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Cable-powered electrification of heavy equipment
We convert diesel excavators, loaders and material handlers into cable-powered electric machines. Same work, same seat, same controls, at a lower running cost and with no exhaust at the point of use.
Why it matters
Heavy equipment is built to last. The diesel engine isn't.
The boom, undercarriage, frame and hydraulics of a large excavator can keep working for decades. The engine is the most maintenance-intensive part of the machine, and it burns fuel every hour the machine runs.
Over a machine's working life, fuel and engine maintenance typically cost far more than the original purchase price. For many operators, the choice has seemed to be between two options. We offer a third.
How it works
Replace the part that wears out. Keep the parts that don't.
In most hydraulic machines, the diesel engine doesn't drive the tracks or the boom directly. It turns hydraulic pumps, and pressurised oil powers everything else.
So we replace the power source at the pumps, with an electric motor matched to the original engine's power, and leave the rest of the machine exactly as it was. Its working behaviour stays familiar because the hydraulic system is the same one it always had.
Removed
The high-wear diesel drivetrain
- Diesel engine
- Fuel tank and fuel system
- Exhaust and aftertreatment
Installed
Electric drive and cable power
- Electric motorMatched to the original engine's power, coupled to the existing pumps
- Motor drive or soft starter
- Switchgear and protection devices
- TransformerWhere the incoming supply is at a higher voltage
- Cooling for the new components
Cable management
- Cable reels, slip rings, heavy-duty connectors, cable guides and protection
Kept exactly as it was
Everything downstream of the pumps
- Hydraulic pumps
- Cylinders and valves
- Boom, undercarriage and frame
- Cab and controls
- Attachments
Because the cab, levers and hydraulic system are untouched, operators work the machine exactly as they did before. No retraining needed.
Features
The cable is a critical system, not an accessory
A damaged cable halts the machine, and a damaged high-voltage cable is a serious safety hazard. That's why the cable handling equipment is built for the conditions found in ports, mining and heavy industry.
Continuous power without batteries
A large excavator can draw several hundred kilowatts continuously. A cable tether supplies energy for as long as the machine is connected, with no charging breaks, no battery replacement costs and no drop in performance late in the shift.
Automatic cable handling
Reels mounted on or near the machine pay out and retrieve cable as it moves. The cable is held under controlled tension, so it never lies slack where it could be driven over or dragged across sharp rock.
Full 360° swing
Slip rings pass power through the rotating parts, so an excavator's upper structure can swing a full circle without twisting the cable.
Protected connections
Rugged connectors built for wet, dusty, harsh environments let the machine be connected and disconnected safely when it's relocated. Safety contacts prevent arcing and immediately trip upstream breakers if the plug is pulled under load.
Benefits
What the conversion delivers
Lower running costs, less maintenance and a cleaner, quieter worksite, all without changing how the operator works.
Lower energy costs
A diesel engine turns only about 35–45% of its fuel energy into useful work. An electric motor is typically more than 90% efficient, and electricity is often cheaper than diesel per unit of energy. Exact savings depend on local fuel and electricity prices.
Reduced maintenance
Oil changes, fuel filters, injectors, turbochargers, particulate filters and AdBlue/DEF are all gone. The hydraulics still need normal servicing, but a large share of routine maintenance goes away.
No fuel logistics
No delivery trucks, storage tanks, spill risk, refuelling time, theft risk or staff time spent managing diesel on site.
Safer power handling
Managed cable reels keep high-voltage cable off the ground, and purpose-built connectors protect against arcing and disconnection under load.
Cleaner, quieter worksites
No exhaust at the point of use and much less noise. Better air and comfort for operators, lower ventilation needs underground, and potentially longer permitted working hours near homes and businesses.
Capital savings
Converting an existing machine usually costs less than buying a new electric one, and it extends the life of equipment you already own.
Support for carbon targets
Cable power helps cut emissions on site, with the overall climate benefit depending on how the grid electricity is generated.
Where it fits
Where cable-powered equipment fits best
The solution suits machines that work within a defined area, where power infrastructure can be set up once and used for weeks or months. The trade-off is mobility: a tethered machine can only work within reach of its cable.
A strong fit
- An excavator feeding a crusher from a fixed position
- Machines working a slowly advancing quarry face
- Material handlers at scrap yards, ports and recycling plants
- Equipment in tunnels, underground mines and enclosed buildings
Not suited
- Haul trucks
- Machines that travel long distances around a site
- Contractor equipment that moves between jobsites every few days
Frequently asked questions
Which machines can be converted to cable power?
Hydraulic machines such as large excavators, loaders and material handlers are good candidates. In these machines the engine drives hydraulic pumps, so an electric motor can take its place without changing the rest of the system.
Why use a cable instead of batteries?
A large excavator can draw several hundred kilowatts continuously. A shift-length battery would be heavy, expensive and slow to recharge, and it would lose capacity over time. A cable provides uninterrupted power for as long as the machine is connected.
Does an electric conversion change how the machine is operated?
No. The cab, controls, hydraulics and attachments stay the same, so operators don't need retraining.
How is the cable protected from damage?
Cable reels pay out and retrieve cable automatically under controlled tension, keeping it off the ground. Slip rings allow full 360-degree swing without twisting, and cable guides add further protection.
Is cable-powered equipment suitable for every site?
No. It works best where machines operate within a defined area, such as crushing operations, quarry faces, ports, scrap yards, tunnels and underground mines. It isn't suited to haul trucks or equipment that moves between jobsites frequently.
Contact
Thinking about electrifying your fleet?
If your machines work within a defined area and you're looking for ways to cut operating costs, we can help you assess whether a cable-powered conversion is right for your site.
Email us abyjoseph@tristaruvs.com