Electric vs Propane Forklift: 4 Questions That Decide It (With Real Prices)
Electric vs propane forklift comes down to four questions: whether the truck runs indoors all day, what the same capacity costs in each fuel, how it refuels between shifts, and what an hour of work costs once the truck is paid for. On price, the gap is smaller than most buyers expect. Warehouse Gear Hub lists the same EKKO 4-wheel truck in both fuels at five capacities, and today the lithium-electric version costs $1,330.00 more at 4,000 lb, $2,660.00 more at 5,000 and 6,000 lb, $5,320.00 more at 7,000 lb, and the same $43,889.05 at the top of the range. On indoor use, the rule is written down: 29 CFR 1910.178(i)(1) caps carbon monoxide from forklift operations at the 1910.1000 limit, which is 50 parts per million as an 8-hour average, and only the electric truck produces none. The full comparison, the matched-model price table, the refueling rules OSHA attaches to each fuel, and the arithmetic for an hour of run time are below.
- Question 1: Does the truck work indoors all day?
- Question 2: What does an electric vs propane forklift cost at the same capacity?
- Question 3: How does it refuel, and how many shifts does it cover?
- Question 4: Which costs less per hour to run?
- Which forklift should you buy?
- Frequently asked questions
Question 1: Does the truck work indoors all day?
An electric forklift has no tailpipe. A propane forklift has one, and inside a building that tailpipe is regulated. 29 CFR 1910.178(i)(1) states: "Concentration levels of carbon monoxide gas created by powered industrial truck operations shall not exceed the levels specified in § 1910.1000." Table Z-1 of 1910.1000 lists carbon monoxide at 50 ppm (55 mg/m³), and paragraph (a)(2) makes that an 8-hour time-weighted average: exposure "shall not exceed the 8-hour Time Weighted Average given for that substance in any 8-hour work shift of a 40-hour work week."
OSHA's forklift eTool is blunter. Its page on enclosed and hazardous areas says "Forklifts powered with internal combustion engines can cause high levels of carbon monoxide in enclosed work areas" and "Do not operate a combustion engine within a warehouse, plant or onboard ship without adequate ventilation." The numbers behind that warning come from a 1996 Colorado Department of Public Health and Environment and NIOSH study of propane forklifts in warehouses: worker exposures of 25 to 68 ppm with peaks to 639 ppm at one site, readings above 300 ppm at another, and tailpipe readings of 9.5 percent (95,000 ppm) before maintenance. The study's remedies were "repair of the forklift's propane fuel system, addition of catalytic converters to the forklift's exhaust system, or substitution of electric-powered forklifts."
A modern propane engine is a different machine from a 1996 one. The EKKO TLP series runs a Kubota or PSI 2.4L engine that EKKO lists as Tier 4 EPA and CARB 4 compliant, and EKKO rates the trucks for indoor and outdoor operation. That is a well-tuned engine in a ventilated building, and plenty of warehouses run propane inside every day. It still means an exhaust to keep tuned, ventilation to keep running, and a carbon monoxide number you are responsible for. The electric truck removes the question. So if the truck spends its shift inside, in a building where the doors close in winter, or anywhere food, pharma, or people-dense work happens, the electric truck is the default and propane has to earn its way in on the next three questions.
Question 2: What does an electric vs propane forklift cost at the same capacity?
Most electric-versus-propane articles quote a price range for each type and leave the reader to guess. The cleaner comparison is one manufacturer, one frame size, both fuels. EKKO builds its 4-wheel counterbalanced truck as a lithium-electric GT-Li and as a propane TLP at matching capacities, with a 185 in mast, a 24 in load center, solid pneumatic tires, a Cascade side shift, and a pre-plumbed Shimadzu 4-way valve on both. The table runs the five pairs at the prices listed on Warehouse Gear Hub today.
