Propane Sit-Down Forklifts: Pros, Cons & Safety Checklist

Quick Summary:

Propane sit-down forklifts are known for their power, quick refueling, and versatility in both indoor and outdoor environments. This guide breaks down the pros and cons, ideal use cases, and safety protocols every warehouse or logistics operation should follow when operating these types of machines.

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What Is a Propane Sit-Down Forklift?

A propane sit-down forklift, sometimes labeled an LPG forklift, is a type of sit-down rider that’s powered by liquefied petroleum gas. It’s one of the most common lift trucks used across warehouses and distribution centers that need their machine to operate indoors and outdoors. 

Many warehouse operators prefer propane models over electric forklift trucks because they offer greater flexibility and increased run-time, especially in mixed-use cases. 

Benefits of Propane Forklifts

• Long Operating Hours: last longer per shift than the average electric forklift’s battery life.

• Rapid Refueling: only takes minutes to swap an empty propane tank for a new one. 

• Consistent Power: ensure consistent operating power until the propane tank is empty.

• Mixed Indoor/Outdoor Use: provide a seamless transition between indoor and outdoor surfaces in industries with diverse needs. 

• Widely Available: most manufacturers offer propane models.

• Strong Power-to-Weight Ratio: can handle heavy loads while staying extremely maneuverable. 

• Reduced Emissions: when compared to diesel- and gasoline-powered trucks.

• Lower Acquisition Costs: new and used propane forklifts usually cost less upfront than electric units.

“Propane forklifts give us flexibility. We use the same units in the warehouse and the loading yard without worrying about range or power.”

— Jill Harper, Logistics Manager, SouthBay Fulfillment

Drawbacks of Propane Forklifts

• Emissions: still expel more exhaust fumes than electric models, so proper indoor forklift ventilation is a necessity. 

• Noise Levels: much louder than electric machines, which can be disruptive or hazardous in certain environments.

• Fuel Leaks: risk of potential propane leaks, which can be a fire hazard or health risk to operators if undetected.

• Higher Maintenance: more moving engine parts than electric, which can lead to more frequent maintenance checks and repairs. 

• Higher Operating Costs: could lead to a higher total cost of ownership when factoring in fuel and maintenance costs.

• Special Training: requires special propane forklift training to learn safe tank handling, storage, and inspection of fuel line procedures. 

Propane Forklift Safety Training

OSHA mandates that all US forklift operators obtain a certification before operating a truck. These trainings include 3 parts: education, a written test, and a skills evaluation. Operators must complete a forklift certification test that’s specific to the forklift class they’ll be using. 

Propane sit-down forklifts fall under Class IV or V machines, which requires all operators to understand the following safety requirements:

1. How to safely handle, change, and refuel LPG forklift cylinders.

Always stop the engine before refueling and make sure secure tanks are secure before turning back on. Learn how to detect potential propane leaks using the “look, listen, smell” method, and how to dispose of spills safely when they occur.  

2. How to ventilate your warehouse and detect carbon monoxide exhaust fumes.  

Keep CO levels below 50 ppm (25-35 ppm is even better). Install roof or wall-mounted exhaust fans to filter out the gaseous air. Install fixed gas monitors at operator breathing height and set alarms for ppm levels exceeding 25-35. 

3. How to store LPG cylinders safely.

Cylinders must be upright and secured in ventilated areas away from physical damage or heat/flame exposure.

4. What personal protective equipment (PPE) is required.

Operators must wear flame-retardant clothes, insulated gloves to protect from the extreme cold of liquid propane, and eye protection to guard against vapor exposure. 

5. How to prepare for emergencies and respond to incidents.

Keep extinguishers at a safe distance in case of a propane fire. Understand your warehouse’s evacuation procedures in case of a large leak or risk of explosion. Keep contact information for propane suppliers and safety experts handy. 

Safety Checklist

How Much Does a Propane Forklift Cost?

The price of propane sit-down forklifts can vary based on the condition, operating specifications, and manufacturer. In general, here’s the average price you can expect to pay for a propane forklift with a lift capacity of ~5,000 lbs:

Total Cost of Ownership

Buying a forklift is an investment, but operating one is, too. Be sure to factor in the cost of the truck’s upkeep – maintenance, repairs, and fuel costs – on top of the initial price tag. 

Propane vs. Electric Forklifts: Which Is Right for You?

Still not sure which sit-down forklift fuel type is best for you? Use this table to compare the most important features of LPG vs. electric forklifts:

Ideal Environments for Propane Sit-Down Forklifts

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