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Conversion kit for short-distance heavy transport

HomeConversion kit for short-distance heavy transport
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Complete EV Conversion Solutions for short-distance heavy transport

Green Motor Tech provides complete EV conversion kits and electrification solutions for short-distance heavy transport vehicles, including industrial tow tractors, tugger trains, airport baggage tractors, yard tractors, and heavy-duty indoor logistics vehicles.

Our solutions include electric motors, motor controllers, battery systems, chargers, DC-DC converters, VCU, wiring harnesses, and complete integration support.

Compared with traditional fuel-powered transport equipment, electric heavy transport vehicles offer significant advantages:

  • Lower operating and maintenance costs
  • Zero emissions and environmentally friendly operation
  • Low noise and reduced vibration
  • High torque output for heavy load start and low-speed operation
  • Improved efficiency for frequent start-stop working cycles
  • Easier maintenance with fewer mechanical parts
  • Suitable for factory logistics, airports, ports, and industrial transport applications

We can provide complete powertrain matching and customized electrification solutions based on different vehicle platforms, load requirements, and working conditions.

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Parts Included in the Conversion kit for short-distance heavy transport

🔌 Electric Motor System

⚡ Power Electronics

🔋 Battery System

🧩 Vehicle Support Systems

We can also provide you with other modification parts, or customize modification solutions for you, please contact us
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Motor and Controller Selection for short-distance heavy transport

For short-distance heavy transport vehicles such as industrial tow tractors, tugger trains, airport baggage tractors, yard tractors, and heavy-duty logistics vehicles, the motor and controller selection is generally based on load capacity, duty cycle, traction demand, and operating environment.

Green Motor Tech provides complete electric powertrain solutions for light to heavy-duty industrial transport vehicles, including 48V, 72V, 96V, and 144V systems.

Our typical solutions include:

48V 3–7.5KW PMSM System
Peak torque: up to 120 N·m
Suitable for light-duty tugger carts, AGVs, and compact warehouse transport vehicles

72V 11–20KW System
Peak torque: up to 200 N·m
Suitable for medium-duty tow tractors, baggage tractors, and factory logistics vehicles

96V 15–40KW System (Liquid-cooled available)
Peak torque: up to 250 N·m
Suitable for heavy-duty indoor/outdoor logistics and airport/port transport equipment

144V 30–65KW System (High-torque platform)
Peak torque: up to 252 N·m
Suitable for high-load yard tractors and demanding short-distance heavy transport applications

In addition, we also provide:

  • Liquid-cooled motor and controller solutions
  • 96V / 144V high-power liquid-cooled systems
  • Custom drive axle solutions
  • Customized gear ratios (final drive ratio)
  • Customized PCD (Pitch Circle Diameter)
  • Full powertrain matching and vehicle integration support

Our electric heavy transport solutions are designed to provide:

  • High starting torque for heavy loads
  • Stable performance in frequent stop-start operation
  • Improved energy efficiency
  • Lower operating and maintenance costs
  • Reduced noise and emissions
  • Reliable performance for industrial logistics environments

We can customize complete electrification solutions according to different vehicle platforms, load requirements, and working conditions.

500W 48V to 12V High Efficiency DC DC Converter for Reliable Power Regulation 4
DC-DC Converter for Conversion kit for short-distance heavy transport

DC-DC converter solutions for short-distance heavy transport vehicles such as industrial tow tractors, tugger trains, airport baggage tractors, yard tractors, and heavy-duty logistics vehicles are typically divided into three voltage platforms:

Low-voltage platforms such as 48V and 72V, suitable for light-duty AGVs, tugger carts, and compact logistics vehicles, offering advantages in safety, cost efficiency, and simple system integration, but with limited power output.

Medium-voltage platforms including 96V and 144V, which are the mainstream choice for tow tractors, baggage tractors, and medium-duty industrial transport vehicles, providing a balanced solution in performance, efficiency, and system scalability.

High-voltage platforms ranging from 300V to 600V or higher, typically used in heavy-duty yard tractors, airport tow tractors, and high-power auxiliary systems such as GPU and air conditioning units, offering higher power density and improved efficiency but with increased system complexity and cost.

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 and application requirements.

Once the voltage level is defined, we further optimize the complete system architecture, including DC-DC converters and other key components, ensuring a fully matched, reliable, and efficient electrification solution for each vehicle application.

