Conversion Kit for Narrow-Aisle Forklifts – 3 Ton

HomeConversion Kit for Narrow-Aisle Forklifts – 3 Ton
Diesel-to-Electric Retrofit Solution with Original Transmission Retained Project Concept 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: Remove the original diesel/gasoline engine Install an electric motor through a customized adapter plate Retain the original gearbox/transmission Retain the original PTO hydraulic structure Retain the original differential and axle system Maintain original driving habits and hydraulic functionality This solution is especially suitable for customers who want: Lower retrofit cost Faster conversion time Minimal chassis modification Reliable industrial operation Easier maintenance Reuse of existing forklift platforms

Conversion Kit for Conversion kit for narrow-aisle forklifts

Conversion Kit for Conversion kit for narrow-aisle forklifts

Diesel-to-Electric Retrofit Solution with Original Transmission Retained

Project Concept

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:

  • Remove the original diesel/gasoline engine
  • Install an electric motor through a customized adapter plate
  • Retain the original gearbox/transmission
  • Retain the original PTO hydraulic structure
  • Retain the original differential and axle system
  • Maintain original driving habits and hydraulic functionality

This solution is especially suitable for customers who want:

  • Lower retrofit cost
  • Faster conversion time
  • Minimal chassis modification
  • Reliable industrial operation
  • Easier maintenance
  • Reuse of existing forklift platforms

Parts Included in the Conversion kit for narrow-aisle forklifts

🧩 Vehicle Support Systems

We can also provide you with other modification parts, or customize modification solutions for you, please contact us
223 1
20kW Motor & Controller System for Conversion kit for narrow-aisle forklifts

To support the Conversion kit for narrow-aisle forklifts, our company provides complete conversion solutions tailored to different equipment types and operational requirements.

System Architecture

Original Structure Retained

The following original components remain unchanged:

  • Mechanical transmission / gearbox
  • PTO hydraulic pump system
  • Differential and drive axle
  • Steering system
  • Hydraulic lifting system
  • Chassis structure

Only the power source changes from:

Internal Combustion Engine → Electric Motor

Core Conversion Solution

Adapter Plate Coupling Structure

The electric motor is connected to the original transmission through a customized adapter plate and coupling system.

Main advantages:

  • No major gearbox modification
  • Easy installation
  • Preserves original gear ratios
  • Maintains forklift climbing ability
  • Maintains hydraulic lifting functionality
  • Lower engineering risk

The adapter plate is designed according to the original engine mounting dimensions and transmission interface.

Electric Drive System

Proposed Motor Configuration

Recommended motor type:

  • AC Induction Motor or PMSM Motor
  • Voltage platform: 80V / 96V
  • Power range: 15kW – 30kW
  • High low-speed torque output
  • Suitable for industrial forklift operation

Typical working requirements:

  • High torque at startup
  • Frequent forward/reverse switching
  • Long operating hours
  • Stable low-speed control
  • Regenerative braking capability
500W 48V to 12V High Efficiency DC DC Converter for Reliable Power Regulation 4
DC-DC Converter for Conversion kit for narrow-aisle forklifts

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.

DP 06C 1
Minimalist Battery Meter for Conversion kit for narrow-aisle forklifts

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.

on board battery charger
Compact On-Board Charger for Conversion kit for narrow-aisle forklifts

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.

pack
Space-Optimized Battery Packs for Conversion kit for narrow-aisle forklifts

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

If you have any questions about theConversion kit for narrow-aisle forklifts electric conversion, please feel free to contact us!

Successful Conversion Cases

conversion kit for folk-lift
adapter
conversion procedure

Electric Drive System

Proposed Motor Configuration

Recommended motor type:

  • AC Induction Motor or PMSM Motor
  • Voltage platform: 80V / 96V
  • Power range: 15kW – 30kW
  • High low-speed torque output
  • Suitable for industrial forklift operation

Typical working requirements:

  • High torque at startup
  • Frequent forward/reverse switching
  • Long operating hours
  • Stable low-speed control
  • Regenerative braking capability

PTO Hydraulic System Retained

One major advantage of this retrofit architecture is:

Original PTO Structure Remains Functional

The original hydraulic pump continues to operate through the retained gearbox and PTO system.

This means:

  • No redesign of hydraulic lifting system
  • No major hydraulic piping changes
  • Original mast lifting performance maintained
  • Lower retrofit engineering cost

This architecture is especially important for narrow-aisle forklifts where hydraulic response stability is critical.


Battery System Recommendation

Recommended battery platform:

ItemSuggested Specification
Battery TypeLithium LiFePO4
Voltage80V / 96V
Capacity200Ah – 400Ah
BMSSmart BMS Integrated
ChargingFast Charger Compatible

Battery capacity can be customized according to:

  • Daily working hours
  • Lift frequency
  • Warehouse operation intensity
  • Charging schedule

Controller System

Recommended controller features:

  • CAN communication
  • Regenerative braking
  • Multi-speed torque mapping
  • Anti-rollback protection
  • Thermal protection
  • Programmable acceleration curves

The controller can also communicate with vehicle dashboard systems if required.


Key Advantages of This Conversion Solution

Lower Retrofit Cost

Keeping the original transmission and PTO greatly reduces mechanical redesign expenses.

Faster Development Cycle

No need to redesign the entire drivetrain architecture.

Easier Installation

The conversion mainly focuses on:

  • Engine removal
  • Motor mounting
  • Adapter plate installation
  • Battery integration
  • Electrical system installation

Preserved Driving Feel

Operators can continue using familiar gear shifting and driving habits.

Reduced Maintenance

Electric motors require significantly less maintenance than diesel engines.

Environmentally Friendly

  • Zero exhaust emissions
  • Lower noise
  • Reduced vibration
  • Better indoor warehouse operation

Typical Application Scenarios

This conversion kit is suitable for:

  • Narrow-aisle forklifts
  • Counterbalance forklifts
  • Industrial warehouse forklifts
  • Aging diesel forklift retrofit projects
  • Fleet electrification programs

GMT Electric Forklift Conversion Capabilities

GREEN MOTOR TECH supports:

  • Forklift motor systems
  • Transmission adapter plate design
  • Motor-controller matching
  • Lithium battery integration
  • Wiring harness development
  • CAN communication integration
  • Prototype development
  • OEM/ODM electric conversion projects

We provide customized electric conversion solutions for industrial vehicles, forklifts, utility vehicles, and low-speed EV platforms worldwide.

Questions About Conversion kit for narrow-aisle forklifts

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 :

[email protected]

whatsapp/wechat: + 86 1812358 9096

We are more than welcome for your inquiries.

Contact us for a more complete retrofit

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