A project to repower 18 open-top MAN diesel buses with a battery-electric driveline that incorporates an Allison T280R six-speed automatic transmission has been completed in Germany.
Those CityTour vehicles are used by sightseeing specialist Willms Touristik in Cologne and other cities. The work has captured six different models built on MAN chassis, ranging from 37-year-old SD202 vehicles to examples dating from as recently as 2019.
A multi-million-euro grant from the German Federal Ministry for Digital and Transport has contributed to the electric repower, with conversion carried out by Danish specialist Banke ApS working with Allison authorised distributor DGS Diesel- und Getriebeservice GmbH.
The T280R unit has been adapted specifically to suit electric buses, Allison says. Use of a transmission will “optimise the electric motor and increase the efficiency of the overall system,” it adds.
At the centre of the battery-electric driveline is a Dana TM4 Sumo HP electric motor that delivers 145kW and 625Nm of torque in continuous operation. Six lithium iron phosphate battery packs per bus with a total capacity of 240kWh give a range of around 124 miles.
Conversion of the buses saw the diesel powertrain removed and a rigorous chassis inspection carried out.
Batteries are within the engine bay and the passenger area at the cost of between two and six seats compared to the previous layout.
Willms Touristik Executive Assistant Karsten Flamming says the operator believes that without use of the Allison gearbox as part of the battery-electric driveline, range of the vehicles would be lower.
Director Sascha Willms adds that the Allison units have proved smooth when coupled to an electric motor, in terms of both acceleration and gearchanges.
“We deliberately decided against a gearless direct drive and instead selected a drive system that has already proven itself in the municipal sector, in vehicles for refuse collection,” he adds.
The operator has calculated energy consumption at 0.75kWh per km on highways, and an overall average of 1.1kWh per km.
The German federal government’s contribution to the repower project has covered 80% of the conversion costs. The operator has provided the remaining €2.2 million, which includes establishing charging infrastructure and training drivers and workshop staff.
