Tag Archives: haul road maintenance

Komatsu offers up another haul road maintenance tool with GD955-7 motor grader

Mining equipment, Mining maintenance, , , , ,

Komatsu has introduced the new GD955-7 motor grader to the North American market, saying the machine offers operators the control and precision needed to build and maintain haul roads for truck fleets of 100 tons (91 t) and up.

This powerful new machine stands out with its 426 horsepower at 1,900 rpm (313 kW at 1,900 rpm) and powerful blade downforce pressure for efficient grading performance, the OEM says. It comes with an operating weight of 47,320 kg and a standard 5.5-m moldboard (6.1-m moldboard is optional).

“With faster working travel speeds compared to the previous model, Komatsu engineered the GD955-7 to increase grading efficiency while helping reduce maintenance requirements and total cost of ownership,” it said.

Despite its large size, the GD955-7 offers excellent manoeuvrability, executing tight U-turns on a standard 91-t class haul road without the need to fully cut the wheel or course correct, the company says. The long wheelbase and large, 27° articulation angle allow a tight turning radius and provide manoeuvrability for narrow haul road applications in confined spaces and around obstacles.

The newly adopted, long-life circle bearing allows for smooth and precise rotation of the moldboard while eliminating the need for circle play adjustments or replacing wear plates, Komatsu added. Coupled with a standard auto-lubrication system, the GD955-7 is engineered to help reduce planned and unplanned maintenance downtime while helping to extend life to overhaul.

“With significant increases in operating weight, blade downforce pressure and working travel speeds, this new size class motor grader will be a smart choice for increased efficiency on our customer’s mine sites,” Joseph Sollitt, Director of Mining Support Equipment at Komatsu Ltd, said.

MaxMine talks up data-led emission reductions for open-pit mines

Environmental, Mining equipment, Mining services, Mining software, Sustainable mining, , , , , , , , ,

MaxMine has been talking up the potential of data in the quest for reducing emissions and boosting productivity at mine sites, with Tom Cawley, Executive Chair and Interim CEO, arguing that there is still plenty of low hanging fruit for mining companies to leverage on their way to achieving longer-term net zero mining targets.

MaxMine, the company says, is an automated, high-resolution data-based business reporting tool that combines advanced data acquisition technology with AI analysis to fully optimise mobile equipment and operator performance within mining and other mobile equipment-based operations, measuring performance differently and using gamification to change behaviours.

According to Cawley, the average open-pit mine can reduce Scope 1 emissions by up to 10-15% by leveraging data, with MaxMine insights enabling this average open-pit mine to improve productivity while also reducing its carbon footprint by around 15,000-20,000 t of CO2.

IM put some questions to Cawley to find out more.

IM: In terms of your expanding product portfolio, where are clients receiving the biggest and potentially quickest return on investments (ROIs) from your solutions?

Tom Cawley, Executive Chair and Interim CEO of MaxMine

TC: MaxMine has the most extensive dataset in the open-cut load and haul mobile mining equipment sector. We continuously collect data from all sensors across 10 original equipment manufacturers or equipment manufacturers. We have around eight million hours of data, enabling MaxMine to provide unique levels of measurement in the mining sector and equip us with an unparalleled range of potential applications. This enables us to cover a broad scope across all mines while delivering tailored solutions to our clients, depending on their requirements from site to site.

The areas of the highest value proposition for our clients include improved TMM (total material moved) by increased payload, reduced cycle times via driver feedback, improved haul road conditions, enhanced safety and faster incident investigations. Cost reductions are delivered by reduced queueing, off-haul travel, idle time, and improved tyre life. High-resolution data is used to measure the performance of and diagnose mining trucks delivering greater efficiency via engine performance improvements and increased availability via predictive analytics and faster fault resolution.

IM: Although you have a specific product focused on decarbonisation (MaxMine Carbon), would you say the majority of your solutions are providing emission reduction benefits? In terms of adding new clients, is this where a lot of the emphasis is?

TC: Yes, there is a strong correlation between productivity and fuel intensity reduction. The better productivity, the better the carbon intensity.

MaxMine Carbon enables mine sites to measure fuel burn on every asset, every second of the day. MaxMine’s high resolution data allows the difference between business as usual and improved operations to be measured, allowing the fuel saved to be included in the productivity benefits.

MaxMine’s high resolution data is used to:

  • Measure actual truck performance, identify trucks operating below design efficiency and provide diagnostic information; and
  • Provide granular feedback to drivers, which can be used to reduce fuel burn.

MaxMine Carbon isn’t only a separate fuel-saving feature; its capability allows open-cut mining companies to measure, manage and reduce their carbon footprint associated with Scope 1 diesel emissions and reduce operating costs related to diesel consumption.

IM: Where is the development of MaxMine Carbon for underground mining? What timelines do you have around the development and rollout of this solution?

