Conversion kit for warehouse tuggers tractors

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warehouse tuggers tractors

Conversion kit for warehouse tuggers tractors 2 tons

Conversion Kit for warehouse tuggers tractors

48V DC Electric Warehouse Tow Tractor Drive System Solution

1.5T – 2T Standing-Type Low Speed Towing Tractor Project Case

Since 1995, GREEN MOTOR TECH has specialized in electric vehicle powertrain systems, electric utility vehicles, and customized low-speed industrial mobility solutions.

This project is developed for a 1.5–2 ton standing-type warehouse towing tractor, designed for logistics parks, warehouses, factories, airports, and industrial material transportation applications.

Parts Included in the Conversion kit for warehouse tuggers

🧩 Vehicle Support Systems

We can also provide you with other modification parts, or customize modification solutions for you, please contact us
DC48V 2200W transaxle and controller
DC Motor + Transaxle System

The tractor uses a 2200W 48V DC drive motor combined with a compact transaxle assembly to provide:

  • High starting torque
  • Stable low-speed operation
  • Smooth acceleration
  • Reliable warehouse transportation performance

The integrated transaxle structure simplifies chassis installation and reduces drivetrain complexity for prototype development.

Drive System Configuration

Item Specification
Vehicle Type Standing-Type Warehouse Tow Tractor
Load Capacity 1.5 – 2 Tons
Motor Type DC Motor
Motor Power 2200W
System Voltage 48V DC
Transaxle Integrated DC Transaxle
Controller 48V DC 130A
Battery Type Lithium Battery Pack
Battery Specification 51.2V 54Ah
Battery Energy 2.7648 kWh
Charger 48V 10A
Charging Time Approx. 5.4 Hours
Wheels Ø250mm Wheels with Rim & Hub
Steering System Handle Bar with Steering Column
Electrical System Complete Wire Harness + Key Switch + DC-DC Converter
500W 48V to 12V High Efficiency DC DC Converter for Reliable Power Regulation 4
DC-DC Converter for Conversion kit for warehouse tuggers

DC-DC converter typically falls into three voltage levels: low voltage platforms such as 48V and 72V, which are suitable for light-duty equipment and offer advantages in cost and safety but are limited in power output; medium voltage platforms including 96V, 144V, and 192V, which represent the mainstream solution and are widely used in applications such as baggage tractors, belt loaders, and small service vehicles; and high voltage platforms ranging from 300V to 600V or higher, typically used in aircraft tow tractors, large loading equipment, and high-demand systems such as GPU and air conditioning units, offering higher power capability and 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 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 warehouse tuggers

In airport Ground Support Equipment (GSE) electrification projects, the power requirement typically ranges from low to high power depending on the application. For towing equipment, power demand includes baggage tractors (5–15 kW), cargo tractors (10–30 kW), and aircraft tow tractors (50–200+ kW). For loading equipment, belt loaders usually require 5–20 kW, while container loaders operate in the range of 20–60 kW. For service equipment, ground power units (GPU) typically require 30–120 kW output power, and air conditioning units range from 20–80 kW.

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 warehouse tuggers

Charging System

48V 10A Smart Charger

Estimated charging time:

54Ah÷10A≈5.4 hours54Ah \div 10A \approx 5.4\,hours

The charging system is suitable for daily industrial operation and overnight charging schedules.

pack
Space-Optimized Battery Packs for Conversion kit for warehouse tuggers

Lithium Battery System

The vehicle is powered by a:

51.2V 54Ah Lithium Battery Pack

Battery capacity:

51.2V×54Ah=2.7648 kWh51.2V \times 54Ah = 2.7648\,kWh

Advantages include:

  • Longer service life
  • Maintenance-free operation
  • Lightweight structure
  • Fast charging capability
  • Stable voltage output

Project Overview

The customer required a compact and reliable electric drive system for a low-speed towing tractor with the following targets: Towing capacity around 1.5–2 tons Compact standing-type chassis High torque at low speed Lithium battery powered Easy integration for prototype development Complete wiring system for first sample build GMT supplied a complete electric drivetrain package including motor, transaxle, controller, battery system, charger, steering components, and wiring harness.

Successful Conversion Cases

handle bar
front steering wheel
tractor

Wheel & Hub Assembly

GMT supplied:

  • Ø250mm wheels
  • Rim and hub assembly
  • Direct mounting compatibility with the transaxle

This configuration improves installation efficiency and ensures stable traction performance for warehouse floor conditions.


Wire Harness Development

For the first prototype stage, GMT supplied:

  • Complete handmade wire harness
  • Key switch system
  • DC-DC converter integration
  • Pre-configured electrical connections

Because prototype projects require flexible electrical layouts, the initial harness was produced manually for rapid development and testing.

For mass production, the harness can be converted into batch manufacturing with standardized connectors and optimized production processes.


Steering System Development

The first prototype includes:

  • Handle bar steering system
  • Custom steering column fabrication

GMT supports customers during prototype engineering stages by providing customized steering structures suitable for compact industrial vehicles.

Application Scenarios

This electric towing tractor drive solution is suitable for:

  • Warehouse logistics
  • Airport cargo transportation
  • Factory material handling
  • Industrial towing vehicles
  • Indoor low-speed transportation
  • Distribution center operations

GMT Custom EV Drivetrain Capabilities

GREEN MOTOR TECH provides:

  • Electric motors
  • Transaxles
  • Controllers
  • Lithium battery systems
  • Vehicle wiring harnesses
  • Steering systems
  • Complete EV drivetrain integration

We support:

  • Prototype development
  • Small batch production
  • OEM & ODM projects
  • Customized industrial vehicle solutions

With over 20 years of EV manufacturing experience, GMT focuses on reliable quality, stable performance, and practical electric mobility solutions for global customers.

Questions About Conversion kit for warehouse tuggers

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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