One crate · motor, controller, battery, harness and brackets all included7 standard items per crateSamples in 3 – 5 days3,500 cycles · 5-year warrantyNo pricing on this page — quotations govern

Conversion kit with battery: where the money goesthe pack is usually the largest line, and the fastest to jump a tier

Q: Why does the battery usually dominate the total cost?

Three reasons. Only the pack gets more expensive on two axes at once — daily distance sets capacity while payload and gradients set continuous and peak current. Only the pack carries a service life and a whole-pack warranty (3,500 cycles, warranted 5 years / 3,500 cycles at 1C charge and discharge to ≥80% SOH). And only the pack is a dangerous-goods item, with UN38.3, MSDS and the Class 9 packing certificate attached to it. That is why raising the platform voltage or adding a capacity tier lifts the total mainly through the pack.

Q: How long does the battery last and how is it warranted?

At 3,500 cycles and one charge/discharge per day the theoretical life is roughly 7–9 years. The warranty is 5 years / 3,500 cycles (1C charge and discharge to ≥80% SOH). Real life depends on depth of discharge, ambient temperature and charging policy — in hot climates keep charging below 0.5C.

The direct answer: inside a kit with battery, the LiFePO4 pack is usually the single largest share of the total, because it sets both range (energy) and loaded gradient capability (current). It is the only item carrying a 3,500-cycle service life and a whole-pack warranty term, and the only dangerous-goods item that ships with UN38.3, MSDS and a Class 9 packing certificate. The motor and controller follow, while DC-DC, cluster, harness and brackets are low-value but non-optional. Labour and calibration depend on who does the build. This page covers the cost structure and the tier steps only — no monetary figure is quoted here; the formal quotation governs.

battery_charging_full

Battery platforms48V / 60V / 72V

bolt

Motor tiers1000W – 2000W

inventory_2

Standard items7 per crate

schedule

Sampling lead time3 – 5 days

request_quoteGet a quote for the kit with battery battery_charging_fullSee what is in the crate

verifiedCost structure and build tiers follow the published kit list; the final price moves with capacity, cell grade and the document set, and the formal quotation governs.

Technician installing a LiFePO4 pack and controller into a three-wheeler

account_balance_walletWhere the money goes

Eight components and the role each one plays in the cost

Inside one crate some money buys drive, some buys service life and some buys build speed. Once each part role is clear, it becomes obvious what can be trimmed and what cannot. No monetary figure appears here — only structure and relative weight.

boltDrive motor

Sets launch torque, loaded gradient ability and top speed. Cost follows the power tier and the architecture: a 2.5kW hub motor is the simplest build and leaves the original transmission alone, while a 3.5–5.0kW mid-drive PMSM makes more torque for heavy or hilly routes. Motors are tiered by displacement and payload and tiers cannot be mixed, so this line rises with the tier.

memoryVector FOC controller

Sets launch torque, top speed and gradient ability. Its current limit must be aligned to both the motor rating and what the pack can deliver continuously (150–250A at platform level). This is the easiest place to save wrongly: a mismatch with the pack trips over-current protection under a loaded climb and the vehicle cuts out.

battery_charging_fullMotive battery pack (usually the largest line)

The pack normally takes the largest share of the total for three reasons. First, it is the only part that gets more expensive on two axes at once — daily distance sets capacity (kWh) while payload and gradients set continuous and peak current (A). Second, it is the only part carrying a service life and a whole-pack warranty commitment (3,500 cycles, 1C charge and discharge to ≥80% SOH, warranted 5 years / 3,500 cycles). Third, it is the only dangerous-goods item, so UN38.3, MSDS and the Class 9 packing certificate all sit on it. That is why moving from 60V to 72V and up a capacity tier lifts the total mainly through this line.

electrical_servicesDC-DC step-down module

An independent 12V supply isolated from the main circuit by dual fuses, feeding headlight, horn, indicators and cluster. The part itself is inexpensive, but omitting it — or tapping 12V straight off the bus — burns the lighting assembly and cluster the moment the lights come on.

speedInstrument cluster / LCD

Displays voltage, SOC, speed and gear, versioned by platform voltage, and drops into the original instrument position with SOC calibrated to the BMS before dispatch. Cutting this line does not save money, it removes the ability to judge remaining charge and manage shift distance.

cablePlug-and-play harness

A pre-formed modular flame-retardant loom with an ignition-lock relay and keyed IP67 connectors that plugs into the factory ignition, headlight and brake light. It sets both build time and failure rate: with a proper loom two technicians finish a vehicle in 35–45 minutes, while hand-spliced joints bring heat build-up and short-circuit risk.