| Capacity at 24 in | Lithium-electric model | Battery | Electric price | Propane model | Engine | Propane price | Electric premium |
|---|---|---|---|---|---|---|---|
| 4,000 lb | EK20GT-Li | 80V / 205Ah lithium-ion | $31,919.05 | EK20TLP | Kubota or PSI 2.4L, 63 HP | $30,589.05 | $1,330.00 |
| 5,000 lb | EK25GT-Li | 80V / 205Ah lithium-ion | $34,579.05 | EK25TLP | Kubota or PSI 2.4L, 63 HP | $31,919.05 | $2,660.00 |
| 6,000 lb | EK30GT-LI | 80V / 230Ah lithium-ion | $35,909.05 | EK30TLP | PSI 2.4L, 63 HP | $33,249.05 | $2,660.00 |
| 7,000 lb | EK35GT-LI | 80V / 280Ah lithium-ion | $39,899.05 | EK35TLP | Kubota or PSI 2.4L, 63 HP | $34,579.05 | $5,320.00 |
| 8,000 lb electric / 8,500 lb propane | EK40T-Li | 80V / 230Ah lithium-ion | $43,889.05 | EK40TLP | PSI 2.4L, 63 HP | $43,889.05 | $0.00 |
Two things in that table change the usual argument. First, the electric premium at the 4,000 lb size is $1,330.00, which is 4.3 percent of the propane price, and at 8,000 lb the two trucks are listed at the same number. The five-figure gap in most comparison articles comes from pricing a bare electric truck plus a separate lead-acid battery and charger: Conger Industries puts a 5,000 lb propane truck at $24,000 to $30,000 and the electric equivalent at $35,000 to $40,500, with a $7,000 to $9,000 battery and a $3,000 to $5,000 charger inside that number. The lithium pack is built into the GT-Li price, and the gap shrinks to what the table shows. Second, the premium is not a straight line. It is smallest at the bottom and top of the range and largest at 7,000 lb, so a buyer at 7,000 lb has a real $5,320.00 to justify, and a buyer at 4,000 lb has $1,330.00.
Read the last row carefully: the propane EK40TLP is rated 8,500 lb and the electric EK40T-Li 8,000 lb, and the electric truck's 230Ah pack is smaller than the 280Ah pack in the 7,000 lb EK35GT-LI. Same price, 500 lb of rating apart, so the right question at that size is whether your heaviest pallet clears 8,000 lb.
80V / 205Ah lithium-ion battery, InMotion AC drive, Cascade side shift and Shimadzu 4-way valve pre-plumbed, solid pneumatic tires, 45.2 in wide with an 88.9 in turning radius, 3-year limited warranty.
Question 3: How does it refuel, and how many shifts does it cover?
This is the question propane wins, and the reason it wins is time. A propane forklift refuels by swapping a cylinder, and Ferrellgas puts a 33-pound cylinder at 6 to 8 hours of work. Run out mid-shift, and the truck is back in service as fast as a trained person can change the cylinder. Three shifts means three cylinders, not three batteries.
The rules that come with the swap are specific. OSHA's eTool page on internal combustion power sources states that "Only trained and authorized personnel should replace LPG containers," and explains why: "LPG vapor is heavier than air and will seek the lowest lying area. If not adequately dissipated, it will collect in pockets and possibly ignite when exposed to a heat source," and "LPG is extremely cold when exposed to the atmosphere. If your skin is exposed to LPG, you can get frostbite." Cylinder storage is governed by 1910.178(f)(2): "The storage and handling of liquefied petroleum gas fuel shall be in accordance with NFPA Storage and Handling of Liquefied Petroleum Gases (NFPA No. 58-1969)." Budget for a cylinder cage in the right spot and for the exchange contract that keeps it full.
The electric truck refuels on a charger, and EKKO's GT-Li trucks ship set up for a 480V 3-phase charger, with 220V 3-phase and 110V single-phase options for buildings without 480V service. EKKO does not publish a charge time for the 80V / 205Ah pack, so get the charger's output in amps on your quote and do the division before you commit to a shift plan. The charging area has its own paragraph in the standard. 1910.178(g)(1): "Battery charging installations shall be located in areas designated for that purpose." 1910.178(g)(2): "Facilities shall be provided for flushing and neutralizing spilled electrolyte, for fire protection, for protecting charging apparatus from damage by trucks, and for adequate ventilation for dispersal of fumes from gassing batteries." The GT-Li carries a lithium-ion pack, not a lead-acid battery, so the electrolyte-spill and gassing language in (g)(2) describes a battery type this truck does not have; the designated area, the fire protection, and the barrier against truck strikes still apply.
The shift math is simple. One shift a day with a 16-hour gap: the electric truck charges overnight and the propane truck's speed advantage never comes into play. Two or three shifts back to back with no window to charge: propane, or a second electric truck, or a charger fast enough to fill the pack in the break between shifts, which is a number you need from EKKO before you buy.
