Thinking about charging into the world of electric forklifts? Electric forklifts have never been more powerful and more ready to lift.
But are they right for you? What would switching to electric look like? This article discusses when to stick with internal combustion engines (ICE), when switching to electric makes sense, and how to effectively transition your fleet if needed.
Don’t do it: When ICE may still be your ticket
Electric has come a long way, and there are a lot of great electric forklifts out there that will amaze you.
But sometimes you look at your options and think, “I’m gonna stick with gas.” Following are some of the reasons you may want to stand pat and keep your ICE lifts.
- Electric forklifts require a charging infrastructure. If you don’t have the electrical capacity to add load for a charging infrastructure, electric forklifts won’t work for you yet.
- You prioritize up-front costs over long-term ROI. For you, it’s all about the up-front costs. Electric vehicles may still have an up-front cost premium compared to traditional ICE forklifts, though it’s much less than it used to be. However, electric forklifts have lower operating and maintenance costs. The more you use them, the better your ROI.
- You own a short-term rental fleet of high-use forklifts. Typically, rental companies want ICE forklifts because they can be quickly refueled and don’t require 480v charging like electric. Low-usage electric rentals could be charged using an onboard charging station and a 110v on-site electrical outlet, but it may be less convenient than an ICE truck.
For some, the devil you know is better than the devil you don’t. In most places, there’s no law against doing it the old way using ICE lifts powered by propane, diesel, or gasoline – though more and more states are creating emissions regulations.
Go time: When plugging into electric might be right for you
Electric forklifts have come a long way, and they keep improving. For most uses, an electric forklift is a great option to consider. They are just as powerful and fast as their ICE counterparts, and they don’t emit CO2 or heat into your warehouse when operating.
Following are the top 4 reasons to consider going electric for your forklift fleet.
- You have access to incentive programs. Many states offer incentives for switching from ICE to electric, including California CORE, Colorado Clean Fleet Vehicle and Technology Grant Program, New York NYTVIP, Texas TERP, and Massachusetts MassCEC programs like Mass Fleet Advisor. You could also apply to receive a clean vehicle tax credit.
- You prioritize long-term ROI over up-front cost. The up-front cost of an electric forklift is typically higher than ICE, but electric forklifts typically cost less to operate and maintain. We estimate a 3-4-year ROI for the average electric forklift user.
- You’re operating indoors. ICE forklifts emit fumes like CO2. If you are operating indoors, you may have to upgrade your HVAC to ensure safe indoor air quality and comfortable indoor air temperature. Electric forklifts have no CO2 emissions and generate much less heat.
- You want to reduce your CO2 emissions. In the U.S., 93% of CO2 emissions come from fossil fuel combustion. Companies with environmental goals are choosing to rev down on the gas and switch to electric.
Let’s talk about raw power
Do you think that electric forklifts lack power and speed? Think again. Electric forklifts are as powerful as their ICE counterparts, with comparable lifting capacity and travel speeds.
In the past, electric trucks have typically had lower ground clearance and smaller operator compartments than ICE trucks to accommodate the electric battery. However, many companies are developing electric trucks with competitive ground clearance and more roomy compartments similar to ICE forklifts.
Steps to transition your forklift fleet from ICE to electric
So, you’re ready to plug into electric. In this section, we’ll talk about the steps to transition your forklift fleet to ICE, including:
1. Charging infrastructure
Unlike ICE, you can’t just pour fuel into your electric forklift. Typically, forklift charging stations require a 480v power source. You’ll need dedicated floor space to park your truck for charging. Chargers can be floor- or wall-mounted and will be hard-wired into your electrical system.
Some models have onboard chargers that pair with a 110v electrical outlet, but charging your forklift on a regular 110v outlet will take longer than charging with a dedicated 480v charging station.
2. Buy your battery
You can choose to buy your CLARK forklift with a lead-acid battery or without a battery and purchase an after-market lithium-ion battery.
But which is better: a lead-acid battery or a lithium battery?
