Converting a 4-ton truck from petrol to electric involves replacing the internal combustion engine (ICE) with an electric motor, along with upgrading the vehicle’s powertrain. The process includes selecting a suitable electric motor with the required power output, installing a battery pack to provide sufficient range, and integrating an inverter and controller for managing the power delivery. Key considerations include the truck’s Gross Vehicle Weight (GVW), load capacity, and intended range. This conversion significantly reduces emissions and operational costs, making the vehicle more eco-friendly and efficient. Additionally, the conversion may include modifying other systems like the cooling, braking, and charging systems to optimize performance.
Before installing the new electric system, it is necessary to determine the parts that need to be removed, as follows:
- The old diesel engine
- In this case, the old transmission gearbox needs to be removed too. we provide 50kw rated motor with a double ratio gearbox to make the truck to acheive a powerful torque and good speed (up to 91kph, check attached video) after conversion.
3. The power steering, brake pump, and air conditioning compressor driven by the fuel engine
4. On the other hand, when installing new electronic components, the first thing to consider is how to fix these parts. Unlike the original parts that have mounting interfaces matching the original vehicle chassis, new parts often require new brackets for support and fixing. So, after fully measuring the size (he had to calculate the size needed after all the accessories were installed, so that the subsequent stacking of parts would not be insufficient), Zool custom-made a parts bracket locally to support the installation of the new assembly.
Parts Included in the 4-Ton Truck Conversion Kit
- (1).PMSMMotor
- (2)Electric Motor Controller
- (3).DC to DC Converter
- (4).Car Dashboard Display
- (5).Lithium Battery Charger for Electric Vehicles
- (6).12V vacuum pump booster
- (7).LeFePO4battery cell PACK
- (8) Wire harness
- (9) gearbox
The motor is in the original position of combustion engine by using spline coupler and adapter plate to fix motor with original transmission; Meanwhile, motor controller is liquid cooling type to avoid motor heating problem during drive.
When choosing the model of the motor, you can consider motor power, cooling method, torque, rotation speed, max speed & mileage per full charge after conversion, battery voltage, space of the components and car original space, kit price etc to make a final most suitable solution.
You need to know clearly how fast you want the car to travel after modification. What’s the horsepower of the original engine? What’s the layout of the original engine? In this case, the truck has a front engine, rear wheel drive drivetrain layout
This high efficiency intelligent charger is designed to meet the charging needs of power batteries for electric vehicles. This series of products adopt LLC resonance, active power factor correction, microcomputer measurement and control, full digital setting, full airtight waterproof and many other most advanced high frequency switching power supply technology and process design.
With: wide input voltage range, universal global voltage; The input power factor is up to 0.99, which significantly reduces the input current, thus reducing the cable heating. It can be safely used in the home distribution system. Low harmonic current, low interference to other electrical equipment ; Power switch to achieve a wide range of soft switch, high conversion efficiency and small electromagnetic interference, use time can save money; According to IP66 protection grade design, high waterproof performance; Small volume, light weight, quiet work, beautiful appearance, simple process, standardized production, high reliability, simple installation, operation, maintenance and other characteristics.
USES the microcomputer measurement and control technology, embedded CPU can accurately detect the various states of battery, the advanced hiNengDuo sections of charging model can prevent the battery overcharge, owe charging, minimizing rechargeable batteries overheating caused by water loss phenomenon, slow down the battery discharge phenomenon caused by the plate, prolong the service life of battery. When the battery is fully charged, the charger will stop automatically.
With the functions of temperature compensation, automatic shutdown at full charge, battery reverse connection protection, output short circuit protection, output overvoltage protection, ac input overvoltage protection, overheat protection and so on, it is safe and reliable to use.
In conventional fuel vehicles, the vacuum assisted brake pump uses the vacuum generated by the engine intake manifold to provide power.
In the process of changing from oil to electricity, the vehicle power system is changed from a fuel engine to an electric drive system, but the brake system still needs help to ensure that the driver can easily press the brake pedal. The vacuum assisted brake pump can maintain this assisted function.
Compatible with the original braking system
Oil to electric conversion kits usually want to use as much of the braking system components of the original vehicle as possible. As an important part of the original brake system, the vacuum booster brake pump can be well compatible with brake pipe, brake caliper and other components.
Lithium batteries are the core power components of electric vehicles.
Compared with traditional fuel engines, lithium batteries can provide a quieter and smoother power output for the vehicle. This is because the operation characteristics of the motor are not like the vibration and noise in the combustion and mechanical transmission process of the internal combustion engine, making the driving experience of electric vehicles more comfortable during the driving process.
The double ratio gearbox has gear ratios of 1:1 and 2.3:1
Successful Conversion Cases We've Delivered for Our Clients：
Questions About 4-Ton Truck Conversion
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.
Contact us for a more complete retrofit
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Before installing the new electric system, it is necessary to determine the parts that need to be removed, as follows:
- The old diesel engine
- The 70kw motor is a direct drive motor and the old transmission system need to be removed, connecting the motor with original drive axle by a flange or adapter, then drive axle to the original rear axle.
3. The power steering, brake pump, and air conditioning compressor driven by the fuel engine
4. On the other hand, when installing new electronic components, the first thing to consider is how to fix these parts. Unlike the original parts that have mounting interfaces matching the original vehicle chassis, new parts often require new brackets for support and fixing. So, after fully measuring the size (he had to calculate the size needed after all the accessories were installed, so that the subsequent stacking of parts would not be insufficient), Zool custom-made a parts bracket locally to support the installation of the new assembly.
