Terex Utilities and Mack Trucks Roll Out a New Medium-Duty Electric Bucket Truck

A partnership between Terex Utilities and Mack Trucks is bringing a new all-electric medium-duty bucket truck to the utility fleet market. The two companies rolled out the electric Mack MD7 chassis with Terex’s Optima HR55 aerial device during NTEA Work Truck Week in early March. The new offering adds to Mack’s battery electric vehicle (BEV) portfolio and marks the manufacturer’s entry into the specialized utility segment.

“This electric bucket truck represents the next natural step in our commitment to sustainable transportation solutions,” said George Fotopoulos, vice president of E-mobility at Mack Trucks. “Our lightweight electric chassis provides the capability to handle more demanding applications, and when combined with Terex’s expertise in utility equipment, we’re delivering a solution that pushes the boundaries of what’s possible in zero tailpipe emissions utility vehicles.”

“Our collaboration with Mack Trucks represents continued movement forward in zero-emissions utility vehicles,” said Tyler Schwingler, product marketing manager at Terex Utilities. “By combining our Optima HR55 aerial device with Mack’s electric MD7 chassis, we’re providing utility companies with a solution that doesn’t compromise on performance or capability while meeting their sustainability goals.”

The new offering, according to Terex, delivers more payload capacity and range for utility fleet operations. The Mack MD Electric chassis enables up to 1.5 times greater range compared with other Class 6 and 7 medium-duty electric bucket trucks, the company noted, while providing double the rear axle payload capacity. This advancement directly addresses challenges in the utility sector where the combined weight of aerial equipment and battery systems often presented operational limitations.

The Terex aerial device on the Mack MD Electric chassis is powered by the HyPower SmartPTO by Viatec. Operating independently from the truck’s power system, the configuration ensures utility crews can complete a normal workday with the boom and outriggers without impacting the truck’s driving range.

While the plug-in electric power take-off connects to the hydraulic system for aerial device operation, it also provides battery power to the chassis for lighting and in cab HVAC to operate while the truck engine is off. The truck’s conventional PTO remains available for environments like disaster recovery where plug-in battery charging might not be possible.

Optima Advancements

First introduced in 2017, the Terex Optima series includes five overcenter and five non-overcenter models. Frequently used for construction and maintenance of distribution lines, the Optima HR55 was the model selected for Terex Utilities’ debut of the industry’s first all-electric bucket truck in 2022 when the aerial device was mounted on an International eMV Class 6 medium-duty electric chassis.

Operator aids on the Terex Optima series include optional load alert monitors that analyze the truck’s jib and basket capacity and provide visible and audible alarms when an overload has been detected. Also to support safe work practices, a positive attachment lanyard (PAL) warning device from Terex Utilities is designed to remind operators to connect their fall protection harness before elevating a bucket.

The new all-electric Mack bucket truck is also equipped with the 3rd Eye digital platform that integrates advanced camera systems and artificial intelligence technology to maximize safety and productivity. With up to six high definition (HD) cameras displayed on a seven-inch in-cab monitor, the system provides a complete, real-time view of the vehicle’s surroundings, reducing blind spots when reversing, changing lanes or operating in tight or high traffic areas.

“The 3rd Eye system is wirelessly connected to the cloud, continuously capturing and storing critical operational data and video, providing fleet managers real-time visibility into driver performance, chassis and body activity and equipment status,” said Eric Monsen, vice president of sales and marketing for Environmental Solutions Group, the provider of the 3rd Eye system. “These insights not only improve safety and reduce liability but also create a detailed event record that can help identify coachable opportunities to reinforce safe driving behaviors.”

Mack’s EV Expansion

The Mack MD Electric chassis, first introduced in 2023, features a three-phase permanent magnet synchronous motor. Power for propulsion and on-board accessories comes from nickel manganese cobalt (NMC) oxide lithium-ion batteries. Offered in 150 kilowatt (kWh) or 240 kWh configurations, the MD Electric can be charged through AC or DC charging units while a regenerative braking system helps recapture energy. The Mack MD Electric is supported by Mack dealers, many of which are Mack-certified electric vehicle (EV) dealers.

The Class 7 electric Mack model with the Terex Optima HR55 aerial device has a gross vehicle weight rating (GVWR) of 33,000 pounds. The truck manufacturer also offers a Class 6 MD Electric model with a GVWR of 25,995 pounds. The Mack MD series is available in 4x2 configurations and has a short bumper-to-back-of-cab measurement of 103 inches and a sharp wheel cut for enhanced maneuverability in tight urban settings.

According to Mack and Terex, their partnership is now providing another option for electric utility customers looking for zero-emissions vehicle and equipment solutions. Their new electric bucket truck will be available in limited quantities in 2025 with a standard delivery time of 12 to 18 months.

“With this new offering, electric utilities can field an electric truck with the apparatus they need to service poles and lines,” Fotopoulos said. “As we continue to work with body builders to progress the MD Electric across various Class 6 and 7 commercial truck applications, this collaboration with Terex Utilities demonstrates Mack’s commitment to delivering sustainable solutions that meet our customers’ specific needs.”