Electric Conversion for Diesel Fleet: Scalable 96V and 144V Electric Drive Systems
As fuel costs, maintenance expenses, emissions regulations, and environmental requirements continue to increase, fleet operators are looking for practical ways to reduce the operating cost of diesel vehicles without completely replacing their existing fleet.
Electric conversion for diesel fleets provides an effective solution. Instead of purchasing a new electric vehicle, existing diesel vehicles can be converted to electric power by replacing the internal combustion engine and related fuel-system components with an electric drive system and battery pack.
For fleet operators, this approach offers an important advantage: the existing vehicle platform, chassis, body, and working equipment can often be retained, while the powertrain is upgraded to electric.
Green Motor Tech provides scalable electric drive systems for different vehicle sizes and operating conditions, including 96V 15kW, 96V 20kW, 144V 25kW, and 144V 40kW systems.
Why Convert a Diesel Fleet to Electric?
Many commercial and industrial vehicles have predictable routes, fixed operating areas, and relatively high annual operating hours. These characteristics make them excellent candidates for electrification.
Compared with a conventional diesel powertrain, an electric drive system can provide:
- Lower energy and fuel costs
- Reduced routine maintenance
- Zero tailpipe emissions
- Lower noise and vibration
- Instant electric motor torque
- Simplified powertrain architecture
- Better suitability for low-speed and stop-and-go operation
- Potential for regenerative braking
- Easier integration with fleet charging infrastructure
For vehicles operating inside factories, warehouses, ports, campuses, industrial parks, farms, resorts, airports, or other controlled environments, electric conversion can be particularly attractive.
Instead of replacing an entire fleet, operators can begin with several pilot vehicles, evaluate real-world performance, and then gradually expand the conversion program.
A Scalable Electric Drive Platform
Different fleet vehicles have very different requirements. A small utility vehicle does not need the same powertrain as a heavy-duty commercial vehicle.
This is why we offer multiple voltage and power configurations.
96V 15kW Electric Drive System
The 96V 15kW system is designed for compact and light-duty vehicles where moderate power and efficient operation are the priority.
Typical applications include:
- Small utility vehicles
- Light commercial vehicles
- Airport and industrial vehicles
- Campus transportation vehicles
- Small trucks
- Low-speed logistics vehicles
- Agricultural and special-purpose vehicles
The 96V platform provides a practical balance between system voltage, cost, packaging, and performance.
For fleet operators starting their electrification journey, the 15kW system can be a cost-effective solution for vehicles with relatively low speed and payload requirements.
96V 20kW Electric Drive System
For vehicles requiring more acceleration and higher load-handling capability, the 96V 20kW system provides an additional performance margin.
It is suitable for applications such as:
- Light trucks
- Delivery vehicles
- Utility trucks
- Small agricultural vehicles
- Industrial transport vehicles
- Passenger shuttles
- Special-purpose vehicles
The system can deliver strong low-speed torque, which is particularly useful for commercial vehicles that frequently start, stop, climb ramps, or operate with changing loads.
For fleet applications, the 96V 20kW platform can also be configured according to the original vehicle’s transmission, differential ratio, wheel size, target speed, and payload.
144V 25kW: A Higher-Voltage Solution for Commercial Vehicles
When vehicle weight, operating speed, range, or continuous-load requirements increase, moving to a higher-voltage platform can provide significant advantages.
Our 144V 25kW electric drive system is designed for medium-duty conversion projects where more performance is required while maintaining a relatively compact and cost-effective system architecture.
Typical applications include:
- Medium-size commercial vehicles
- Pickup trucks
- Light-duty trucks
- Utility vehicles
- Agricultural vehicles
- Industrial vehicles
- Special-purpose vehicles
Compared with a lower-voltage system delivering the same power, a higher-voltage architecture can reduce the current required by the motor and controller.
Lower current can help reduce electrical losses and thermal stress in cables, connectors, busbars, and power electronics.
This makes the 144V platform an attractive option for vehicles that operate for extended periods or under relatively high loads.
144V 40kW: For Larger and More Demanding Fleet Vehicles
For heavier vehicles and applications requiring stronger acceleration, higher climbing performance, and greater continuous power, our 144V 40kW electric drive system provides a significant step up in capability.
The system is suitable for applications such as:
- Medium-duty trucks
- Larger utility vehicles
- Pickup and commercial vehicles
- Agricultural machinery
- Industrial vehicles
- Special-purpose vehicles
- Heavy-duty vehicle conversion projects
A 40kW electric motor can provide substantially more usable low-speed torque than a conventional diesel engine operating at low RPM, making it well suited to vehicles that frequently operate under load.
The 144V 40kW platform can also be engineered around the original drivetrain. Depending on the vehicle, the electric motor can work with the original manual transmission, automatic transmission, reduction gearbox, or a customized direct-drive/reduction solution.
More Than Just an Electric Motor
Fleet electrification is not simply a matter of replacing a diesel engine with an electric motor.
A successful conversion requires the complete electric powertrain to work together.
Our electric conversion systems can integrate key components including:
Electric Motor + Motor Controller + VCU + DC-DC Converter + Battery System + Charger + Display/HMI + Wiring Harness + Auxiliary Systems
The motor and controller are matched according to the required operating conditions. The VCU manages vehicle-level control, while the battery and BMS provide the necessary energy and protection functions.
This integrated approach helps simplify engineering and makes the conversion process more repeatable when the same vehicle model is used across a fleet.
From One Prototype to an Entire Fleet
One of the biggest challenges in fleet electrification is scalability.
A conversion that works on one vehicle must also be practical to reproduce on 10, 50, or 100 vehicles.
Our approach is to first evaluate the original diesel vehicle, including:
- Vehicle weight
- Payload
- Maximum speed
- Differential ratio
- Tire size
- Operating cycle
- Gradeability
- Daily mileage
- Average energy consumption
- Available installation space
- Existing transmission
- Auxiliary electrical loads
Based on these parameters, we can recommend an appropriate power and voltage platform.
For example:
96V 15kW → Compact and light-duty fleet vehicles
96V 20kW → Light commercial and utility vehicles
144V 25kW → Medium-duty and higher-load applications
144V 40kW → Larger commercial and demanding work vehicles
The exact system configuration can then be optimized according to the actual vehicle and operating conditions.
A Practical Path Toward Fleet Electrification
Diesel-to-electric conversion does not have to happen all at once.
A practical fleet electrification strategy can start with a pilot conversion, followed by real-world testing and data collection.
Operators can evaluate:
- Energy consumption per kilometer
- Battery range
- Charging time
- Vehicle performance
- Gradeability
- Maintenance requirements
- Driver feedback
- Total operating cost
Once the pilot vehicles meet the required targets, the same engineering platform can be standardized for additional vehicles.
This creates a gradual transition from diesel fleet → pilot electric vehicles → standardized conversion platform → large-scale electric fleet.
Conclusion
Electric conversion for diesel fleets is not only about replacing fuel with electricity. It is about creating a more efficient, quieter, cleaner, and potentially more economical vehicle platform while maximizing the value of existing fleet assets.
With scalable 96V 15kW, 96V 20kW, 144V 25kW, and 144V 40kW electric drive systems, Green Motor Tech can support a wide range of diesel-to-electric conversion projects.
Whether you are converting a small utility vehicle, a light commercial truck, an agricultural vehicle, or a medium-duty fleet, we can help evaluate the original vehicle and develop a suitable electric powertrain.
Start with one vehicle. Prove the technology. Standardize the solution. Then electrify the fleet.
