How to Convert a Traditional Diesel Loader into a Pure Electric Loader

Loaders are widely used in building construction, road construction, ore loading, port cargo handling, warehousing and logistics, municipal garbage cleaning, and other areas. This is due to their powerful loading and handling capabilities, which significantly boost work efficiency and reduce labor intensity. To save energy and reduce operating costs, an increasing number of steel mills, coal plants, sand and gravel plants, and mining companies are exploring truck conversion solutions, particularly by transitioning their loaders to environmentally friendly electric drives.

Brogen's electric loader truck conversion solution

Brogen has now mastered mature loader electrification conversion technology and has extensive experience. We offer two electrification conversion options for loaders. The pure electric program is recommended for a wide range of work and non-uniform working conditions. We are pleased to introduce our pure electric loader conversion program.

The engine is replaced with a motor, the torque converter is retained, and the remaining engine accessories are reselected and reconfigured.

The motor is a dual-axis extension motor. One side connects to the torque converter gearbox, while the other side links to the air conditioning compressor, generator, and pump via a pulley.

The entire modification is cost-effective, minimizing costs while maintaining high performance.

The motor’s outer transition flange directly connects to the torque converter housing, fitting most 50 loader models.

The motor’s output shaft can be mounted on the original flywheel via an adapter shaft, then connected to the torque converter’s flexible plate, matching the engine’s interface.

The motor’s rear output shaft connects to the generator, air conditioning compressor, and air pump through a belt, ensuring normal operation of the vehicle’s low-voltage electrical, air conditioning, and braking systems.

We use an all-in-one controller for higher integration and space-saving arrangement.

The battery has a capacity of 282kWh, allowing continuous operation for about 5 hours on a full charge and a full recharge time of 1 hour.

Technical specifications of 150 kW PMSM motor

Technical specifications of motor controller

Technical specifications of 282 kWh battery pack

After electrification, operating costs are significantly reduced. For example, operating 12 hours a day with a diesel consumption of 20 liters per hour, you can save 7,200 liters of fuel per month. The benefits are considerable, greatly reducing operational costs.

Contact Brogen

If you need to electrify your engineering fleet, please contact us. We will provide a suitable solution for you. Reach out to our experts at inquiry@brogenmotors.com. We promise to get back to you within two business days.

Brogen is a leading ev solutions provider for commercial vehicles. You can find more ev solutions in our website, for example, electric vehicle powertrain solution, battery solution, and electric axle systems. Beside that, we have the cutting-edge axial flux motors for Automakers, who pursue excellent engine performance. We are proud to serve as your one-stop solution for navigating the rapidly expanding electric vehicle (EV) market.

For more videos please click Brogen’s Youtube. For the latest news please view Brogen’s Linkedin. Please note that our products are not ready-made or plug-and-play type. Depending on customers' different requirements, it may involves many customizations and modifications.