Low Medium-high Medium-high Medium-high Low Low Refueling speed Fast-slow (1-8 hours) Fast Medium Medium Medium Fast Fuel availability Wide Medium-wide Wide Wide Low Low Maintenance Minimal Regular Regular Regular Minimal Minimal Market availability Wide Wide Uncommon Less common Uncommon Rare Cost Higher upfront, lower overall Lower upfront, higher overall Lower upfront, higher overall Higher upfront, higher overall Higher upfront, lower overall Higher upfront, lower overallNeed more help deciding which forklift fuel type is right for you? Contact us today. We'll be glad to lend a hand.
Contact us to discuss your requirements of 5 ton forklift diesel consumption per hour. Our experienced sales team can help you identify the options that best suit your needs.
Common Forklift Fuel QuestionsForklifts use different fuel types including electricity, propane (LPG), diesel, gasoline, compressed natural gas (CNG), and hydrogen.
Forklifts can be gas or propane (LPG) or they can be dual-fuel (if in the same truck). Dual-fuel forklifts are less common. Forklifts can also be electric, gasoline, or hydrogen. Electric and LPG forklifts are the most common.
Forklifts use 'liquified petroleum gas' (LPG), commonly known as propane.
Most forklifts run on liquid LPG, which is commonly called propane. Air-cooled forklifts (those without a radiator) use vapor LPG, which comes in the familiar 'BBQ'-style tank.
Some of the top reasons why many forklifts use propane instead of gas are because propane:
Propane allows forklifts to run on 100% power throughout operation, boosting productivity, especially during forklift outdoor operations where higher speeds are allowed. Also, propane engines can last up to 2X as long as their gasoline counterparts, saving you money on maintenance. See our electric vs. propane forklifts article for more benefits of propane as a forklift fuel source.
On average, a 33 lbs. propane tank (the size used in the majority of forklifts) can last up to eight hours. Though, 4 to 6 hours is more common. The actual duration depends on the age of the forklift, how it's used, the size of the loads handled, the kind of shape the truck is in mechanically, the terrain operated on, and other factors.
The average forklift fuel consumption should be about 0.7 gallons (approx. 6 lbs.) of LPG propane per hour. About 90% of propane-fueled forklifts utilize an 8-gallon (or 33 lbs.) propane tank that can last up to eight hours. Some larger forklifts run on a 10-gallon (43 lbs.) propane tank to fuel their larger engines.
The newest propane forklift models can produce as low as 5% carbon monoxide (CO) exhaust gas concentration when tested at the tailpipe. If the forklift is an older model or poorly maintained, the tailpipe output percentage could be higher. Overall, LPG forklifts produce low oxides of nitrogen (NOX), carbon monoxide (CO), and total hydrocarbon (THC) emissions, while emitting less carbon dioxide (CO2) and particulates.
The most common cause is that the forklift is too cold. The solution is that you bring the tank (and ideally the lift truck, if you can move it at all) inside to warm up, then try again.
Another common issue for forklifts that will turn over but won't start is the spark plugs. If you have a spark tester, you can check the strength of the spark. If the spark is weak and yellow, the plug may need replacing. A good spark is a solid blue spark.
See our Common Forklift Repairs post for causes/solutions of common no-start scenarios. You can also see the Propane Forklift Engine Troubleshooting Guide for possible solutions.
Forklifts can be either gas or diesel but they can't be both. Each engine/fuel type works too differently not to be separate. Forklifts can also be LPG, hydrogen, electric, or compressed natural gas.
Some forklifts are powered by diesel fuel. Diesel forests are usually heavy-duty and have a higher lifting capacity. For Toyota forklifts, any model containing the letter 'D' designates a 'diesel' fuel type. For example, a Toyota model 8FDU25 is a 5,000 lb. capacity diesel forklift with pneumatic tires. Read more about Toyota forklift models.
