Caterpillar at CES 2025

If there’s one thing we’ve learned over the course of a century in business, it’s this: Different customers have different needs, and no single solution is right for everyone. That’s why, when it comes to electrification of the jobsite, our strategy isn’t to switch to battery-electric equipment exclusively. We’re not telling customers, “It’s our way or the highway.” Instead, we’re focused on giving them options, so they can choose what fits their needs and goals best.

Some customers are ready to transition to fully or partially electric jobsites now, and we’re ready to support them with our lineup of battery-electric prototype machines and charging solutions. For others, our diesel-electric and diesel-mechanical equipment simply makes more sense for the time being. We’re also exploring a third option that falls in between our two existing solutions — and it’s the centerpiece of our CES 2025 booth.

Our CES exhibit will feature a “technical demonstrator” for an extended range electrified machine hybrid retrofit. That’s a mouthful, so let me try to explain it simply.

We’ve taken an existing Cat^® 972 wheel loader and retrofitted it with a battery, inverter and motor powering the traditional drivetrain – and we did this in under two months, with a small but focused team. What sets this machine apart from our battery-electric prototypes is the addition of a power source. A conventional diesel generator runs AC power to a rectifier, which converts energy from AC to DC. That energy can then be used to charge the battery, drive the machine or both.

This technology would allow a customer to operate on 100% zero-exhaust emission battery power for several hours. Or, for longer operation, the machine could run in hybrid mode with electricity generated by the onboard generator — which could be powered by alternative fuels. The machine can charge overnight on a regular utility grid connection at 240V.

We’re just in the testing stage with this hybrid retrofit, and our next step is to get it out on real jobsites and start gathering customer feedback on what works and what needs improvement. But we’re excited about its potential for a couple of key reasons:

• One, it should eliminate the need for additional electric infrastructure on the jobsite. In our tests so far, the demonstrator maintains performance similar to a 972mxe diesel machine in terms of power and run-time (provided the machines are being used in similar applications) without requiring DC charging. That’s critical, because a lack of infrastructure (or the cost of installing it) is a challenge that’s holding some customers back from going electric right now.
• Two, it takes advantage of our built-to-be-rebuilt philosophy. Cat equipment is designed to work for multiple lifecycles. Major components can be remanufactured or rebuilt to like-new condition — often multiple times — rather than being discarded after a single use. This retrofit option would allow our customers to convert an existing machine into a hybrid machine at rebuild time, without requiring a financial investment in new equipment. A lower cost of entry may make switching to a lower-emissions solution more feasible for more operations.

At Caterpillar, continuous innovation has always been driven by one thing: what our customers need. And what they need right now are options that solve today’s problems while taking them to the next step in their own energy transition journey.

A lot has changed since 1925, most notably the challenges our customers face and the technologies available to address them. What hasn’t changed is our commitment to finding creative ways to solve real problems, and this hybrid retrofit is just one example. Innovation has always been our competitive advantage — and sustainable innovation is what will drive us forward into our next century.

For a firsthand look at the technical demonstrator extended range electrified machine hybrid retrofit, visit our booth (#6416) at CES 2025, where we’re also showcasing a remote operating station and a virtual jobsite of the future. Can’t attend? Learn more about what’s on display by visiting cat.com/CES or following #CATatCES on social media.