IoT Solution for Backhoe Loaders – Engine Utilization, Location Tracking & Remote Control

A leading OEM specializing in construction equipment such as backhoe loaders, with a strong domestic and international market presence. They required an integrated telematics solution to remotely monitor, control, and service their equipment to ensure optimal usage, timely maintenance, and financial compliance.

Duration of Implementation: 4 months
Deployment Scope: Global (Multiple Countries)

Solution Overview

A comprehensive IoT solution was deployed to enable:

• Real-time location tracking
• Engine utilization analysis (RPM, running hours, idling)
• Remote immobilization control
• Field service request triggering
• Seamless integration with J1939 CAN protocol
• Multi-user mobile application interface for OEMs, Dealers, and Customers

Business Requirement

The key goals included:

• Accurate location visibility of construction equipment for security and usage tracking
• Access to operational insights from CAN data (RPM, engine hours, fuel level)
• Ability to remotely immobilize equipment in case of financial defaults
• Enabling field personnel to raise real-time service requests from site
• Provide a mobile app and cloud platform to OEMs, customers, and dealers for actionable visibility

Solution Modules

Location Update Module:

• Real-time GPS tracking of vehicles integrated with map-based view.
• Location accuracy dependent on installation positioning.
• Captures and transmits: Latitude, Longitude, Altitude, Speed, and Timestamp.
• Updates pushed to server every 5 minutes.
• Logs are stored onboard and uploaded for historical analysis.
• Intelligent power management implemented to conserve battery life.

Remote Immobilization Control:

• Immobilization relay integrated via OEM wiring (provided by customer).
• Immobilization requests are triggered securely from the central application.
• Conditions for activation:
  • Ignition OFF / Vehicle not running.
  • No tamper alert detected on the device.
• Status verification is done when ignition is turned ON post-immobilization.
• Remote deactivation (de-immobilization) possible anytime via the application.
• Relies on cellular connectivity for command transmission.

      Assumptions:

• GPS and immobilizer hardware is installed by certified technicians.
• GSM/ESIM network required for command execution.

Field Service Trigger Module:

• A physical service switch is provided with the machine.
• When pressed, it triggers a high-priority alert to the central system.
• Device continuously monitors switch state and instantly sends an alert upon activation.
• Alerts are pushed to the relevant service team as per app configurations.
• Enables faster service dispatch and assistance to end-users in remote areas.

CAN Bus Data Capture (J1939):

• CAN communication via J1939 protocol for standardized OEM-level data capture.
• Device listens to CAN bus and transmits data to cloud server without modification.
• Captures include:
  • Engine Speed (RPM)
  • Engine Running Hours
  • Fuel Level
• More PGNs can be added as shared by OEM.
• Data is periodically sent in raw SPN format for backend decoding and analysis.

Value Addition

Feature	Benefits
Real-Time Location Tracking	Enhanced asset visibility and operational efficiency
CAN-Based Engine Insights	Accurate analysis of utilization and maintenance needs
Remote Immobilization	Financial risk mitigation via equipment control
Field Service Requests	Improved customer support responsiveness
Battery Optimization Logic	Extended hardware lifespan, reduced maintenance
Mobile App Ecosystem	Seamless collaboration for OEMs, dealers, and customers
ESIM-Enabled Devices	Reliable international deployment with minimal configuration effort

 

ROI & Key Benefits

Metric	Value Delivered
Reduction in Downtime	25% improvement via timely service alerts
Enhanced EMI Compliance	Complete remote immobilization control for maximum security
Service Response Time	Reduced by 30% due to real-time alerts
Installation Flexibility	Enabled global rollout with ESIM integration

 
The IoT solution enabled real-time tracking, CAN data capture, and remote control for heavy equipment, giving OEMs visibility, insights, and improved service. Its scalable design supports digital transformation and operational control for other OEMs.