Manitowoc Mobile Crane

SUNCAR is proud to announce its collaboration with Manitowoc, a leading manufacturer in the mobile crane industry, for the launch of its new hybrid mobile crane GMK5150XLe Plug-In Hybrid. The vehicle combines the best of both worlds – exceptional performance and energy efficiency with lower emissions.
The hybrid mobile crane has been developed to meet the growing demand for sustainable solutions in the crane industry and represents a significant milestone in reducing local carbon emissions and offering an environmentally friendly powerful alternative.

Key features

• Hybrid drive train: The crane operation is powered purely by battery energy but can be recharged via the diesel engine. The battery capacity is sufficient for an average working day with 2–3 jobs per working day.
• Flexible charging options: The crane has an AC and DC charging interface, and the battery can also be charged via the generator/diesel engine.
• Efficiency gains: Energy recovery when travelling and diesel-free mode when operating the crane.
• Innovative system integration: Minimal modification work on the crane model, intelligent control, optimized thermal and power management.

Project goals

The project to electrify the crane operation had clear milestones that were defined in a structured timeline. The preliminary study was completed by the end of September 2023 and the project was launched in October 2023. Commissioning of the prototype crane took place in October 2024, with a period of three months for tests and further adjustments.

Results

The aim of the project was to electrify the crane in the superstructure so that it could cover a regular working day purely electrically.

Technical specifications

The technical specifications of the upper carriage include a motor that drives the hydraulic pump and a battery with 180 kWh. The battery enables both AC and DC charging, which ensures a flexible energy supply. If necessary, the crane can be charged via the charger during operation – the so-called ‘cable run’ function. The hydraulic drive units are operated by a powerful electric motor in the superstructure, which improves hydraulic efficiency through intelligent control.
A generator with 170 kW, an AC charger with 22 kW charging power and a DC charging interface with 250 kW are installed in the carrier.

Efficient charging and energy concept

The charging and energy concept includes charging from the mains with 400V/32A, charging during operation and charging by the onboard generator with up to 1C.
One advantage of the system is the possibility of regeneration while cruising and braking, which also extends the working time on battery power. When the crane is set up on the construction site, it can also be charged via the generator, which enables better utilization of the diesel engine. For the typical use of a crane with 2–3 jobs per working day, the new system therefore offers a high level of efficiency. The battery can be charged with 16A/32A at 400V and enables self-charging via the generator, whereby a recharge from 5% to 80% is achieved in less than an hour. The crane delivers the same performance as the standard GMK5150XL.

Innovative system integration with minimal modification effort

The system integration is based on a conventional crane model with minimal modification effort. The electric motor is combined with the existing hydraulic pump.
The thermal management of the system is linked to the air conditioning of the upper cab. The system also includes advanced power management, special control software and extensive service and maintenance options.