Diesel and lithium-ion batteries are 2 common power sources for forklift trucks. When choosing between them, there are several considerations businesses must make. These span across maintenance requirements, operator experience, and sustainability.
In this article we’ll outline the key differences between diesel powered and lithium-ion forklifts to help you choose the right machine for your application.
Similarities Between Diesel and Lithium-Ion Forklifts
Although this article focusses on differences, we must first understand the similarities between diesel and lithium-ion forklifts:
- A robust chassis
- Industrial quality build
- Designed to handle daily tasks
- Capable of handling 2.5-10 tonne loads
- Comparable configurations
These commonalities mean that regardless of power source, forklifts can be configured to perform a similar operational function.
Diesel Forklifts vs Lithium-Ion Forklifts Comparison Table
|  Lithium-Ion Forklifts | Diesel Forklifts | |
| Â Power output | Â Consistent and stable power until the battery is fully drained | Â Remains high-power until fuel runs out |
|  Time to refuel |  Charged electrically and supports opportunity charging |  Quick to refuel – often within minutes |
| Â Noise level | Â Typically very quiet | Â Higher levels of noise pollution which can impact staff comfort |
| Â Operator experience | Â Quieter with smooth handling | Â More familiar, especially for highly experienced operators |
| Â Maintenance | Â Fewer routine maintenance requirements | Â Requires regular engine servicing and fluid and filter checks |
| Â Environment | Â Best suited to indoor and mixed-use settings | Â Typically preferred for outdoor and heavy-duty operations |
Benefits of Lithium-Ion Forklifts
Noise reduction
Lithium forklifts are typically quieter which helps create a better and more productive working environment, particularly when used indoors.
Improved safety
Lithium forklifts remove the safety risks such as acid or fuel spillages which could lead to harmful fumes and fire risks.
Limited downtime
When considering an electric forklift, businesses often worry about re-charging causing increased downtime. However, unlike with lead-acid batteries, lithium-ion forklifts support opportunity charging and have faster charging times. This means that you can keep trucks in operation even in high demand environments.
Operational efficiency
Lithium forklifts often have smoother handling when compared to diesel-powered models and deliver a consistent power output. This allows operators to optimise their workflow and function more efficiently.
Minimal maintenance requirements
Because lithium-ion batteries are sealed units, they require less maintenance. There’s no need for water top ups, battery cleaning or equalisation charging. This allows forklift drivers to instead focus on core operations.
Drawbacks of Lithium-Ion Forklifts
Performance on uneven terrain
Lithium forklifts are best suited to indoor operations with smooth, even flooring. They are unable to handle more heavy-duty tasks associated with working outdoors on a potentially rough terrain.
End of life disposal
Lithium batteries can be difficult to get rid of and many recycling centres don’t accept them. Businesses must specifically arrange for old lithium batteries to be disposed of responsibly.
Compatibility and space
To utilise a lithium forklift, businesses must ensure they have the available space for a suitable charging area. They must also confirm that charging connectors are compatible with the desired truck.
Benefits of Diesel-Powered Forklifts
Quick refuelling
Diesel forklift trucks help to maximise operational efficiency by minimising the amount of time spent on refuelling. When fuel runs out, there’s no wait associated with recharging – simply refuel and go.
High torque output
Diesel forklifts handle demanding tasks with ease, and there is no torque depletion as fuel is used up. This reliability can be crucial for businesses operating at a high capacity around the clock.
Operator experience
For a lot of experienced forklift operators, diesel powered trucks are the go-to because of their familiar performance and engine sound.
Performance outdoors
The strong performance of diesel forklifts is maintained in any environment, including outdoors and on uneven surfaces. This means that they can reliably handle a wide range of heavy-duty tasks
Drawbacks of Diesel-Powered Forklifts
Noise pollution
Diesel forklifts create more noise when in use, compared to electric models. This is particularly limiting within indoor operations
Emissions
Diesel engines emit more pollutants than electric motors. Not only is this worse for the environment, it can be harmful to operators and other colleagues when working indoors
Maintenance requirements
Diesel forklifts require regular servicing for the engine, fluids and filters to ensure they remain reliably functional
Considering Costs
Diesel forklifts require a lower upfront investment than lithium-ion powered alternatives. However, when comparing the two, it’s important to consider the total cost of ownership (TCO). This total cost includes not only the upfront cost, but the costs that are incurred over the lifespan of the machine such as:
- Energy/fuel usage
- Maintenance costs
- Costs associated with downtime
Diesel forklifts cost less to buy but have higher fuel consumption and servicing costs. Lithium powered trucks on the other hand require a higher upfront investment but lead to lower daily running costs since electricity is generally cheaper than diesel. Additionally, lithium trucks cost less to maintain thanks to their simple design with fewer moving components.
Ultimately, depending on usage, these differences can balance out over the lifespan of a forklift truck. Both power types provide value to businesses, but the difference lies in where costs are distributed throughout the truck’s ownership.
Read more about reducing the operating costs of your forklift fleet here.
Choosing The Right Forklift for Your Business
Despite the similarities we initially outlined, key differences mean that each power type lends itself to different applications. Both diesel and lithium-ion forklifts are reliable and hard-working – choosing which one is right for your business will depend on your unique operational needs.