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dashboard for Conversion kit for short-distance heavy transport

The dashboard plays an important role in short-distance heavy transport vehicles such as industrial tow tractors, tugger trains, airport baggage tractors, yard tractors, and heavy-duty logistics vehicles.

A suitable dashboard should display real-time data including speed, battery SOC, voltage, current, and fault warnings. For industrial applications, CAN communication dashboards are strongly recommended for more accurate system monitoring and reliable controller integration.

We also provide an advanced 10.1-inch touchscreen smart dashboard, designed for modern electric logistics vehicles. It features:

  • CAN communication support for stable system integration
  • Real-time vehicle and battery status display
  • High-definition touch interface for intuitive operation
  • Multi-language support for global applications
  • Strong compatibility with different controller protocols and system voltages (48V, 72V, 96V, 144V)

For industrial environments, the system is designed with:

  • Waterproof and dustproof protection
  • Vibration resistance for harsh working conditions
  • High reliability for continuous commercial operation

This 10.1-inch smart dashboard significantly improves vehicle monitoring, operational efficiency, and system intelligence for electric heavy transport applications.

on board battery charger
Compact On-Board Charger for short-distance heavy transport

A compact on-board charger is an important component in short-distance heavy transport vehicles such as industrial tow tractors, tugger trains, airport baggage tractors, yard tractors, and heavy-duty logistics vehicles.

Compared with external charging systems, on-board chargers provide greater convenience for daily operation, especially in continuous industrial transport and high-frequency start-stop working environments.

Most industrial vehicle platforms use 48V, 72V, 96V, or 144V lithium battery systems, requiring chargers with stable output voltage and intelligent charging protection. Compact high-frequency chargers offer higher efficiency, lower heat generation, and reduced installation space requirements.

For heavy-duty applications operating in harsh environments, waterproof and vibration-resistant designs are strongly recommended. CAN communication capability also improves compatibility with the BMS, enabling real-time monitoring of charging status, battery temperature, current, and fault diagnostics.

A properly selected on-board charger improves charging safety, battery life, and overall system reliability in industrial logistics applications.

pack
Space-Optimized Battery Packs for short-distance heavy transport

Battery installation space is a key challenge in short-distance heavy transport vehicles such as industrial tow tractors, tugger trains, airport baggage tractors, yard tractors, and heavy-duty logistics vehicles. Unlike factory-built EV platforms, integration projects must balance compact layout, weight distribution, and high-load performance within limited chassis space.

To meet different power and endurance requirements, we provide multiple compact lithium battery pack options, including:

  • 51.2V 122Ah / 230Ah
  • 73.6V 122Ah / 230Ah
  • 102.4V 122Ah / 230Ah

The 51.2V platform is suitable for light-duty tugger carts and compact AGVs with short-distance operation needs. The 73.6V system is widely used in medium-duty tow tractors and baggage tractors, offering better efficiency and climbing performance. The 102.4V platform is designed for heavy-duty industrial transport vehicles, delivering lower operating current, better thermal management, and higher drivetrain efficiency.

All battery packs are equipped with integrated BMS protection, including over-voltage, under-voltage, over-current, and temperature protection functions. The compact modular design also simplifies installation, maintenance, and long-term system reliability for industrial applications.

Successful Conversion Cases

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One of our customers from Russia is currently using our 96V 15KW PMSM electric powertrain solution for a short-distance heavy transport vehicle electrification project, including applications such as industrial tow tractors, tugger trains, airport baggage tractors, and yard logistics vehicles.

The project is now in the integration stage, and we are looking forward to receiving operational feedback and field performance data soon.

This solution combines:

  • 96V high-efficiency PMSM motor system
  • Peak torque: 170 N·m
  • Rated speed: up to 7000 RPM
  • Air-cooled design for reliable thermal performance
  • High low-speed torque output
  • Compact and robust structure
  • Quiet and zero-emission operation
  • Lower operating and maintenance costs compared with traditional fuel systems

Electric heavy transport vehicles are widely used in modern industrial logistics, especially in:

  • Factories
  • Airports
  • Warehouses
  • Ports
  • Industrial parks

Green Motor Tech provides complete EV powertrain solutions for short-distance heavy transport equipment, including:

  • Electric motors and controllers
  • Battery systems
  • Chargers and DC-DC converters
  • Rear axle customization
  • Gear ratio optimization
  • Customized PCD solutions
  • Complete powertrain integration support

If you are working on industrial transport electrification projects, we can support you with customized EV solutions based on different platforms and working conditions.

Contact us for a more complete retrofit

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