Kubota or PSI 2.4L LPG engine, 63 HP at 2,700 RPM, Tier 4 EPA and CARB 4 compliant, 7.00-12 front and 6.00-9 rear solid pneumatic tires, Cascade side shift and Shimadzu 4SV valve pre-plumbed, full suspension cab.
Question 4: Which costs less per hour to run?
The two industries publish different numbers, and the one that applies to you comes from your own utility bill and your own cylinder quote. Start with the number that can be worked from a spec sheet. The EK25GT-Li pack is 80V at 205Ah, which is 16.4 kWh of storage. The U.S. Energy Information Administration's June 2026 retail figures put industrial electricity at 9.17 cents per kWh and commercial at 14.19 cents. Filling that pack from empty costs $1.50 at the industrial rate and $2.33 at the commercial rate, before charger losses. The 280Ah pack in the EK35GT-Li holds 22.4 kWh, or $2.05 per fill at the industrial rate. Whatever an 8-hour shift draws from the pack, the electricity for it costs low single-digit dollars.
Propane is bought by the cylinder from an exchange supplier, and the price is whatever your contract says. For scale, EIA's most recent monthly U.S. residential propane price was $2.668 per gallon in March 2026. Cylinder exchange is a separate service with its own pricing, so use the EIA number only to judge whether a quote is in the neighborhood.
The two camps put it this way. Ferrellgas, a propane marketer, works its comparison out to $1.41 per hour for propane against $1.48 per hour for electricity, a wash. Conger Industries, a forklift dealer that sells both, cites a FirstEnergy cost-of-ownership comparison in which electric trucks are 75 percent cheaper to operate, and puts maintenance at $1.25 per hour for electric against $2.00 for propane. The spread between those two claims is the propane price and the maintenance schedule, which is why the calculation has to be yours: cylinders per week times your cylinder price, against kWh per week times your rate, plus the engine oil changes, spark plugs, and exhaust checks that an engine needs and a motor does not. At 2,000 hours a year, even a $1.00 per hour difference is $2,000.00 a year, which covers the $1,330.00 to $5,320.00 electric premium in the table above inside one to three years if the electric number is the true one.
80V / 205Ah lithium-ion battery, InMotion AC drive with regenerative braking, Cascade side shift and Shimadzu 4-way valve pre-plumbed, 45.2 in wide, 86.2 in turning radius, 3-year limited warranty. $1,330.00 over the propane EK20TLP.
Which forklift should you buy?
Match your operation to the line that describes it.
- Indoor warehouse, one shift, 4,000 to 6,000 lb pallets: the lithium-electric GT-Li at that capacity. EK20GT-Li ($31,919.05), EK25GT-Li ($34,579.05), or EK30GT-LI ($35,909.05). The premium is $1,330.00 to $2,660.00, the truck charges overnight, and the carbon monoxide question never comes up.
- Yard work, gravel, trailers in the rain, or a building with the doors open all day: the propane TLP. EK25TLP ($31,919.05) or EK30TLP ($33,249.05). Both fuels ride on solid pneumatic tires, so the ground is not the deciding factor; the weather and the refuel are.
- Two or three shifts with no charging window: propane, unless you are prepared to buy the charger output that fills the pack in the break, or a second truck.
- 7,000 lb loads: this is where propane saves the most. The EK35TLP is $34,579.05 against $39,899.05 for the EK35GT-LI, a $5,320.00 gap that needs the run-cost math in Question 4 to close.
- 8,000 lb loads: the EK40T-Li ($43,889.05) at the same price as the 8,500 lb propane EK40TLP. If nothing you lift is over 8,000 lb, the electric truck costs nothing extra.
- Loads under 3,500 lb that never leave the floor: a counterbalanced forklift is more truck than the job needs. Our electric vs manual pallet jack guide covers that decision with prices.
80V / 230Ah lithium-ion battery, Inmotion AC drive, Cascade side shift and Shimadzu 4-way valve pre-plumbed, solid pneumatic tires, 45.2 in wide on a 62.9 in wheelbase, 3-year limited warranty. Listed at the same $43,889.05 as the 8,500 lb propane EK40TLP.