TC: Open-cut mining is a large sector and offers significant opportunities for growth. It is much more energy-intensive at the equipment level compared with underground mining.

MaxMine is growing robustly in this area, and we’ll continue focusing on further penetration in the open-cut mining space in the near and medium term.

IM: Is your market proposition stronger at bulk mining operations than others?

TC: Our market is focused on open cut-mining and larger-size trucks, with a size class greater than 100 t.

IM: Outside of your existing portfolio, where do you see room for growth with different solutions? Are you actively engaged in pursuing such opportunities?

TC: We continue to focus and remain disciplined on our core markets, and our unique selling proposition delivers huge opportunities for MaxMine and the open-cut mining industry.

Caterpillar looks to reduce haul road dust with new Cat 777 (05) Water Solutions Truck

Automation, Environmental, Mining equipment, Mining maintenance, Mining services, Water management, , , , , , , , ,

Caterpillar has released a new water truck that, it says, provides an integrated solution to help reduce haul road dust by solving overwatering and underwatering issues.

The new Cat® 777 (05) Water Solutions Truck is built on the Cat 777E truck platform, proven at mine, quarry and construction sites globally. An innovative truck that uses less water for controlling haul road dust, the design integrates the truck, tank and water delivery system, connected with technology, the company says. Its Cat Water Delivery System (WDS) combines with Cat MineStar Edge™ connectivity to help operations manage the site more safely and productively with flexible levels of technology to meet site needs.

Boasting a 75,700 litre Cat-branded water tank, the 777 (05) comes complete with spray system, splash guards, fill chute and rock ejectors. It is powered by the 765 kW Cat C32B engine that meets China Nonroad Stage III emission standards, equivalent to US EPA Tier 2.

The new water truck’s exclusive Cat WDS features a self-contained hydraulic system that controls spray patterns independent of engine rpm for consistent watering, Caterpillar says. Variable water flow, based on the truck’s speed, automatically starts and stops when the truck slows or comes to a halt, preventing overwatering and subsequent poor traction at road intersections. The pump features soft start-ups and automatically shuts off when the tank is empty to prevent system damage.

WDS components include a water cannon, oil cooler, variable displacement pump, hydraulic oil tank, electronic control boxes and hydraulic motor/water pump. Covering up to a 24-m-wide road in a single pass, the system sprays at rates reaching 0.8 litres/sq.m at speeds from 4-40 km/h. With its maximum 61 m spray distance, the truck’s water cannon offers a maximum flow rate reaching 4,732 litres/min.

Factory-installed, ergonomic water controls are integrated into the truck’s design for convenient system operation, Caterpillar says. Its automated water delivery feature enables the operator to remain focused on driving and site traffic to enhance safety. Complete with auto shut-off to prevent overfilling, the water tank is filled remotely, allowing the operator to remain inside the cab during the cycle to reduce potential operator slips and falls.

Flexible levels of the cloud-based MineStar Edge technology are integrated with the Cat WDS to collect and communicate machine data, allowing site supervisors to monitor the water truck to know where and when it’s spraying water. Asset management options include productivity, water usage, fuel and water tank levels, when and where to apply water, geofencing, asset location and remote management of water distribution.

Providing tracking capabilities without the need for infrastructure investment, Edge Equipment Tracking delivers basic connectivity without interfering with existing fleet management systems. Equipment Tracking helps to achieve a lower total cost of ownership, providing insights to help mines better manage their assets, the company said. It features service meter readings, fuelling and recording data, location accuracy and replay, time utilisation tracking with downtime and operator tracking, automatic stoppage measurement and health event recording.

Paired with Equipment Tracking, MineStar Edge Production Recording delivers premium connectivity with an accurate and automated near-real-time measurement solution that reports on every aspect of the watering cycle without requiring operator input. Giving visibility to the entire operation, it helps to discover opportunities for improving productivity. This premium package also includes water usage by truck/fill station, volume and rate of water put down over time and area covered, water delivery system setting by location, truck, and conditions, activity breakdown with time and distance – watering, not watering, stopped, etc.

This integrated system with Cat-branded tank options is fully supported by the Cat dealer and parts network. Covered by the Caterpillar factory standard warranty, the water truck, including tank and components, is eligible for Cat equipment protection plans and customer value agreements. Cat dealer installation of the integrated system is available, and retrofit kits for existing Cat 777E truck platforms in the field have planned availability in the future.

New High-Performance Circle boosts Cat 24 and 24M motor grader performance

Equipment maintenance, Mining equipment, Mining maintenance, Mining services, , , , , ,

Caterpillar’s new High-Performance Circle (HPC) for Cat® 24 and 24M motor graders improves machine performance, efficiency and uptime availability when maintaining haul roads at large mines, according to the manufacturer.

When paired with Cat exclusive extended life blade rail wear strips, the HPC reduces total cost of ownership for the drawbar circle moldboard and downtime by up to 80%, it claims.