There are different reasons why your forklift won't start:
Glow plugs are 'warmers' located inside the combustion chamber in diesel engines designed to heat the space and make it easier for fuel to combust. They're required because diesel forklifts don't start well with cold combustion chambers. Be aware: the solution to this can vary by model. For example, on a Toyota diesel, turn the ignition to the 'On' position ' look for the glow plug indicator to cycle ' then try to start.
If the glow plugs don't solve the problem, check the battery. Make sure it's charged and properly connected. If not, try jumping or recharging it. If the battery can't charge, it might need replacing. You should also check that the battery is not too cold. Just like a car, a forklift battery can struggle to get going in minus temperatures. Move the battery in to warm up.
If these actions don't work, contact your local authorized service center.
The top American LPG suppliers include AmeriGas, FerrellGas, Energy Distribution Partners, and 21st Century Energy Group. You can find other forklift gas suppliers here.
In case of a fuel spill, apply sand, straw, sawdust, ground corn cobs, or commercial absorbents such as kitty litter or oil dry. Rather than wash them away with water, this helps to absorb petroleum residues. Absorbent materials used to clean up fuel spills may be disposed of at a sanitary landfill with prior approval of the landfill operator.
ConclusionThat's it: Everything you need to know about forklift fuels.
,'How much fuel does a forklift consume per hour?' is a frequently asked question when customers rent or buy a diesel-powered forklift.
The fuel consumption rate is calculated by the amount of diesel used (unit: litre) continuously by the forklift in 1 hour, denoted by l/h.
Nowadays, the diesel-powered forklift is a popular choice in construction, industry and agriculture.
In Vietnam, the diesel powered forklift is proven to be well-suited with climate conditions and current companies' demands.
Typically, the lifting/lowering and handling of material are mostly performed outdoors and on complicated terrains. The diesel powered forklift will be an optimal solution as it offers excellent features, including:
Powerful engine
Long working hours without having to compromise productivity
Maneuverable wheel tire system
Easy repair and maintenance
Flexible and high efficiency
When using a diesel-powered forklift; Operating cost is the first thing that comes to customer's concern. This operating cost includes:
Maintenance cost
Fuel fee
Labour cost
In which, fuel fee is the most concerning expense as it is a frequently incurred amount.
However, there is no exact answer for the fuel consumption rate of diesel-powered forklift as it varies depending on many factors namely:
Max. lifting capacity
Engine type
Actual working conditions
Machine working hours
Operator's skill
This fuel consumption rate is sometimes shown in product's specifications of some manufacturers. However, it is just a relative number which is based on standard conditions.
Let's us take an example:
The forklift is mounted with a 35,4 kW engine; Performing lifting of kg package in a 40m route.
A is the loading location, B is the unloading location
At A, the forklift works at the lifting height of 3m
The travelling speed from A to B is 15 km/h
Unloading at B and return to A with no-load
A basic lifting cycle like this will consume about 2,4 litres of diesel per hour for a professional operator.
Fuel consumption rates per hour for reference:
1ton diesel forklift: 4L ~ 3.3L
1,5ton diesel forklift: 2.5L ~ 3.6L
2ton diesel forklift: 2.6L ~ 3.6L
2,5ton diesel forklift 2.7L ~ 3.8L
3ton diesel forklift: 2.9L ~ 3.9L
Remarks: The fuel consumption rate of diesel-powered forklift may vary from 10-30% compared with the calculation depending on actual working conditions.
To save cost when using a diesel forklifts, here are some tips:
How long a piece of property lasts depends on how one cares for it. Therefore, the operator plays an important role in the life of a forklift. A professional operator masters usage; maintenance and operation of the equipment . This will help the business save the cost.
Operating forklift in its correct function will help you save the cost and extend the equipment life.
Working overload also chews up fuel consumption and leads to quick deterioration.
It is necessary to carry out maintenance on time as advised by the manufacturer. You should prepare periodic maintenance plans to ensure the machine remains in its best conditions.
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