Switching from LPG or diesel to lithium: a practical fleet guide

1. Match the truck to the work.

Before comparing models, document the conditions your existing trucks face every day:

• Loads: typical and maximum weight, load dimensions, lift height and attachments.
• Workload: operating hours, number of shifts and peak demand.
• Routes: aisle widths, ramps, loading docks, travel distances and indoor or outdoor use.
• Environment: temperature, moisture, dust and floor or yard conditions.
• Breaks: realistic opportunities to charge without interrupting work.

Check rated capacity at your required lift height and load center, including attachment effects. Matching the headline lifting capacity alone is not enough.

For outdoor or cold-storage work, confirm the proposed truck’s environmental limits, tires, battery thermal management and charging temperature limits. Suitability depends on the complete configuration.

2. Compare the full ownership cost.

Use the same ownership period, operating hours and workload for both options. Request itemized quotes and use your own operating records wherever possible.

Lithium-electric trucks eliminate combustion-engine service items such as engine oil changes and generally need less powertrain maintenance. Actual savings depend on utilization, local energy prices, equipment condition and maintenance practices.

Tires, brakes, forks, lift chains, hydraulics and other components still need inspection and service. Budget for the whole truck throughout its working life.

3. Build a charging plan before ordering.

Select the truck, battery and charger as a compatible system. An approved lithium battery and charger combination may support opportunity charging during breaks, but those windows must cover the energy your duty cycle uses.

Ask a qualified electrician to confirm the charger’s voltage, phase, circuit capacity and installation requirements. Review simultaneous charging, utility demand charges and the capacity needed for future fleet growth.

Place charging equipment where operators can reach it without blocking aisles or emergency access. Assign responsibility for connecting trucks, checking charge levels and reporting charger faults so that charging becomes a reliable daily routine.

Confirm charging time using the proposed battery, charger output, actual workload and available breaks. A generic “fast charging” claim does not establish whether a truck can complete your shift.

4. Prepare operators for the change.

Electric forklifts produce no tailpipe exhaust and generally run more quietly than IC trucks. These characteristics can benefit indoor operations where engine exhaust and noise are concerns.

During evaluation, review visibility, seating, entry and exit, control layout and response during travel and lifting. Judge productivity by safe, consistent handling under normal working conditions.

Operator preparation should cover the specific truck’s controls, pre-use inspections, charging procedures and workplace hazards. Employers remain responsible for appropriate operator training and evaluation when equipment or working conditions change.

5. Start with a measured pilot.

Begin with one clearly defined application and establish an IC baseline before expanding the change. Track:

• Work completed per shift and productive operating hours.
• Battery charge remaining, charging windows used and any missed charging opportunities.
• Energy consumption, service work and interruptions.
• Operator feedback and fit with the daily workflow.

Compare results under similar loads, routes and shift conditions. Use the findings to adjust battery capacity, charging schedules or truck configuration.

A mixed fleet may be the right answer. LPG or diesel equipment can remain appropriate where charging access is limited or the available electric configuration does not support a particular duty cycle.