Tadano is launching two new all terrain cranes intended to serve as the introduction to a new hybrid concept with a battery electric superstructure. The AC 4.070HL-1 is the market-ready version of the four-axle 70-tonne crane that the innovation leader showcased as a tech demo all the way back in 2022. Since then, the corresponding pre-production models have received an overwhelmingly positive response after both testing and real-life use. The 120-tonne AC 5.120H-1 crane, which was developed on the basis of this experience, is the next model in the series and will be presented at bauma 2025 in Munich.
An ambitious backdrop: lower emissions, higher energy efficiency
The backdrop behind these new hybrid crane developments consists of Tadano’s ambitious “Tadano Green Solutions” (TGS) environmental protection strategy, which has the goal of reducing the company’s CO2 emissions between 2019 and 2030 by 25% worldwide. Over the same period, Tadano aims to cut CO2 emissions from the use of its products by 35%. The goal is to be completely climate neutral by 2050. One important step towards this goal consists of our hybrid crane solutions, which generate about 60% less CO2 than diesel-powered superstructures. Electric crane operation has a system efficiency of around 85%, which represents more than double the energy efficiency of an efficient diesel engine.
Flexible power options
A combination of conventional travel and fully electric on-site operation is made possible by the new Tadano AC 4.070HL-1 hybrid crane and the upcoming AC 5.120H-1. More specifically, the diesel carrier engine is responsible for bringing the crane to its work site, where the engine can then be switched off for the duration of the job once the outriggers have been deployed. Meanwhile, the high-voltage (HV) battery in the superstructure powers an electric motor, as well as the thermal management system and the superstructure cab’s air conditioning. The electric motor powers the hydraulic system used for crane operation, all with zero restrictions on the corresponding performance. Tadano hybrid cranes can be operated both self-sufficiently with their own battery power and with the support of an external power source, such as temporary work site power. The latter not only extends a unit’s multi-hour electric runtime, but can also relieve the load on the HV battery. In addition, these hybrid cranes remain fully operational even when the HV battery is fully depleted and no external power supply is available. This is thanks to a generator that is driven by a power take-off on the carrier’s diesel engine and that charges the HV battery and allows for continued crane operation. Finally, the hybrid cranes also feature a separate and time-tested 24-V vehicle electrical system that can be used for de-rigging in case of emergency.
Versatile real-life advantages for everyone
Crane owners and rental companies benefit directly from reduced operating costs as a result of the maintenance-free electric motor and the elimination of the superstructure diesel engine. In addition, these hybrid solutions make it possible to tackle new jobs in areas where noise and exhaust emissions must be kept to a minimum. There is also, of course, the boost in terms of environmental image, which should not be underestimated and can continue to pay dividends long after paying the acquisition costs for the crane. For companies with solar panels at their yard, free and straightforward charging becomes an additional business and environmental plus. Extensive testing has shown that operating personnel is quick to appreciate these hybrid cranes. For starters, the electric motor means that there are no exhaust emissions anymore and that vibration and noise are kept to a minimum, all of which is coupled with continuous heating and air conditioning even in standby mode. This makes working in the superstructure cab and in the crane’s proximity much more pleasant, not to mention safer, as important noises and instructions can be heard better at work sites. Moreover, all stakeholders benefit from a high level of operational reliability resulting from power source redundancy. The advantages for the environment when it comes to hours-long hybrid crane operation are also obvious: little noise, no exhaust emissions, and a reduction in CO2 emissions of around 60%.
Under the hood: the hybrid technology in detail
The HV components and their accessories in the superstructure are housed in the packaging space that would normally correspond to the eliminated superstructure engine. The compact electric motor is in the exact same position as the internal combustion engine it replaces, and runs with the same maximum speed. This makes it possible for the hydraulic unit used for crane operation to remain unchanged and in its original position – a major plus when it comes to maintenance and spare parts for the unit, which can be smoothly activated and deactivated. The HV battery is located above the electric motor, surrounded by battery thermal management system components and battery management system components. The HV components’ layout is optimized for short cable runs, good coolant flow to cooling elements, and ease of maintenance and repair. The vehicle inlet for charging can be found on the right side of the rear end, leaving enough storage space to the left, as well as enough space for a trailer hitch in the center. When selecting HV components, Tadano follows its tried-and-true strategy of using components that come from reputable suppliers and confirm to well-established industry standards. As a result, the HV battery has a modular design and can be accessed in a straightforward manner.
Enough power to go the distance: versatile operating modes
- Battery-only mode: The charged HV battery supplies all the power that the electric motor needs in order to drive the crane’s hydraulic pump. In this mode, the AC 4.070HL-1 can run for more than four hours with a full battery charge, while the AC 5.120H-1 can run for an entire working day under the same conditions.
- Battery mode assisted by external power supply: During crane operation and pauses in operation, the HV battery is continuously recharged through the external power supply connected to the CEE vehicle inlet. Depending on the selected amperage, this makes continuous electric crane operation possible.
- External-power-supply-only mode: Even if the HV battery is depleted, the crane can continue to work through its external power connection. Since the HV battery is also charged during pauses in crane operation, it can deliver levels of performance exceeding the externally supplied energy after charging briefly.
