Conversion Kit for Conversion kit for narrow-aisle forklifts
This project is designed for the conversion of 3-ton narrow-aisle forklifts from internal combustion engines to electric drive systems while retaining the original drivetrain architecture.
Unlike a complete vehicle redesign, this conversion kit keeps the factory mechanical transmission and PTO system unchanged, significantly reducing modification complexity and development cost.
The core concept is:
This solution is especially suitable for customers who want:
To support the Conversion kit for narrow-aisle forklifts, our company provides complete conversion solutions tailored to different equipment types and operational requirements.
The following original components remain unchanged:
Only the power source changes from:
The electric motor is connected to the original transmission through a customized adapter plate and coupling system.
The adapter plate is designed according to the original engine mounting dimensions and transmission interface.
Recommended motor type:
Typical working requirements:
We provide a full range of voltage platforms from 48V, 72V, 96V, 144V up to high-voltage solutions, allowing customers to select the most suitable configuration based on power requirements. Once the voltage and power level are defined, we further optimize the complete system architecture, including components such as DC-DC converters and other key parts, ensuring a fully matched and reliable electrification solution for each application.
Our solutions cover a wide power spectrum from 5 kW to 65 kW and are compatible with different voltage platforms such as 48V, 72V, 96V, and 144V. Based on the selected power level, we provide a fully matched system configuration, including motor, controller, battery system, and auxiliary components. The instrument system supports CAN communication with the controller, and can also integrate with the customer’s original dashboard. In addition, we can provide a dedicated compact battery state display to ensure clear and reliable real-time monitoring of system status.
When developing an electrification (conversion kit) solution for Conversion kit for narrow-aisle forklifts, several key factors must be carefully evaluated to ensure optimal system performance. Equipment type directly determines the required power level, while operating duration defines the necessary battery capacity. Continuous operation requirements have a direct impact on thermal management design, and existing hydraulic systems determine the integration strategy between the motor and hydraulic pump system.
In addition, the charging solution can also be fully customized based on customer requirements. We can provide onboard charger (OBC) configurations supporting single-phase or three-phase charging, and the system can also be designed to utilize airport ground power supply where applicable.
Regarding the battery system, we also provide fully customized solutions based on customer requirements. Different voltage platforms are matched with corresponding battery architectures, including optimized selection of cells, BMS, and system integration to ensure performance, safety, and reliability.
For Conversion kit for narrow-aisle forklifts we can design battery systems ranging from low-voltage to high-voltage configurations, tailored to specific power demand, duty cycle, and operational environment.
For example, our modular battery solutions can be adapted to 96V and similar platforms, using LiFePO4 technology to deliver stable and efficient energy output. Typical configurations may include standard and high-capacity options to balance endurance and performance requirements, ensuring reliable operation across different GSE applications.
In addition, the battery system is engineered with optimized cell selection, advanced BMS integration, and thermal management design to ensure safety and long service life under continuous airport operation conditions.
Our goal is to provide a fully matched energy solution that integrates seamlessly with the motor, controller, and charging system, enabling a complete and reliable electrification package for Conversion kit for narrow-aisle forklifts
Recommended motor type:
Typical working requirements:
One major advantage of this retrofit architecture is:
The original hydraulic pump continues to operate through the retained gearbox and PTO system.
This means:
This architecture is especially important for narrow-aisle forklifts where hydraulic response stability is critical.
Recommended battery platform:
| Item | Suggested Specification |
|---|---|
| Battery Type | Lithium LiFePO4 |
| Voltage | 80V / 96V |
| Capacity | 200Ah – 400Ah |
| BMS | Smart BMS Integrated |
| Charging | Fast Charger Compatible |
Battery capacity can be customized according to:
Recommended controller features:
The controller can also communicate with vehicle dashboard systems if required.
Keeping the original transmission and PTO greatly reduces mechanical redesign expenses.
No need to redesign the entire drivetrain architecture.
The conversion mainly focuses on:
Operators can continue using familiar gear shifting and driving habits.
Electric motors require significantly less maintenance than diesel engines.
This conversion kit is suitable for:
GREEN MOTOR TECH supports:
We provide customized electric conversion solutions for industrial vehicles, forklifts, utility vehicles, and low-speed EV platforms worldwide.
Yes, we provide all electronic parts for conversion. We also provide wire diagram system, each part user manual, so you will have no obstacles for installation and connection of the system.
Yes, we provide motor spline coupler and adapter plate to install motor to original transmisison. But the original transmission’s clutch need to get removed. If you want to keep clutch, you need modify the spline coupler to clutch a bit. Because we do not have car in hand, so we bought a old transmission without clutch to make the coupler and adapter kit.
We provide two years for battery, and one year warranty for other parts. We only use top grade quality products. If any parts failure from manufacturing issues, we provide repair parts for replacement.
If we have stocks ready to go, the lead time is one weeek after order confirmed. if we have no stocks, lead time might be 4 weeks after order confirmed.
After you have discussed with sales manager all details of the order, he or she will make proforma invoice with all details and bank accounts for payment, normally payment is through bank to bank T/T. Other payment ways are also flexible to accept after discussion.
We only use top brand of cells in China, like EVE, like Gotion etc, most of the case we use EVE brand pure new and A grade cells to make pack. And in our battery pack we surely use real automobile grade BMS, not simple protection board.
We care about reputation more than our customers!
We are real manufacturer, not sales trade office/company, we started our motor production from 1995 in China. In conversion we now have more than 10 year experiencee. In the whole drive systems, we do not produce all parts, but motor we make, controller we provide CAN BUS and technical requests to our partner, same as lithium battery pack and wire hanress of the system, the design and CAN BUS are from us. other accessories like gas peda, meter etc we get from reliable partners.
Except motor and drive train solution, we also owns our own low speed electric vehicle assembly factory, its website/brand is www.gmtlsv.com
In short, we are EV expert with decades experience in China!
Yes, our key electronic components are with CE certificate for Europe markets, so at the moment, we ship to Europe like France, UK, Germany, Italy, Sweden, Belgium, Turkey etc.
We also have ISO9001 quality manage certificate.
For our EV products, we also have WMI (World Manufacturer Identifier) certificate, each vehilce has its VIN number.
To some particular countries, they have requests in import or tax reduces policy such as for Africa countries and Middle East, COC or SABER might needed for import. For some countries, certificate of origin: FORM A, FORM E etc are requested. We all have experience to make for customers.
Yes, of course, our engineers who can speak English directly, video talk/email/Whatsapp they can communicate and serve customers without obstacles.
No matter before-sales or after sales, we all request in time response 24 hours and 7 days as long as we see the requests.
For necessary project, we can also send engineers to customers’ company for guide or training.
We also welcome customers to send engineers to us for onsite learning and training!
Yes, no problem, we support that. We hope customers can do longterm business so customization of his logo is OK
Please consult with our sales Director :
whatsapp/wechat: + 86 1812358 9096
We are more than welcome for your inquiries.
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