Providing a 16,000-hour service life, the new HPC eliminates hours of monthly planned maintenance for frequent inspection, wear strip replacement and circle shoe adjustments associated with conventional circles. Industry-leading machining capabilities designed to tight tolerances help ensure the drawbar, drives and circle perfectly align and require no adjustments for the life of the grader, Caterpillar says.

Cat proprietary heavy-duty planetary gearboxes with integrated forged pinion shaft and gear replace the work drive gearbox and pinion gear system. The gearboxes, meanwhile, have sealed-for-life slip clutches that eliminate adjustments and isolate the clutches from the rest of the drive to increase reliability. Significantly reducing maintenance time, the slip clutch assemblies can be changed out in less than an hour and come adjusted from the factory, according to the company. The brass circle wear strips and shim system is replaced with a sealed roller bearing.

The new fully-sealed roller bearing delivers smooth and effortless blade rotation. Fully integrated with standard machine auto lube, the design eliminates daily greasing and can require no maintenance, adjustment or replacement for 16,000 hours, depending on the application.

A new pinion gear shape with increased shaft diameter for improved durability allows drives to be removed vertically without drive adjustments. And dowel locators precisely position motors for easier servicing, optimal tooth contact and longer pinion life, the company says. Its new design improves component reliability to reduce downtime and maintenance costs.

Caterpillar says: “Beyond lowering total cost of ownership, less required circle maintenance reduces component handling to properly maintain the machine, which improves safety for service technicians. At 16,000 hours, if the circle teeth have reached their wear limit, they can be rotated 180° to double the component’s service life. The new HPC maintains the same machine connection interface, so it is retrofittable to all Cat 24 and 24M Motor Graders.”

Increased power and more robust structures for the new Cat 24 make it an ideal pairing for Caterpillar’s longer 8.5-m moldboard option, the company says. The grader’s new Cat C27 engine, up to 37% increase in torque and new HPC are well equipped to accommodate the blade’s increased weight and width without slowing or bogging down the machine.

At 16% longer than the standard 7.3-m blade, it helps improve safety at larger mines by reducing the amount of time spent in the middle lane to clear the windrow. When used for a wider pass, it brings haul roads back to specification in fewer passes, eliminating one pass when supporting ultra-class trucks, Caterpillar claims. Longer moldboard reach places the windrow farther away from the rear tandems to increase traction. It also allows the operator to use a more aggressive blade angle to reduce machine load, increase speed on passes and help improve material handling.

The 8.5-m moldboard option is retrofittable to existing fleet Cat 24 motor graders. It can be connected to the machine with Cat extended life blade rail wear strips, available for both standard and high-performance circles, to achieve up to three times longer service life than standard rail wear strips.

Milestone Cat 24 Motor Grader set for Rio Tinto’s Pilbara operations

Mining equipment, Mining maintenance, Mining services, Steel and iron ore, , , , , , , , , , ,

Twenty-seven years after introducing the Cat® 24 Motor Grader to the mining market, Caterpillar has celebrated the production of its 1,000th unit.

At a ceremony held on September 22, 2022, Caterpillar executives and motor grader production team members gathered in Decatur, Illinois, to celebrate the production and sale of this milestone machine. The grader, destined for Australia, was sold by Cat dealer, WesTrac Pty Ltd, to Rio Tinto’s Pilbara Operations in Western Australia.

During the event, Caterpillar team members heard from both WesTrac and Rio Tinto Iron Ore representatives, through videotaped comments. The milestone machine includes a special 1,000th unit commemorative plate.

In 1995, Caterpillar introduced the Cat 24 Motor Grader specifically designed to build and maintain haul roads at mining sites with ultra-class haul trucks. Now in its third generation, the Cat 24 offers 399-518 kW of power, weighs 61,950 kg, comes with a 7.3 m moldboard – with an 8.5 m moldboard option – and technology as standard to work wide haul roads efficiently, according to the OEM.

Sam Vedhakumar Manoharan, Caterpillar’s Vice President of Product Management, Earthmoving, said: “The Cat 24 Motor Grader was and continues to be a game changer for maintenance efficiency of the wide haul roads necessary for ultra-class trucks. We thank the many global mining operations and dedicated Cat dealers around the world for their loyalty to the Cat 24 grader.”

Today’s Cat 24 Motor Grader features more than 30% higher power, 13% more weight and a longer rebuild life than previous generations. It will also soon feature a high-performance circle design for further improved reliability.

Stephen Jones, Rio Tinto Iron Ore Managing Director of Planning, Integration and Assets, said: “For years, we have used Cat 24 Motor Graders to maintain our haul roads for our ultra-class trucks. The Cat 24 series offers a great combination of power, weight and blade width to support road maintenance coverage for our large mining fleet. We are honoured to receive the commemorative 1,000th 24 Motor Grader, and this represents the third generation we’ve used across our Pilbara mining operations.”