For a long time, the honest answer to "can electric replace my propane or diesel forklifts?" was "not really." Lead acid batteries were the reason. They lost power as they drained, needed regular watering and a dedicated charging room, and often meant swapping batteries in the middle of a shift. For most heavy-duty work, propane won by default.
Integrated lithium-ion changed that. Electric sit-down counterbalance forklifts now handle the same work as propane and diesel trucks in a wide range of facilities. If you're weighing the switch, here are three things to look at.
1. What it costs to run your fleet
Purchase price gets most of the attention. Operating cost is where the decision usually gets made.
Fuel. Electric forklifts use energy more efficiently than internal combustion (IC) trucks, and electricity prices tend to be steadier than propane or diesel. Results depend on your region and duty cycle, but operations can see up to 80% savings on fuel costs after switching.
Maintenance. An electric forklift has no engine, no oil changes, no spark plugs, no fuel system and no exhaust. Fewer moving parts means less to service, and preventive maintenance intervals are typically longer than on IC trucks.
Truck life. With fewer wear parts, electric forklifts generally stay in service longer than IC trucks. That spreads the cost of each truck over more years of work.
Purchase price. The upfront gap has largely closed. Big Joe's integrated lithium-ion Class 1 forklifts are priced in line with comparable LPG trucks, so you aren't trading a higher sticker price for lower operating costs.
Want to see what this looks like for your fleet? Run your numbers with the Big Joe ROI calculator.
2. Where regulation is heading
California has set the direction. In June 2024, the California Air Resources Board (CARB) adopted the Zero-Emission Forklift Regulation, which phases propane, gasoline and natural gas forklifts out of California fleets over time. The rule took effect January 1, 2026.
Right now, CARB is enforcing the rule for state and local government fleets, and enforcement for private fleets is on hold. The regulation is still on the books, though, and other states tend to watch what California does on emissions.
If you buy forklifts to run for ten years or more, it's worth asking whether a propane truck bought today will still fit the rules in your state at the end of that run. Learn more about the CARB regulation.
Regulation isn't the only pressure. Many companies have emissions targets of their own, and a forklift fleet is one of the more measurable places to make progress. Replacing propane trucks removes indoor exhaust and the cylinder storage that comes with it.
3. What changes on the floor
This is where lithium-ion made the biggest difference. It removes the problems that kept operations away from electric in the first place.
- Consistent power all shift. Lead acid trucks get sluggish as the battery drains. Lithium-ion holds its performance from a full charge to a low one, so the truck lifts and travels the same at hour seven as it did at hour one.
- No battery swaps. One battery per truck, charged in place. No battery changing room, no change-out equipment, and no heavy batteries moving through the building.
- No watering or acid handling. Lithium-ion batteries are sealed. There's nothing to water and no acid for your team to handle.
- No fumes indoors. No propane exhaust for operators to breathe all shift, and no charging fumes that call for ventilation systems.
- Floor space back. The space you used for battery rooms or propane cylinder storage goes back to work.
Where Big Joe fits
Big Joe offers one of the largest integrated lithium-ion Class 1 portfolio in the market. We design our own batteries and build every Class 1 truck around them, so the truck, battery, charger and Big Joe Pulse telematics work as one system from one company. There's no matching batteries from different suppliers and no finger-pointing when something needs service.
- Capacities from 3,500 to 15,000 lb. in three-wheel, four-wheel cushion tire and four-wheel pneumatic tire models
- UL 2580-certified integrated lithium-ion battery standard on every Class 1 truck
- Flexible charging. A standard onboard single-phase charger handles overnight and idle-time charging. Every model is also compatible with industrial three-phase chargers, so two- and three-shift operations can top off during breaks and shift changes.
- Big Joe Pulse telematics with five-year coverage. Pulse gives you visibility into how hard each truck works and when it charges, and it's the tool our team uses to help you plan and size your move to electric.
Big Joe has been an American brand since 1951, with U.S.-based parts, warranty and support. We're backed by EP Equipment, with 130,000 Class 1 units globally since 2020.
Ready to see it in your operation? Contact your local Big Joe dealer to schedule a demo, or start with the ROI calculator.
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