Every truck in the table, plus the 3-wheel EK16A and EK18AT electrics, the cushion-tire propane models, and the stand-up riders, is in the electric forklifts and propane forklifts collections. Which paragraph of 1910.178 applies to your building, and what your carbon monoxide readings are, is a question for your safety lead. For the fit question, call 1-800-794-1049, 8 AM to 4 PM Central, with your heaviest pallet, your shift schedule, and the voltage available at the wall, and we will confirm the model and send a written quote.
Frequently Asked Questions
Can you use a propane forklift indoors?
Yes, with ventilation and a tuned engine, and with the carbon monoxide limit met. 29 CFR 1910.178(i)(1) requires that carbon monoxide from powered industrial truck operations "shall not exceed the levels specified in § 1910.1000," and Table Z-1 of that section sets carbon monoxide at 50 ppm as an 8-hour time-weighted average. OSHA's forklift eTool adds: "Do not operate a combustion engine within a warehouse, plant or onboard ship without adequate ventilation." The EKKO TLP engines are listed as Tier 4 EPA and CARB 4 compliant and rated for indoor and outdoor use; the exposure number in your building is still yours to measure.
How long does a propane tank last on a forklift?
Ferrellgas puts a 33-pound forklift cylinder at 6 to 8 hours of operation. EKKO does not publish a run time per cylinder for the TLP series, so treat 6 to 8 hours as a planning figure and confirm it against your first month of exchange invoices.
Can an electric forklift be used outside?
The EKKO GT-Li trucks ride on the same solid pneumatic tires as the propane TLP models, so packed gravel, asphalt, and dock ramps are within their range. EKKO does not publish a water-ingress rating for the GT-Li series, so a truck that will be parked in the rain or washed down is a question to put to EKKO in writing before you order. For a truck that lives outdoors in all weather, the propane TLP is the safer default.
What do the E, ES, EE, LP, and LPS forklift designations mean?
They are the fire-safety classes in 29 CFR 1910.178(b). "The E designated units are electrically powered units that have minimum acceptable safeguards against inherent fire hazards." ES units are E units "provided with additional safeguards," EE units have "the electric motors and all other electrical equipment completely enclosed," and EX units differ from the other three in how "the electrical fittings and equipment are so designed." On the propane side, "The LP designated unit is similar to the G unit except that liquefied petroleum gas is used for fuel instead of gasoline," and "The LPS designated units are liquefied petroleum gas powered units that are provided with additional safeguards to the exhaust, fuel, and electrical systems." Paragraph (c) of the same section says which class is the minimum for a given hazardous location, and (c)(1) adds that "industrial trucks having greater safeguards may be used if desired." Ask for the designation on the nameplate of any truck you are quoted.
Is an electric forklift cheaper to run than propane?
Electricity for a full charge of the EK25GT-Li's 16.4 kWh pack is $1.50 at EIA's June 2026 industrial rate of 9.17 cents per kWh. Propane is priced per exchanged cylinder by your supplier. Conger Industries cites a FirstEnergy comparison putting electric at 75 percent cheaper to operate and maintenance at $1.25 per hour against $2.00 for propane; Ferrellgas works it out to $1.41 per hour for propane against $1.48 for electric. Run the calculation with your rate and your cylinder price. The maintenance side, with no engine oil, spark plugs, or exhaust system on the electric truck, moves in the electric truck's favor whichever fuel figure you use.
Does OSHA require a special room to charge an electric forklift?
It requires a designated area, not a separate room. 1910.178(g)(1) states that "Battery charging installations shall be located in areas designated for that purpose," and (g)(2) requires facilities "for flushing and neutralizing spilled electrolyte, for fire protection, for protecting charging apparatus from damage by trucks, and for adequate ventilation for dispersal of fumes from gassing batteries." The electrolyte and gassing clauses in (g)(2) are written for lead-acid batteries, which the lithium-ion GT-Li does not carry; (g)(1) applies to every battery truck.
Same truck, both fuels, priced side by side
EKKO lithium-electric and propane counterbalanced forklifts from 3,500 to 10,000 lb, with the spec sheet on every product page.
Shop forklifts →Authorized EKKO and UltraTech dealer. Questions on capacity, charging, or a fleet quote: call 1-800-794-1049 (8 AM to 4 PM Central) or email info@warehousegearhub.com.