Merlo – Hybrid-Electric Telehandler for Agricultural and Industrial Use
Sector: Agriculture / Industrial Lifting
End Client: Merlo S.p.A.
Project Summary
FACOS developed a custom hybrid-electric traction system for a Merlo telescopic handler, aimed at reducing fuel consumption and emissions without compromising performance or autonomy.
The vehicle operates in three modes: diesel, hybrid, and full-electric.
This solution received the Gold Medal for Technological Innovation at Agritechnica in Hannover in 2013, the world’s leading agricultural innovation trade fair.
Background
In the agricultural and industrial sectors, demand is growing for low-emission or zero-emission machines, especially for use in enclosed environments such as greenhouses, barns, or warehouses.
Merlo required a system that could be integrated into an existing chassis, offering operational flexibility, diesel-equivalent power, and environmental compatibility.
Client Requirements
- Reduce emissions and fuel consumption in indoor workspaces
- Maintain hydraulic power and movement precision
- Enable operation in diesel, hybrid, and electric modes
- Ensure seamless integration on an existing frame
- Support continuous full-shift operation
FACOS Solution
FACOS delivered a fully integrated electric system including:
NAUTY 800 → programmable brushless drive, liquid-cooled
BatteryPack LiFePO₄ – 80V / 170Ah → high-power, self-heating modular battery
EPM800 → safety interface with DC-DC converter and pre-charge logic
Custom CAN interface for control of both hydraulic and electronic functions
Key FACOS Technologies
- High-performance drive for heavy-duty loads
- Liquid cooling for reliable operation
- Modular high-density battery pack
- CANbus connectivity for diagnostics and system control
- Award-winning system for technological innovation
Results Achieved
- ✅ Zero emissions in indoor work areas
- ✅ Diesel-comparable power and performance
- ✅ Full-shift operating range
- ✅ Smooth and precise movement control
- ✅ International recognition at Agritechnica