Tracking Electric & Hybrid Construction Equipment: What's Different

The construction site of tomorrow is quieter, cleaner, and increasingly electric. From compact excavators to hybrid dozers, electric and hybrid machinery is moving from "experimental" to essential for equipment rental companies and construction firms aiming to meet sustainability mandates and lower operating costs.

However, managing a mixed fleet of diesel, hybrid, and electric assets introduces a new layer of complexity. You cannot manage an electric skid steer the same way you manage a diesel one. The fuel metrics are gone, replaced by kilowatts and charging cycles. The maintenance triggers have shifted from engine hours to battery health.

To operate efficiently, you need construction fleet tracking that speaks the language of electrification. In this guide, we will break down exactly how electric construction equipment telematics differs from traditional tracking and how to adapt your operations for a high-voltage future.

Electric Construction Equipment Telematics: The Core Differences

At a high level, the goal of telematics remains the same regardless of the power source: visibility, utilization, and security. However, the data points required to achieve those goals change drastically when you remove the internal combustion engine (ICE).

Traditional telematics relies heavily on engine run time, idling ratios, and fuel levels. For electric construction equipment telematics, the focus shifts to energy management. If a diesel generator runs out of fuel, a fuel truck can resolve the issue in 20 minutes. If an electric excavator runs out of charge mid-shift without a fast charger nearby, that asset is dead weight for hours.

1. State of Charge (SoC) vs. Fuel Level

Fuel level is a linear metric; you fill it up, and it burns down. State of Charge (SoC) is dynamic. Temperature, load weight, and age of the battery all impact how long that "50%" charge will actually last on the job site. Effective telematics for EVs must monitor real-time discharge rates to predict remaining work time accurately.

2. Charging Logistics and Workflow

With diesel equipment, refueling is a logistical task usually handled at the end or beginning of a shift. With electric equipment, "refueling" (charging) must be integrated into the workflow. Telematics data helps you identify:

• Opportunity Charging: Identifying downtime windows (e.g., lunch breaks) where equipment can be plugged in.
• Charger Availability: ensuring high-voltage assets are near power sources when parked.
• Peak Load Management: Avoiding charging all assets simultaneously if the job site has limited amperage capacity.

Battery Health Monitoring: The New Maintenance Standard

Maintenance on electric equipment is generally simpler than diesel—no oil changes, fuel filters, or transmission fluid to worry about. However, the battery itself is the single most expensive component of the machine. Protecting it is paramount to preserving the Total Cost of Ownership (TCO).

Advanced telematics allows you to monitor:

• Charging Cycles: Tracking how many full cycles a battery has undergone to estimate remaining lifespan.
• Deep Discharge Events: Alerting managers when operators drain batteries below recommended levels (e.g., <5%), which damages long-term capacity.
• Thermal Runaway Risks: Monitoring battery cell temperatures to prevent overheating during intense operation.

The Mixed Fleet Challenge: Unifying Data

For the foreseeable future, most construction and rental companies will operate mixed fleets. You will have diesel dozers alongside electric mini-excavators and hybrid lifts. The biggest risk to operational efficiency is data fragmentation—having one screen for your Caterpillar diesel machines and a separate app for your Volvo electric units.

This is where AEMP unified fleet data becomes critical. Your telematics platform must be able to ingest ISO 15143-3 (AEMP) data from all OEMs, regardless of fuel type, and normalize it into a single dashboard. You need to see "Fuel Level" and "Battery Charge" side-by-side to make dispatching decisions.

Security and Theft Recovery for High-Value EVs

Electric equipment often commands a higher purchase price than its diesel counterparts, making it a prime target for theft. Furthermore, because electric equipment is quieter, it is easier for thieves to move off a job site unnoticed at night.

Modern security tactics go beyond simple GPS dots on a map. For high-value electric assets, you should employ:

• Geofencing with Instant Alerts: Triggers an alarm the moment an asset leaves the designated work zone.
• Immobilization: Remote disable capabilities that prevent the machine from being started or charged.
• Hidden Trackers: As we discussed in our guide on telemetry vs telematics, having a redundant, battery-powered tracker hidden on the asset ensures you can recover it even if the main power source is disconnected.

Calculating TCO for Electric Assets

Rental companies and construction firms are adopting EVs to lower operating costs, but proving that savings requires data. Electricity is cheaper than diesel, but is it enough to offset the higher upfront purchase price?

By using Hapn’s platform to track energy consumption against engine hours, you can generate precise "Cost Per Hour" reports. This data is essential for:

1. Rental Pricing: Setting accurate rental rates that cover the asset's depreciation.
2. Bidding: improving bid accuracy by knowing exactly what the energy costs will be for a specific project duration.
3. Resale Value: Providing a documented history of battery health to potential buyers, increasing resale value.

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Future-Proof Your Fleet with Hapn

Whether you are running 100% diesel, fully electric, or a mix of both, you need a single source of truth for your assets. Hapn provides the visibility you need to optimize battery life, prevent theft, and maximize ROI on your electric investments.

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