By the Power Forklifts team, with technical input from Rohit Jaswal, Service Technician at Power Forklifts. Updated November 2026.
Choosing between LPG, diesel, lead-acid electric and lithium electric affects what a forklift costs to run, where you can use it, and how your shift is organised. This guide uses real figures from our own service workshop in Henderson, Auckland, not brochure claims, so you can compare the options for your site.
The short answer
- Diesel suits outdoor work: yards, timber, building supplies and rough ground.
- LPG suits mixed indoor and outdoor work, and long or multiple shifts, because a bottle swap only takes a few minutes.
- Lead-acid electric suits indoor, single-shift work where the forklift can charge overnight.
- Lithium electric suits indoor or mixed work where you want zero exhaust, little maintenance and the option to top up the battery during breaks.
Side-by-side comparison
| LPG | Diesel | Lead-acid electric | Lithium electric | |
|---|---|---|---|---|
| Runtime | About 6–8 hours per 18 kg bottle | About 2–4 litres per hour (2.5–3.5 t) | About 5–7 hours at medium use, depending on battery size | About 3 hours at medium use on an 80V/175Ah battery, plus top-ups |
| Refuel or recharge | Bottle swap | Fill the tank | 8–10 hour charge, plus cooling time | 2–4 hour full charge; 15–20 minute top-ups |
| Exhaust | Yes (carbon monoxide) | Yes (carbon monoxide and particulates) | None | None |
| Routine upkeep | Engine oil and filters, spark plugs and ignition parts | Engine oil and filters | Battery watering with distilled water, cleaning | Sealed battery, no watering |
| Best for | Mixed indoor/outdoor, multi-shift | Outdoor, heavy work | Indoor, single shift | Indoor or mixed, multi-shift with top-ups |
Runtimes and fuel use are approximate figures from our service team and vary with load, operator and site.
How long does a forklift run on one charge or fill?
These are the real-world figures our service technician sees on customer machines:
| Battery | Stored energy | Light use | Medium use | Heavy use | Full charge |
|---|---|---|---|---|---|
| Lead-acid 48V / 725Ah (e.g. articulated forklifts) | 34.8 kWh | ~14 h | ~7 h | ~4 h | 8–10 h + cooling |
| Lead-acid 48V / 500Ah | 24 kWh | 9–10 h | ~5 h | 2–3 h | 8–10 h + cooling |
| JAC lithium 80V / 175Ah | 14 kWh | ~6 h | ~3 h | ~2 h | 2–4 h, depending on charger |
Why the lithium figures look shorter
The lithium battery in this table stores 14 kWh. The lead-acid batteries store 24 kWh and 34.8 kWh. Comparing them side by side is like comparing a 40-litre fuel tank with an 80-litre one.
Adjusted for size, they come out about even. At light use, each 10 kWh of battery gives roughly 4.0 hours on both lead-acid batteries and roughly 4.3 hours on lithium. Lithium’s real advantage is not a longer run on one charge. It is how quickly and how often it can be recharged.
Topping up on breaks (opportunity charging)
Lithium batteries can be charged in short bursts during smoko and lunch breaks without harming the battery. On an 80V/175Ah battery:
- a 50A charger adds about 10% in 20 minutes
- a 100A charger adds about 19% in 20 minutes
Standard lead-acid batteries usually need a full charge cycle and a cooling period, unless they are designed for opportunity charging. That is why lead-acid sites often run overnight charging or a spare battery.
Size the battery to your shift
Worked example (estimate): an 8-hour shift at medium use.
- Lead-acid 48V/500Ah: about 5 hours. You would need a battery change, or a larger battery.
- Lead-acid 48V/725Ah: about 7 hours. This is close to a full shift.
- Lithium 80V/175Ah: about 3 hours, plus roughly 1.5 hours from top-ups on a 100A charger at two smokos and lunch. That suits lighter work or shorter shifts.
- Lithium with about twice the capacity: about 6 hours, plus top-ups. That is a full medium-use shift with no battery swaps.
The right choice is the battery that fits your hours and workload. JAC lithium forklifts are available with larger battery options, and we can work out the size you need from how you run your site.
What does each one cost to run per hour?
