Terex Hypower System
Plug-in to the Future of Hybrids
Terex Selected Parker as Our Development Partner – January 2008
The Global Leader in Motion & Control Technologies
Terex Corporation is a diversified global
manufacturer with 2007 net sales of $9.1
billion. Terex operates in five business
segments: Terex Aerial Work Platforms,
Terex Construction, Terex Cranes, Terex
Materials Processing & Mining, and Terex
Road building, Utility Products and Other.
Terex manufactures a broad range of
equipment for use in various industries,
including the construction, infrastructure,
quarrying, surface mining, shipping,
transportation, refining and utility
industries. Terex offers a complete line of
financial products and services to assist in
the acquisition of Terex equipment through
Terex Financial Services.
With annual sales exceeding $12 billion, Parker Hannifin
Corporation is the world's leading diversified manufacturer
of motion and control technologies, providing systematic,
precision-engineered solutions for a wide variety of
commercial, mobile, industrial and aerospace markets.
“Raising Values to New Heights”
Auxiliary/Emergency Power Systems – The
original electric hybrid?
Auxiliary power – Provides enough hydraulic
power to lower the aerial device to the ground
from full working height and store the outriggers.
Motor/pump assembly can be used over several
cycles.
Emergency lowering – Provides enough
hydraulic power to lower aerial device to the
ground from full working height. Motor/pump
assembly is typically a single use component.
These systems are used as an independent backup system to the traditional truck engine, pto, and
pump drivetrain. They are generally not designed
for full unit speed operations.
“Raising Values to New Heights”
Why is Terex Utilitiies offering a hybrid system?
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Terex Utilities saw an interest from our Utilities customers to operate our equipment from
alternative energy sources.
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Terex Utilities believes as the manufacturer of the aerial device we are able to optimize our total
system.
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Single source solution for support
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This will compliment our equipment offering and not be a self sustained product line.
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Terex Utilities engineers developed a hybrid approach that would meet the needs of our Utility
customers.
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Terex Utilities teamed with Parker, the global leader in motion & control technologies to
develop and produce a utility industry specific hybrid solution to reduce carbon emissions and
fuel consumption.
“Raising Values to New Heights”
Terex Plug-in Hybrid Power System
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“Engine Off” hybrid operation of the aerial
device
Engine off time with Absorbent Glass Mat
(AGM) type batteries – 6-8 hours depending
on cycle time
Optional APU provides 3.8kw 110V power
supply for lighting, tools, chargers, etc.
Optional HVAC system provides electric cab
air conditioning and heating
System weight under 2200 pounds
Will be available on new vehicles as well as
retrofit on older units
Greenhouse gas reduction - reduces up to
13 metric tons of carbon dioxide per year (10
metric tons average).
Three recharge options
1. Plug-in mode – 8 hrs to full charge 110V
2. Automatic mode – 5 minute engine on provides 15 minutes of boom operation
(continuous cycle)
3. Manual mode – operator can select to have engine run for 25 minutes to fully replenish
battery charge
“Raising Values to New Heights”
Terex Plug-in Hybrid Power System (Distribution style application)
The Hypower system does not limit the
engine HP, transmission type or towing
capacity
• Optional - 3.8kw 110V A/C power
supply for lighting, tools, chargers
• Optional - electric cab air conditioning
and heating
• Minimal interference with chassis and
body
• Maximized ground clearance
• Available on new units as well as
retrofits
• Greatly reduces noise pollution on
work sites
• Estimated fuel savings of 1000 gallons
per year which equals a Greenhouse
gas reduction of 10 metric tons of
carbon dioxide per year, avg.
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“Raising Values to New Heights”
Terex Plug-in Hybrid Power System (Trouble truck application)
Does not limit the chassis type,
engine HP, transmission or towing
capacity
• Optional - 110V A/C power supply
for lighting, tools, chargers
• Optional - electric cab air
conditioning and heating
• System weight 500 pounds
• Minimal interference with chassis
and body
• Maintain chassis factory ground
clearance
• Available on new units as well as
retrofits
• Reduces noise pollution on work
sites
• Low cost to replace battery packs
• Battery charges while driving
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“Raising Values to New Heights”
Hypower Hybrid Drive Advantages:
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Reduced fuel consumption and emissions reductions
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Quiet operation enhances jobsite communications
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Hybrid system is transparent to lineman in operation of aerial
device
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Towing capacity is only limited by the chassis
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Hypower system manages the chassis battery and prevents
issues with parasitic draw
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Available on any chassis
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Fully configurable to alternate battery technologies
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Fully retrofitable into existing fleet
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Recharges in 8 hours
“Raising Values to New Heights”
Terex Hybrid System…enabled with Parker technologies
“Raising Values to New Heights”
Terex Hybrid System
•Engine
•Transmission
•PTO
•Aerial Lift
No launch assist
•Motor/Generator
•Clutch
•Hydraulic Pump
•Hydraulic Tools
•Engage
•Disengage
•Start
•Recharge
•Battery
•Status
•Batteries
•BMS
•OK
•Controller
•Chassis
•Batteries
•DC/DC
•Converter
•(Trickle Charger)
•5 KVA / 3800 W
•Inverter
•Power Panel
•DC/DC
•Converter
•Air
•Conditioner
•DC/DC
•Converter
•Cabin
•Heat
•Options
“Raising Values to New Heights”
Production Hypower Drive System
PTO
Pump
Integrated PTO / Pump
/ Motor Generator
Motor/Generator
“Raising Values to New Heights”
Photos of the line truck installation
“Raising Values to New Heights”
Motor/Generator
“Raising Values to New Heights”
PRICE AND AVAILABILITY UPDATED 11/12/2009
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Line truck application (480 volt system)
Price for the base system is $59,900.00
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Retrofit price is $9,344.00 additional
Optional 3.8 kVA power system is $4860.00
Optional cab AC heat system is $3765.00
Units 1-4 are complete.
Units 5-15 are in process.
Units 16-25 are on order.
Planning to complete 15 units by year end 2009.
Production capacity is available beginning May 2010.
“Raising Values to New Heights”
PRICE AND AVAILABILITY UPDATED 11/12/2009
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Trouble truck application (48 volt system)
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Price for the base system is $19,950.00
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Optional power system
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Optional cab AC heat system
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Unit 1 is complete and has been shown at ICUEE and on the
Terex Tour.
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Units 2-11 are in process.
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Planning to complete 10 more units by year end 2009.
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Production capacity is available now.
“Raising Values to New Heights”