Lead-acid batteries:
If you want a less expensive option and you don’t mind regular maintenance, lead-acid batteries might be your best option. Lead-acid batteries shouldn’t be opportunity charged, as charging a partially charged battery can cause overheating and damage. During charging, they emit fumes like hydrogen and oxygen. A venting system may be required in a tight space with many batteries charged at the same time. Consult an expert to maintain peak indoor air quality while charging lead-acid batteries.
When driving a lead-acid powered forklift, power output decreases as the battery discharges, reducing performance and lifting capacity by the end of a shift.
Lead-acid batteries typically last 500 to 1,000 cycles or 2-5 years, depending on use and conditions. Always consult an expert and follow manufacturer guidelines for safe charging.
Lithium batteries:
Lithium batteries cost more upfront but require no maintenance, can be opportunity charged during breaks, and don’t emit fumes during regular use or charging.
When driving a forklift with a lithium battery, power output remains consistent until nearly empty, then drops quickly, so monitor it with a battery display indicator (BDI).
Lithium batteries typically last around 3,500 cycles, or 7-10 years, depending on usage and conditions. The lithium used in forklift batteries is lithium-ion phosphate, a much more stable lithium compound than the compound used in cell phone batteries. Always follow manufacturer guidelines for safety.
We recommend lithium unless the up-front cost is a limiting factor. It offers ease of use, reduced maintenance, and a better ROI.
3. Battery display indicator
Lithium batteries are connected to a battery management system that monitors things like voltage, temperature and life. We recommend purchasing a BDI with your lithium battery. Mount it in the operator’s compartment on your forklift. The display will give you information on how the battery is operating.
Our newest SMART dash integrates the battery management system into the truck. The battery is connected to the truck through a CAN network and displays faults and alarms on the SMART dash.
Whether you choose the new SMART dash with integrated battery management system or another option, be sure to purchase a remote BDI. Mount it in the operator compartment, and the operator will always know the battery’s state of discharge.
4. Driving training
Whether you’re a seasoned forklift operator or just beginning to navigate material handling equipment, safety training is vital to making you a better driver.
When switching from ICE to electric, you should train your drivers on the features of the new electric forklift. In many ways, driving an electric forklift is similar to an ICE forklift, but there are a few key differences.
Shifting
The shifting experience with an electric forklift may be slightly different. ICE trucks have an inching pedal to partially disengage the transmission for a smooth, controlled stop. Sometimes, drivers hot shift directly from forward to reverse without fully stopping or using the pedal. This is hard on the transmission, and the wear and tear can reduce its lifespan.
Electric forklifts typically do not require an inching pedal. On CLARK electric forklifts, drivers can shift from forward to reverse in a process called plugging. The forklift’s software slows the drive motor, bringing the vehicle to a stop, and then engages the reverse motor. Alternatively, drivers can use the standard brake to slow the forklift and come to a complete stop before shifting from forward to reverse.
Braking
Braking in an ICE forklift may feel different than in an electric forklift than on an ICE forklift. Braking in an ICE forklift relies on traditional mechanical brakes, such as hydraulic or disc brakes.
Electric forklifts have electromagnetic brakes. When you press the brake, the motor itself brakes the truck. Braking may feel smoother. When the truck is stopped, electromagnetic brakes hold the truck in place, similar to a parking brake. The electromagnetic brake engages when the truck is stopped or turned off.
Ready to plug in?
Contact your CLARK dealer. In most cases, we think electric forklifts are the way to go. Electric forklifts may save you money in the long term. They’re good for your bottom line, they’re good for your team, and they’re good for the environment. With electric, hot shifting is a thing of the past, and braking feels smoother. Electric lifts are quieter and don’t emit heat or fumes during operation or normal charging. However, They do tend to be more expensive up-front, however, the long-term cost savings come with reduced needs for gas and repairs.
Whether you need an LPG, diesel, electric, or dual LPG/gas lift, let us help you find the right forklift for your operation.
“Hey, they’ve been around in this industry for 100-plus years. They know what they’re doing.”
Jake Schubert, Used Equipment Manager, Forklifts of Minnesota
