Conversion of Combustion Forklift to Electric

This technical bulletin details the conversion of a combustion-powered Hyster H40-60XT forklift to an electric model, performed by Mercosul Motores Elétricos. The conversion involved replacing the combustion engine and its associated components with a high-performance electric propulsion system, providing a sustainable and economically viable solution for forklift operations.

Components of the Electrification Kit

The electrification kit developed by Mercosul Motores Elétricos includes the following main components:

• Electric Motors:

  • Traction Motor: Three-phase induction motor with a power output of 10.8 HP (8 kW), powered by 34 VAC at 53 Hz. Responsible for the movement of the forklift.

  • Hydraulic Unit Motor: Three-phase induction motor with a power output of 13.6 HP (10 kW), powered by 34 VAC at 80 Hz. Drives the hydraulic pump, which handles functions such as load lifting and accessory movement.

• Battery: LFP (Lithium Iron Phosphate) battery with a current of 90 Ah and a voltage of 51.2 V. The battery capacity can be customized according to the specific needs of each application.

• Controllers: Curtis Instruments equipment, responsible for controlling the speed, torque, and other functions of the electric motors, ensuring optimized and efficient performance.

• Charger: AC battery charger, designed to ensure fast and safe battery charging.

• Accessories: Battery hour meter and electronic accelerator.

Technical Specifications of the Components

• Electric Motors: Both motors are constructed with aluminum housings, providing lightness and high heat dissipation. The choice of frequency and voltage supply was optimized to ensure high torque and a fast response to operator commands.

• Battery: The LFP battery offers high energy density, long service life, and excellent performance under various operating conditions. LFP technology is known for its safety and thermal stability.

• Controllers: Curtis Instruments controllers are widely used in industrial applications and offer a broad range of functionalities, such as protection against overloads, short circuits, and excessive temperatures.

Benefits of the Conversion

Converting combustion forklifts to electric offers several advantages from both economic and environmental perspectives:

• Cost-Benefit:

  • Significant Savings: Conversion is generally more economical than purchasing a new electric forklift, as it reuses existing mechanical components.

  • Asset Value Increase: The converted forklift has a higher market value and an extended service life.

• Sustainability:

  • Reduced Environmental Impact: Lower greenhouse gas emissions contribute to improved air quality and mitigate climate change effects.

  • Circular Economy: The conversion promotes the reuse of equipment, reducing waste generation and the consumption of natural resources.

Conclusion

The conversion of combustion forklifts to electric represents an innovative and sustainable solution for modernizing fleets of material handling equipment. Mercosul Motores Elétricos, through its electrification kit, offers a complete and customized solution that meets the specific needs of each customer. The technology employed ensures high performance, reliability, and durability, making the conversion an attractive option for companies seeking to optimize processes and reduce operational costs.

Note: This technical bulletin aims to clearly and concisely present the technical characteristics and benefits of the conversion of combustion forklifts to electric performed by Mercosul Motores Elétricos.

Author: Alexandre Sesti (Engineering Coordinator)