A machine with sound mechanics but outdated electronics does not have to be scrapped. At EHR Elektronik we rebuild the control electronics of fire vehicles, turntable ladders, aerial rescue platforms and construction machines with today’s components: controllers, displays, sensors, wiring and application software. The machine keeps doing the same job, now with a documented system whose spare parts are available.
When is it needed?
If any of these sound familiar, it is time to talk about a retrofit.
- A failed board or display is no longer produced
- The manufacturer no longer services the older generation, or the vehicle must go back to the factory
- Frequent, unexplained faults and undocumented software
- You are not sure the safety functions (limits, moment, stability) still work
What do you gain?
Longer service life and control of your fleet back in your hands.
- Components that are on the market and supported
- Documented wiring diagrams, parameter list and software
- Fault codes and diagnostic screens for shorter downtime
- A fraction of the investment and lead time of a new vehicle
Which machines do we work on?
Aerial ladders and rescue platforms
Turntable ladders, articulated and telescopic rescue platforms: control, LMI, stability and outriggers.
Fire vehicles
Pump, foam, monitor and tank level control; vehicle intercom and operator panels.
Aerial work platforms
Limitation, load moment and basket load control on articulated and telescopic boom platforms.
Construction and special machines
A new CAN-based architecture replacing obsolete control systems on port, construction and industrial machines.
Our approach: brand-independent, open and documented
We do not copy the old system. We define what the machine has to do today and rebuild the control architecture around it. The main control runs on redundant controllers designed for safety applications, operators use colour graphic displays and consoles, and measurement is done with CANopen length, inclination and wind sensors. All units communicate on one CAN network.
- Control: MOBA MPC113 redundant master controller (CODESYS 3.5, two application processors and a separate watchdog, EN ISO 13849-1 Category 3 internal architecture) and MSC113 slave units
- Operator: GDC800 7″ colour graphic display, outrigger control console, CANcom vehicle intercom
- Measurement: redundant cable length transducer, CANopen inclination sensor, wind sensor
- Software: machine-specific application software, parameter list, fault codes and diagnostic screens; full documentation at handover
We have a long-standing partnership with MOBA Mobile Automation in mobile machine automation and represent MOBA products in Türkiye. Components from other brands are used where they fit the project best, as part of supply and system integration.
Process: from assessment to handover
- Remote pre-assessment. We collect the make, model, year and the problem, plus photos and old diagrams if available, and discuss feasibility and scope.
- On-site inspection. Our team inspects the machine: hydraulic and mechanical condition, existing sensors, cable routes and safety functions.
- Technical proposal. You receive the new control architecture, component list, schedule and test plan in writing.
- Implementation. Cabinets and harnesses are prepared, the old electronics are removed and the new system is installed, on site or in a workshop.
- Commissioning and tests. Movements, limits, load moment and stability functions and emergency functions are tested one by one and recorded.
- Acceptance and training. For inspection body acceptance we prepare the technical documents and test records for the control system as you request, and train operators and maintenance staff.
- Remote support. After commissioning we provide remote support for diagnostics and software updates.
New vehicle or retrofit?
| Criterion | Retrofit makes sense | Consider a new vehicle |
|---|---|---|
| Chassis, turret and boom mechanics | Sound and maintained | Fatigue, cracks, heavy corrosion |
| Hydraulic system | Working, partial renewal if needed | Complete renewal required |
| Source of the problem | Electronics, software, spare parts | Mechanics and hydraulics together |
| Budget and time | Must return to service quickly | Long delivery time is acceptable |
Standards and legal framework
The key standards are EN 14043 and EN 14044 for turntable ladders, EN 1777 for rescue platforms and EN 280 for mobile elevating work platforms. Safety functions are built on hardware designed to EN ISO 13849-1. In the European Union, a modification that changes a machine’s safety functions may count as a “substantial modification” under the Machinery Regulation (EU) 2023/1230, which applies from 2027. The party making the substantial modification takes on the manufacturer’s obligations (CE conformity, technical file). EHR Elektronik is not the machine manufacturer: we design and commission the control system and prepare its technical documentation. We therefore usually work with the company making the substantial modification; where we work directly for the end user, the end user takes responsibility for the modification, and this is stated in writing in the proposal.
From our references
Portugal: Bizzocchi VP33 aerial ladder platform
The complete control architecture of a ladder platform whose manufacturer is no longer active was rebuilt: MPC113 and MSC113 on truck, turret and cage, 7″ operator panels and a dynamic LMI with 10 geometric tables.
62 m firefighting ladder
A European-made ladder facing spare part shortages and no manufacturer support received completely new controls and software and is returning to service abroad.
55 m articulated folding platform
Geometric limitation by main boom length, 10 working tables and moment control by basket load and outrigger spread, with independent software sections for chassis, tower and basket.
Frequently asked questions
Which brands do you work on?
We work independently of the brand. In the pre-assessment we check the mechanical and hydraulic design; since we rebuild the control architecture, we do not depend on original electronic parts.
How long is the machine out of service?
It depends on the condition and scope. Cabinets and harnesses are prepared in advance to keep downtime short; the exact schedule is stated in the technical proposal.
Do you work abroad?
Yes. Our field work abroad includes a ladder platform in Portugal and a material handler in South Africa. Team travel and scheduling are planned in the proposal.
Do we receive the software and documentation?
Wiring diagrams, parameter list, fault codes and user documents are handed over. Source code is not supplied or sold. With our service tools and the compiled software you can commission several machines of the same type and model yourself; the software carries a licence number that ties it to hardware supplied by us.
How is spare part availability ensured?
We select components in series production with ongoing support. Every part used is listed in the handover documentation.
How is the cost determined?
Machine type, number of axes and functions, sensors and test scope determine the cost. After the pre-assessment we define the scope and send a written proposal.
How does inspection body acceptance work?
We record all tests. As the inspection body requires, we prepare the technical documents for the control system; documents covering the vehicle as a whole are the responsibility of the party making the substantial modification.
Do you offer remote support?
Yes. After commissioning we support diagnostics, parameter changes and software updates remotely.
Tell us about your machine
Send the make, model, year and the problem you face. Photos and old diagrams can be sent by e-mail.
Request a pre-assessment →Message on WhatsApp
E-mail: info@ehrelektronik.com · Phone: +90 850 220 3 381
Magirus, Iveco, Rosenbauer, Metz, Bronto Skylift, Bizzocchi, CTE, NAFFCO and other brand names on this page are registered trademarks of their respective owners. They are used here only to indicate the vehicles our service can be applied to. EHR Elektronik is not an authorised service partner, distributor or affiliate of the vehicle manufacturers named; our service is an independent electronic modernisation service.