hardwareAdapter bracket / stamped mount

A 3mm galvanised heavy-duty bracket with grade 10.9 bolts and anti-vibration pads, verified to 3G, locking into the original chassis holes. Mainstream platforms have dedicated tooling and are selected directly by vehicle; non-standard vehicles need a 3D chassis reverse scan and custom brackets, which is where both cost and lead time move.

engineeringLabour and calibration

The kit ships as a turnkey assembly crate and does not include conversion labour: your own bay can build it, or you can request resident engineer coaching. Calibration is the part most often overlooked — writing payload and wheel-diameter parameters, hall self-learning, cluster SOC calibration and the loaded road test. Skip it and speed and state-of-charge readings will be visibly wrong.

checklistWhat is in the crate

What is included and what is not, item by item

Included rows state what happens if the part is missing. Excluded rows are not oversights: they must be sourced locally or added to the order, so confirm every line before you place it.

7 standard items

Item	Included in the kit	Specification	What you need to know
Drive motor	Included	2.5kW hub motor, or 3.5–5.0kW mid-drive PMSM (4.2–9.5kW peak)	Tiered by original displacement and payload; tiers cannot be mixed
Vector FOC controller	Included	Fully potted IP67, electronic brake energy recovery, upper-computer calibration	Current limit is aligned with pack discharge capability before dispatch
LiFePO4 battery pack	Included	48V / 60V / 72V, steel case with potted BMS bay, Tier-1 A-grade cells	Capacity tiered on daily distance and payload; no second-life or salvaged cells
DC-DC step-down module	Included	Independent 12V supply, isolated from the main circuit by dual fuses	Feeds headlight, horn, indicators and instrument cluster
Instrument cluster / LCD	Included	Voltage, SOC, speed and gear display, versioned by platform voltage	Drops into the original position; SOC calibrated to the BMS before dispatch
Plug-and-play harness	Included	Pre-formed modular flame-retardant loom, ignition-lock relay, keyed IP67 connectors	Plugs into the factory ignition, headlight and brake light without touching the original loom
Adapter bracket / stamped mount	Included	3mm galvanised bracket, grade 10.9 bolts and anti-vibration pads, verified to 3G	Locks into original chassis holes; non-standard vehicles need a scan for custom tooling
Dedicated CC-CV charger	Optional, by order	10–40A, matched to the platform voltage with BMS handshake	Not included as standard — specify on the order. Never substitute a lead-acid charger
Quick-release / swap structure	Optional, by order	Quick-release handle or a BMS version that handshakes with swap cabinets	Recommended for double-shift fleets; must match the swap cabinet protocol
Tyres / brake shoes / body panels	Not included	Vehicle wear parts and body components	Sourced locally to suit the vehicle; we do not ship these with the kit
Conversion labour	Not included	The kit ships as a turnkey assembly crate	Your own bay can build it, or request resident engineer coaching
Local registration and approvals	Not included	Belongs to destination market approval	We supply the technical dossier to support your filing; destination law governs
Old lead-acid disposal	Not included	A local environmental recycling process	Please arrange compliant recycling in the destination country

Excluded items can still be arranged: charger and quick-release structure can be added to the crate, and resident engineer training is quoted against fleet size. Lead-acid recycling and registration must be completed locally.

Specification notice:The figures above are engineering reference values. They may differ with production batch, configuration and actual duty cycle, and the percentages for life, efficiency, availability and coverage are engineering estimates and bench references. Contact us for the detailed specification sheet.

tuneThree build packages

Three tiers: how the cost structure shifts at 1000W, 1500W and 2000W

Stepping up a tier is not a single line increase: motor, pack and controller move together. The table states where each tier concentrates its spend.

Sixty volt & seventy-two volt

Package	Motor rating	Battery voltage and capacity	Where the cost structure shifts	Target range	Typical duty
Light duty	1000W (2.0kW peak)	60V 50 – 60Ah (≈ 3.0 – 3.6 kWh)	Smallest pack and lowest controller rating; spend concentrates in the motor and harness	70 – 90 km	Short delivery and community shuttles, 40 – 60km a day, mainly flat
Standard duty	1500W (3.5kW peak)	60V 105Ah (6.3 kWh)	Capacity nearly doubles against light duty, so the pack becomes the main line while the motor steps up with it	110 – 130 km	Full-day passenger taxi work, 90 – 120km a day, with moderate gradients
Heavy duty	2000W (4.2kW peak)	72V 120 – 150Ah (8.64 – 10.8 kWh)	Platform voltage rises to 72V with a larger pack and a bigger motor, so pack and motor step together and controller and harness ratings rise with them	95 – 150 km	Loaded haulage and frequent gradients, 500 – 800kg payload

