Merlo Generation 0 is Coming!!

Generation 0

For many years now, the Merlo Group has been working on various projects to
enable the world of handling to make a further leap forward, starting with a new
concept, which is simple yet revolutionary: that of Generation 0.

On 6 October, the Palace of Venaria hosted the launch of this new generation
with the presentation of the first of the many ranges that will make up Generation
0: the eWorker, Merlo’s first full-electric telehandler. This is a totally new
engineering concept that will change the way people and materials are handled.

The eWorker is the result of years of research into an alternative solution to
vehicles fitted with combustion engines. From the world’s first hybrid telehandler,
which Merlo built in the early 2000s and which allowed it to gain experience in a
new field, today the Merlo Group has taken another step forward. However, this
is not the final destination, because the new generation, called “Generation 0”,
will grow into a family of more and more technological and performing green
products, underlining the Group’s vocation to be “innovators by tradition”.


The creation of the new “Generation 0” is based on four cornerstones common to
all Merlo products:

  1. Performance – in terms of load capacity, transfer speed and boom
  2. Comfort – with the study of optimal driving positions for the operator
  3. Safety – for active and passive protection of the operator
  4. Efficiency – with a focus on reducing working time and operating costs.
    In addition to these cornerstones, Merlo has introduced three more, further
    enhancing driver comfort, reducing the impact on the surrounding environment
    and introducing the Generation 0 concept:
    · 0 emissions
    · 0 noise
    · 0 use of fossil fuels.
    Three new pillars that limit the impact of the vehicle on the environment in which
    it operates and, even more so, on the health of the people who work with our
    products. The Merlo Group chose to take a new and unexplored route by creating
    vehicles that not only reduce noise and emissions, but also offer exceptional
    performance with ultra-compact dimensions to achieve a level of manoeuvrability
    never seen before in a telehandler.


The Merlo Group developed the new eWorker to support its customers in all their
daily activities, meeting the following operational needs:

· Offering high traction for off-road work and at the same time to be
able to operate indoors and in areas where limited environmental impact
is required
· Ensuring the possibility of travelling on public roads and, if necessary,
towing trailers
· Improving standards of manoeuvrability and agility in the world of
· Increasing the versatility of the vehicle by using new solutions and
· Improving working conditions for both the operator and those
working near the vehicle
· Reducing the total ownership costs and above all payback time
To achieve these objectives, Merlo engineers have designed the new Generation
0 telehandlers starting from a blank sheet of paper and with a 100% electric

It is therefore not the electrification of a conventional telehandler, but an
innovative handling product that combines the advantages and winning features
of telehandlers with those of forklifts.
The eWorker is the result of a targeted redesign of all components, from the boom
to the chassis, from the axles to the hydraulic system, in order to obtain a solution
capable of maximising autonomy and performance while reducing the hourly
operating costs to a minimum.



The eWorker has been designed with the aim of creating a machine that is:
· Full electric, but with the autonomy of a full working day
· Compact, with dimensions similar to those of an industrial forklift
· Equipped with a telescopic boom, setting a new working standard in the
forklift industry
· With 4 ISO size, all-drive wheels of a size suitable for working not only
indoors but also off-road in the construction and agricultural sectors.

The two solutions, with 2WD or 4WD, offer unique advantages and are designed
to improve performance at work. The 2WD models have been designed to increase
the autonomy of the machine, with a class-leading maximum encumbrance while
steering of just 2850 mm, thanks to a steering angle of up to 85°. The 4WD
models, on the other hand, ensure maximum performance in terms of
transmission, to guarantee excellent grip on all surfaces, even off-road.
Therefore, during the design phase, all the components and their positioning were

  • First of all, there is the transmission layout with two electric motors at
    the front, one for each wheel, for 2WD models, and the addition of a third electric
    motor at the rear side, positioned vertically and flanged on the rear axle, for 4WD
    models. This solution, patented by Merlo, offers numerous advantages:
    o Layout advantages in positioning the battery in the middle of the vehicle,
    which has lowered the centre of gravity and increased stability.
    o Manoeuvrability advantages thanks to the high steering angle of the rear
    drive wheels
    o Advantages in the electronic traction management that guarantees the
    correct speed of all four wheels without slipping, the automatic insertion of the
    electronic differential lock and regenerative braking. These advantages translate
    into reduced energy consumption and increased off-road traction.
  • A fourth electric motor, connected to a Load Sensing hydraulic pump,
    allows all the movements of the telescopic boom. Again, in order to optimise
    energy efficiency, a dedicated electronic control unit manages the rpm of the
    electric motor and the oil flow of the hydraulic distributor. In addition, to reduce
    battery consumption, the telescopic boom descends by gravity via a valve
    controlled by the same control unit.


The eWorker is designed to be used in different working environments and allows
the use of a wide range of equipment including:
o Forks, floating and with side-shift,
o Multiple bucket types
o Equipment for suspended loads such as lifting hooks, or fly jibs with
hook or winch,
o Equipment for other special applications such as concrete mixers and
sweeper buckets
o Another important application is the aerial work platform with
overhead self-propulsion. This arrangement will allow operators to
drive directly from the aerial work platform, thus drastically reducing
maintenance time at height.

All models can be customised to suit customers’ needs. In fact, both models will
be available with an open or closed cab, with different possible options, such as a
heating system or boom suspension, and they can be approved for road traffic,
either as self-propelled machinery or as a tractor. For applications in special
working environments (e.g. cold stores), heated windscreen and heated seat are

With the eWorker, Merlo has opened up a new way of thinking and working in the
world of industrial and agricultural lifting. This will allow all users to increase
productivity, save money and enjoy a new driving experience.

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