- Battery mode assisted by generator: The carrier’s diesel engine charges the HV battery with the generator and the battery buffers the supplied power. Accordingly, the crane’s hydraulic system can briefly work with peak loads that are significantly greater than the maximum continuous power supplied by the generator. The generator can be used during travel and when stationary, and can work in three operating modes: silent mode, eco mode, and power mode. Thanks to the manual regenerative braking function, the generator can run when the vehicle is coasting during travel, saving fuel as a result. This reduces the load on the retarder and boosts the crane’s braking action.
- Emergency operation: The crane can also be de-rigged with the 24-V vehicle electrical system, in which case the telescoping sections are retracted and the boom is lowered to its transport position.
Sustained work, high-speed charging: the high-voltage system at a glance
The high-voltage system on the AC 4.070HL-1 has been customized to perfectly match the power required by the unchanged hydraulic system. In fact, its system voltage of up to 800 V means that the Tadano hybrid crane is leading the pack in line with the latest cutting-edge battery electric trucks and passenger cars. The unit’s other parameters also speak for themselves:
- HV battery pack: lithium-ion NMC battery (nickel manganese cobalt)
- Battery capacity: 70 kWh total capacity, of which approx. 80% (~56 kWh) is usable
- Electric motor: continuous output of 115 kW, peak torque of 1,200 Nm
- Generator: charging power > 50 kW, continuous output of 85 kW, peak torque of 500 Nm
- Onboard charger: CEE vehicle inlet, 400 VAC, 63 A, limiting to 32 A possible
- Battery runtime: approx. 6.3 h (load cycle 1), approx. 3.9 h (load cycle 3)
- Charging time with onboard charger (63 A): 10% to 90% state of charge (SoC) in approx. 1 h
- Charging time with generator while working at work sites: 10% to 90% SoC in approx. 1 h
- Charging time with generator during travel: +55% SoC in approx. 1 h
Extra utility without side effects
Best things first: Tadano hybrid cranes have the exact same lifting performance, lifting capacities and axle load capacities as their counterparts with two internal combustion engines, meaning that the slight increase in weight represented by the hybrid system is not tied to any loss of performance. As with other electric vehicles, the purchase price is higher than that of comparable models with an internal combustion engine. However, these hybrid cranes pay for themselves as a result of their extra advantages. In fact, quiet and zero-exhaust-emission crane operation means that new applications and potential sources of revenue can be tapped into:
- Use in indoor areas (e.g., buildings in the event, manufacturing, and logistics industries)
- Use in outdoor areas sensitive to exhaust and noise emissions (e.g., urban areas, hospital grounds, zoos, nature reserves, occupied residential buildings)
- Use during quiet hours (at night, on Sundays and public holidays)
An innovative investment in the future
Tadano hybrid cranes are designed for long-term use, making them a sound investment in the future. It is possible that by the end of the 2030s, electricity will be much more affordable than diesel fuel in comparison to today. Moreover, additional and tougher regulations requiring zero-emission and low-noise operation are expected by then. Customers are likely to be glad they invested in a Tadano hybrid crane as a result of significant fuel and engine maintenance savings across the years combined with excellent resale value. In addition, the equipment is designed to last: Not only are the vehicle structure, chassis, hydraulic system, and crane mechanical system all characterized by their familiar heavy-duty robustness, but the high-voltage system is made of durable and modular components as well. The sophisticated thermal management system ensures that the HV battery always works at its optimal operating temperature and that it will reach its optimal service life. The result: a high residual capacity of about 80% of the new battery’s SoH (state of health) even after 3,000 charging cycles. Partial charges only count towards these cycles proportionally and have a more positive effect on the battery’s lifespan the longer and more frequently the state of charge remains in the middle range.
Hybrid crane software: extensive expertise, no fooling around
Tadano did not take any shortcuts when it came to the software used to integrate the high-voltage system. The HV components are linked and controlled with in-house software developed internally by the company with its own IT resources, ensuring the hybrid cranes’ reliable suitability for daily use. The crane functions remain hydraulically powered, giving crane operators the same familiar, highly responsive control feedback, particularly since all HV-specific information has been smoothly integrated into the display solution.
A big future: AC 5.120H-1 just around the corner
The hybrid crane design was planned in such a way as to be used across models, so that Tadano’s electrification for the AC 5.120H-1 is based directly on that of the AC 4.070HL-1. The front section of the five-axle crane’s superstructure supports an optional second HV battery pack. This doubling of the battery capacity to a total capacity of 140 kWh means that battery electric operation for a full working day without any external charging is possible. Thanks to the optimized compact rear storage box next to the vehicle inlet, the machine can easily carry the usual crane equipment. The generator drive has been optimized further and runs maintenance-free directly off the transfer case between the second and third axles.
The bottom line: Tadano makes a compelling case and listens to compelling feedback
The extraordinarily positive feedback from test customers for the first AC 4.070HL-1 hybrid crane model and accolades for the company’s innovative commitment to a green future have served as additional incentives for Tadano to continue electrifying additional crane model ranges. Needless to say, these are ideal conditions for tackling the higher demand for electric construction equipment that is expected for the coming years.