Capacity is reviewed against your real duty cycle and the ranges above are targets — add roughly 20% headroom over daily distance. Light duty converts at about 50 Wh/km; standard duty from the published 65–80 Wh/km passenger average and heavy duty from 95–125 Wh/km heavy-cargo average. Payload, gradient, tyre pressure and riding style all move the result.

compare_arrowsBundled vs self-sourced battery

Sourcing the pack yourself, or buying the kit complete

warning

Kit only, battery sourced locally

Split procurement

cancelMatching riskYou must verify the controller current limit against the BMS protection point; a mismatch cuts out under loaded gradient work
cancelResponsibilityBattery faults and kit faults sit with two suppliers, so diagnosis turns into an argument first
cancelProtocol and displayCluster SOC and BMS data may not interoperate, leaving a visible state-of-charge error
cancelShipping documentsUN38.3, MSDS and the packing certificate are yours to arrange; one missing document holds the container at port
cancelLead timeTwo shipments arrive separately and the build cannot start until both land
cancelWarrantyTwo warranty terms run in parallel and cannot be consolidated into one document

Self-sourcing works, but it assumes your team can size a pack and clear a lithium shipment.

verified

Kit with the battery included

Single responsible supplier

check_circleMatching riskMatched before dispatchController current limit, BMS protection point and keyed harness calibrated kit by kit
check_circleResponsibilityOne responsible supplierMotor, controller, pack, harness and cluster under a single warranty term
check_circleProtocol and displayCluster SOC and BMS data interoperate, calibrated against typical behaviour
check_circleShipping documentsFull set with the containerUN38.3, MSDS and the dangerous-goods packing certificate (Class 9) ship together
check_circleLead timeSamples in 3 – 5 daysAbout 180 three-wheeler packs per 20GP, 320+ per 40HQ, arriving as one container
check_circleWarranty5 years / 3,500 cycles1C charge and discharge to ≥80% SOH

The price of one crate is that the vehicle type and capacity must be right first — which is why we always sample before the container order.

helpCost structure FAQ

Kit with battery cost: six common questions

What exactly is included, and what is not?expand_more

Seven standard items: drive motor, vector FOC controller, LiFePO4 battery pack, DC-DC step-down module, instrument cluster, plug-and-play harness and the adapter bracket. Two optional items: dedicated CC-CV charger and quick-release or swap structure. Four items are explicitly not included: tyres / brake shoes / body panels, conversion labour, local registration and approvals, and old lead-acid disposal.

Why does the battery usually dominate the total cost?expand_more

Three reasons. Only the pack gets more expensive on two axes at once — daily distance sets capacity while payload and gradients set continuous and peak current. Only the pack carries a service life and a whole-pack warranty (3,500 cycles, warranted 5 years / 3,500 cycles at 1C charge and discharge to ≥80% SOH). And only the pack is a dangerous-goods item, with UN38.3, MSDS and the Class 9 packing certificate attached to it. That is why raising the platform voltage or adding a capacity tier lifts the total mainly through the pack.

How do the three tiers step up?expand_more

Light duty is 1000W at 60V 50–60Ah, with spend concentrated in the motor and harness. Standard duty is 1500W at 60V 105Ah, where capacity nearly doubles and the pack becomes the main line. Heavy duty is 2000W at 72V 120–150Ah, where the platform voltage, capacity and motor all step up together and controller and harness ratings rise with them. A tier change moves several lines at once, not one.

Is it cheaper to source the battery myself?expand_more

It can save on purchase price, but it also transfers the matching risk, the protocol work and the shipping documents to you: controller current limit against the BMS protection point, cluster SOC interoperability, and UN38.3 / MSDS / packing certificate handling. Any one of them going wrong either holds the container at port or cuts the vehicle out on a loaded climb. Buying complete costs the freedom to change your mind later, which is why we sample before the container order.

Why is no price given on this page?expand_more

This page does not quote. Price moves significantly with capacity, platform voltage, cell grade and the document set that ships with the container, so a guessed range would be meaningless. Send destination port, payload, daily distance and motor rating and we model FOB / CIF pricing and container allocation. The quotation carries both the included and the excluded item lists.

How long does the battery last and how is it warranted?expand_more

At 3,500 cycles and one charge/discharge per day the theoretical life is roughly 7–9 years. The warranty is 5 years / 3,500 cycles (1C charge and discharge to ≥80% SOH). Real life depends on depth of discharge, ambient temperature and charging policy — in hot climates keep charging below 0.5C.