These are estimates for a 2.5–3.5 tonne forklift at medium use. All figures exclude GST.
- Diesel: 2–4 litres per hour at about $2.77 per litre excl GST (national average of about $3.19 incl GST, late October 2026) comes to about $5.50–$11 per hour.
- LPG: an 18 kg bottle lasting 6–8 hours works out at roughly 2.3–3 kg per hour. Multiply by your gas supplier’s price per kg, as bottle exchange prices vary by supplier and region.
- Lead-acid electric: about 4.8 kWh used per hour, plus roughly 20% lost while charging, is about 6 kWh from the wall. At about 23c per kWh, that is about $1.40 per hour.
- Lithium electric: about 4.7 kWh per hour with very little charging loss, about 4.9 kWh from the wall. That is about $1.15 per hour.
Fuel and power prices change, so treat these as a guide and use your own rates. Electric forklifts usually cost more up front than an equivalent LPG or diesel machine, but cost much less per hour to run.
Working indoors: exhaust and air quality
LPG, petrol and diesel forklifts all produce carbon monoxide, an odourless and colourless gas. WorkSafe New Zealand identifies switching to electric forklifts as the most effective way to eliminate the risk in enclosed spaces. If you run LPG or diesel indoors, you need good ventilation, regular engine tuning and carbon monoxide monitoring. See WorkSafe’s guidance on forklifts and carbon monoxide.
Servicing differences
All forklifts need regular servicing, but what is involved differs by power type:
- LPG and diesel: engine oil, oil filter and air filter at each service. On LPG models, we also check spark plugs, ignition leads and distributor caps. Transmission oil is usually changed around 1,000 hours and hydraulic oil around 2,000 hours, depending on condition.
- Lead-acid electric: check and top up battery water with distilled water, clean the electrical compartments, check motor brushes (where fitted), and check the brakes, hydraulic motor, pump and oil. Hydraulic oil is usually replaced around 2,000 hours.
- Lithium electric: similar to lead-acid, but the battery is sealed and needs no watering or internal maintenance. We inspect the battery’s electrical components for damage.
For every type, we grease the lubrication points and inspect the mast chains, rollers, hydraulic cylinders, brakes, tyres and forks. For how often to service, see our guide to forklift service intervals in NZ.
Battery life
Lead-acid: “9,000–13,000 hours is possible with proper maintenance, but not guaranteed. It depends on how well operators look after it,” says Rohit. Under-watering, deep discharging and opportunity charging a standard lead-acid battery all shorten its life.
Lithium: needs much less routine care and suits top-up charging. The battery management system (BMS) inside the pack is an important part to have supported by your dealer, so buy from a supplier with local service backup.
Which should you choose?
- Mostly outdoors, rough ground or heavy loads: diesel.
- Indoors and outdoors, or more than one shift a day: LPG, or lithium with top-up charging.
- Indoors, one shift, regular hours: lead-acid or lithium electric.
- Food, cold stores or anywhere exhaust is a problem: electric, ideally lithium.
- You want low running costs and little day-to-day maintenance: lithium.
Whatever you choose, size it for where your business will be in 3–5 years, not just today. See 6 forklift buying mistakes to avoid.
Frequently asked questions
Is a lithium forklift worth the extra cost?
Often, yes, when the machine works most days. It costs a fraction of diesel per hour to run, needs no battery watering, and can top up on breaks. For occasional use, LPG or lead-acid can be the better value.
How long does an 18 kg LPG bottle last on a forklift?
About 6–8 hours of typical use, in our technician’s experience. Heavy lifting and long travel distances shorten that.
How much diesel does a forklift use?
A 2.5–3.5 tonne diesel forklift typically uses about 2–4 litres per hour, depending on the work.
Can I charge a lithium forklift battery during breaks?
Yes. Lithium batteries are designed for top-up charging. A 100A charger adds about 19% to an 80V/175Ah battery in 20 minutes.
Talk to us
Power Forklifts is the exclusive New Zealand distributor of JAC Forklifts. Browse our lithium forklifts, LPG forklifts, diesel forklifts and new forklifts in stock. Or call 09 838 0023 and we’ll help you choose the right power type and battery size for your site.
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