Boom battery conversion

Boom battery conversion

With the growing demand for low or zero emission equipment, a question that comes to mind concerns the impact on the economic life of existing diesel powered machines, especially the larger more expensive models. JLG has developed a possible solution in the form of a retrofit kit to convert diesel powered boom lifts - starting with the 66ft 660SJ telescopics - to battery electric power.

The kit uses full traction forklifttype batteries made up of 24 two-volt cells to feed the 48 volt system, and includes automatic monitoring and electrolyte top up. However, a lithium ion option will be available shortly. Surprisingly the overall weight is not affected as much as you might expect, although of the two battery types, the lead acid option is clearly heavier, but the battery locations have been designed to ensure that machine stability is not affected.

The ‘Conversion Kit’ covers two versions of the diesel powered JLG 660SJ - those built between 2015 and 2017 and post 2017 models. The conversion involves removing the engine, fuel tank and fuel lines etc. The engine is replaced with a 30kW permanent magnet AC motor which connects to the existing hydraulic pumps. A new motor controller, inverter and control system connects into the machine’s

CAN bus system, interpreting controller movements to operate the functions selected, while adjusting the motor speed to match the demand on the pump, providing smooth operation and maximum efficiency.

The battery condition is fully monitored with a battery data display screen installed within the lower control panel, to show a wide range of information including battery charge levels and energy usage chart.

The conversion has been fully tested and CE certified by a notified body and is pitched as a way to extend the working life of existing boom lifts, with some seeing this as a more environmentally positive solution than selling and shipping diesel machines half way round the world to less environmentally conscious markets. The company says: “This is intended to provide an option for our customers, it is not for everyone.”

The company chose the 660 to launch the conversion pack as it came out on top in the research the company carried out. The kit will be offered on other models, including larger booms.

So how much will this kit cost? Roughly a third of the cost of a new boom lift. Its take up will depend on how rapidly demand for all-electric machines grows, and the lead time for new electric models. While it does not offer the direct electric drive benefits of the latest allelectric boom lifts, it does offer an interesting option for fleet owners with young diesel models as their utilisation starts to fall away.