The steel and hydraulics of an aerial ladder can serve for many years; its electronics usually run into spare part and service problems much earlier. A display goes dark, a board fails, and the manufacturer no longer supplies parts for that generation or wants the vehicle back at the factory. The ladder or platform is out of service. We rebuild the control system of these vehicles and return them to duty.
Typical symptoms
These problems usually concentrate around 12–15 years of age. At this age structural risks such as metal fatigue also come into play; structural inspection is outside our scope.
- Display or control board failure, part no longer produced
- Unexplained cut-outs in limitation and load moment functions
- Sensor faults that cannot be diagnosed
- Manufacturer service requiring long factory stays
Functions rebuilt
Every control function is rebuilt in the new system.
- Ladder/boom movements and proportional valve control
- Working envelope limitation and load moment (LMI) tables
- Outriggers, stability and vehicle inclination
- Cage load, wind monitoring and emergency functions
What we do
We remove the old control electronics and install a system of redundant controllers, operator displays, CANopen sensors and new harnesses. Truck, turret and cage each get their own control unit and communicate on one CAN network. We write machine-specific application software and build the geometry and moment tables from the vehicle’s real dimensions, verified by tests.
| Section | Typical components | Task |
|---|---|---|
| Truck (chassis) | MSC113, outrigger console, inclination sensor | Outriggers, vehicle inclination, stability preconditions |
| Turret | MPC113, GDC800 display, length and inclination sensor | Motion control, limits, LMI tables, diagnostics |
| Cage | MSC113, 7″ operator panel, wind sensor, CANcom intercom | Cage control, cage load, wind and communication |
Components are selected for each vehicle; the table shows the typical layout in our completed projects.
Safety functions rebuilt
- Working envelope limitation: geometric limits by ladder/boom length, angle and slew position
- Load moment (LMI) tables: dynamic tables by cage load and outrigger spread, with different limits per slew zone
- Stability and outriggers: no turret movement until outrigger spread and ground contact are confirmed
- Smooth motion: motion ramps and acceleration limits reduce oscillation at the ladder tip and allow precise positioning
- Diagnostics: fault codes for every sensor and output, clear messages on the display and event logging
Which brands?
We work on turntable ladders and rescue platforms independently of the brand. The pages below give brand-specific information.
For Magirus turntable ladders
Control system retrofit for DLK 23-12 and other Magirus turntable ladders.
For Bizzocchi platforms
A completed project on a Bizzocchi ladder platform whose manufacturer is no longer active.
Rosenbauer / Metz, Bronto and others
Request a pre-assessment for other ladder and platform brands.
Standards and acceptance
| Standard | Scope |
|---|---|
| EN 14043 | Turntable ladders with combined movements |
| EN 14044 | Turntable ladders with sequential movements |
| EN 1777 | Hydraulic platforms for fire fighting and rescue services |
| EN ISO 13849-1 | Safety-related parts of control systems |
| (EU) 2023/1230 | Machinery Regulation; whether a retrofit counts as a “substantial modification” in the EU |
We record all tests and, as the inspection body requires, prepare the technical documentation for the control system. The party making the substantial modification takes on the manufacturer’s obligations; EHR Elektronik is not the machine manufacturer, and this is stated in the proposal.
Process
- Send photos and details. Make, model, year, working height and the problem; old diagrams and display photos if available.
- On-site inspection. Condition of mechanics, hydraulics and existing sensors, safety functions and cable routes.
- Technical proposal. Architecture, component list, schedule, test plan and documentation scope in writing.
- Installation and commissioning. Short downtime with pre-built cabinets and harnesses; tests of motion, limits, LMI and emergency functions.
- Acceptance, training, support. Support for inspection acceptance, operator and maintenance training, remote diagnostics and updates.
Before and after the retrofit
| Topic | Old system | Renewed system |
|---|---|---|
| Spare parts | Discontinued boards and displays | Components in series production with ongoing support |
| Fault diagnosis | Unclear cut-outs, long fault finding | Fault code and description on the display, event log |
| Safety functions | Status not documented | Rebuilt, tested and recorded |
| Documentation | Incomplete or missing | Diagrams, parameter list, test records, user documents |
| Service | Dependent on the manufacturer, vehicle goes to the factory | On-site service and remote diagnostics |
What you receive at handover
- Wiring diagrams and cable list
- Parameter list, limitation and load moment tables
- Fault code list and description of diagnostic screens
- Commissioning and acceptance test records
- Operator and maintenance documents and a list of the components used
Where we work
Our team is based in Istanbul and works across Türkiye. Abroad, as in our completed project in Europe, we send teams for inspection, installation and commissioning. Fire and civil defence services in Central Asia, the Gulf states and North Africa can reach us in English or Turkish, and the pre-assessment can start remotely from photos and videos.
Completed projects
Portugal: Bizzocchi VP33
MPC113/MSC113 on truck, turret and cage with 7″ panels; 10 dynamic geometric tables, 4 swing zones and lateral tables adjusted by cage load and outrigger position.
62 m firefighting ladder
A European-made ladder with spare part and manufacturer support problems; all controls and software renewed, back in service abroad.
55 m articulated folding platform
A limitation and moment system for retrofit or new build: 10 working tables, 3 cage load limits, 5-step outrigger spread.
Frequently asked questions
Does the vehicle need re-inspection after the retrofit?
Yes. Since safety functions change, acceptance tests are carried out. We record the tests and, as the inspection body requires, prepare the documents for the control system.
What if the old vehicle has no load moment table?
Tables are rebuilt from the vehicle’s dimensions, weights and existing documents and verified with load tests on site.
Do you use original manufacturer parts?
No. Because we rebuild the control system, we do not need original electronic parts; hydraulic and mechanical parts stay in place.
Are you an authorised service partner?
No. We are an independent electronic modernisation company, not an authorised service partner or dealer of the manufacturers.
Does the vehicle have to leave its station?
Not necessarily. We can work where the vehicle is; if a workshop is more suitable, the proposal says so.
Can ladder tip oscillation be reduced?
Motion ramps and acceleration limits are tuned from scratch in the new system, which clearly reduces oscillation at the ladder tip. Mechanical play, if any, has to be fixed separately. This tuning does not replace the patented active oscillation damping systems of some manufacturers; such a system is not part of our scope.
Do you train operators?
Yes. At handover we train operators and maintenance staff and deliver user documentation in English and Turkish. Other languages in the Latin alphabet, and non-Latin alphabets such as Russian where the devices used support them, can be added if the customer provides the translation.
Do you send teams abroad?
Yes. As in our completed project in Portugal, we send teams abroad for inspection, installation and commissioning.
What does it cost?
The cost depends on the vehicle type, number of functions and test scope, and is a small part of the price of a new vehicle. After the pre-assessment we send a written proposal.
What information should we send?
Make, model, year of manufacture, working height, the problem and, if possible, photos of the turret, cage and display.
Request a pre-assessment for your ladder
Send the make, model, year and the problem; photos can be sent by e-mail or WhatsApp. We will assess feasibility together.
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.