Converting a diesel-powered construction machine to electric drive is more than removing the engine: engine-related fault codes, the stepwise throttle input, the operator display and the control software must all be adapted to the new drive. EHR Elektronik takes on the control and software side of these conversions. We are not the machine manufacturer: we design and commission the control system and prepare its technical documentation.
What makes a conversion hard?
A new-generation machine has many engine-related details.
- Advanced systems such as emission control
- Removing the diesel engine
- Eliminating complex fault codes
- Adapting the machine to a new electric drive
EHR’s share
The control and software side.
- Control software that runs the overall system
- A 4-20 mA analog command for the inverter
- Remote commissioning and live monitoring
- Site service and commissioning
From our references
New-generation Caterpillar 374 NG, commissioned entirely remotely
The diesel engine was removed, the machine adapted to electric drive and commissioned remotely without being on site; it was exported to South Africa.
South Africa: site service and commissioning
On-site service and commissioning for the same project in Durban; the machine operates smoothly in daily use.
From throttle step to inverter: 4-20 mA
The excavator’s stepwise throttle input was read over CAN J1939 and a 4-20 mA signal was generated for each step.
From throttle input to inverter
In an excavator conversion we needed a 4-20 mA analog current output to control the frequency inverter precisely; the MOBA MPC113 and MSC113 control units we used lacked this output. The solution: the original stepwise throttle input (“thumbwheel”) of the Caterpillar-based excavator was read over CAN J1939, and an MRS Micro PLC CAN 4 ANA module generated the corresponding 4-20 mA signal for each step. While the MOBA control units managed the overall system, the MRS module completed the missing interface; the electric motor was controlled through the inverter and replaced the diesel engine.
The four I/Os of the CAN 4 ANA can be used as analog outputs for 0-24 mA current and 0-10 V voltage, or configured as analog inputs; the module is programmed with MRS Applics Studio, runs on 9-32 V and measures 30 × 30 × 40 mm.
Remote commissioning and monitoring
In the new-generation Caterpillar 374 NG conversion we commissioned the machine entirely remotely, without being on site. Thanks to the integrated MOBA A4U device, the machine exported to South Africa can be monitored in real time: full diagnostic data, location tracking and remote access for intervention when needed. The project is described here.
Software and display
A conversion may also require the control software to be reworked. In one excavator project we migrated the software from C to CODESYS, replaced the display brand and model and integrated Euro 5 engine DPF control into the system. The CODESYS side is covered on our CODESYS application development page and this project in the project post.
Process
- Rework the system for the new requirements. Control software, display and, where needed, emission/DPF control are redefined for the requirements of the conversion.
- Control architecture. The MOBA MPC113 and MSC113 control units manage the overall system; missing interfaces (e.g. a 4-20 mA output) are completed with a small MRS module.
- Remote commissioning. Where needed, the machine is commissioned remotely without being on site.
- Site service and monitoring. Service and commissioning are carried out on site; the machine is monitored live with MOBA A4U.
Frequently asked questions
In which countries do you provide site service?
Türkiye, Portugal, South Africa, Egypt, Romania, Spain, Italy, Germany, Uzbekistan, Azerbaijan, Kazakhstan, Iran and Russia. We have carried out field work in 13 countries including Türkiye.
What happens to Euro 5 engine and DPF requirements in a conversion?
We develop DPF monitoring and regeneration management for Euro 5 engines: regeneration strategies, system diagnostics and operational safety logic. In one excavator conversion DPF control was fully integrated into the system.
Can our engineers maintain the software?
Yes. In one conversion project we gave hands-on training to the customer’s software development engineer, who can now develop and maintain their own applications. Source code, however, is not supplied or sold.
Can a similar system be applied to our existing machine?
A similar system can also be applied to existing vehicles after a preliminary assessment. Send us the machine type and model.
In which languages do you provide support?
Support is provided in Turkish and English; user documentation is delivered in English and Turkish.
Request a conversion feasibility study
Tell us the machine type, model and what you expect from the conversion; we will get back to you with a pre-assessment.
Request a pre-assessment →Message on WhatsApp
E-mail: info@ehrelektronik.com · Phone: +90 850 220 3 381
Brand names on this page are registered trademarks of their respective owners and are used descriptively only. Electroforce is a registered trademark of EHR Elektronik.