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EQUIPMENT TRUCK UPDATEEQUIPMENT TRUCK UPDATE
Haul truck future
Tmanu acturers wt a num er o maor
m n ng pr ects on o , par t cu ar y
pressurs ng t e u tra-c ass mar et w ere
t e ey contracts are re at ve y ew an aretween, compare to ower-capac ty c asses. e
following details developments at Caterpillar and
Liebherr, but also reveals for the first time BELAZsplans to roll out key models in North America.
Among the other manufacturers, namely Komatsu,
Hitachi and Terex, there have also been someimportant developments. The first Komatsu 960E
fleet is being commissioned at a Peabody coal
peration in the US, following very successful testing
f the truck at Rio Tintos Bingham Canyon mine. Afuture Mining Magazinearticle will examine the
progress of the 960E in more detail. The new Terex
eet at ustra as no ron magnet tem ne s operat ng we , an t e company s pursu ng
pportun t es or t e n ustrys newest u tra-cass
truc e sew ere.tac , w ose truc was ment one
ar er t s year , a y , p , as now s ppe
20 of its new EH3500ACII trucks, which are well spread
ut geographically: three are operating in Australia
with contractor Comiskey, stripping overburden in a
oal mine; two are operating in South Africa with Anglo
oal; four are in Finland at Talvivaaras nickel mine;
nd four others are operating in the US with MasseyEnergy, stripping overburden at a coal operation. The
remaining trucks are waiting to go into service.
The company states that the general feedback has
been positive, with the drive system performingparticularly well. Finally, the all-new EH4000ACII has a
prototype still under test, with product approval due
in December. The new truck is expected to be
vailable commercially in January 2010, subject toboard approval.
n one o t e most s gn cant mar et- eve opment
ec s ons n t e story o e aruss a- ase truc
manu acturer , t e company as c osen tontro uce ts truc s to ort mer ca. t oug t e
firm makes more than 2,000 pieces of equipment per
year for the mining, construction and specialised
vehicle markets, the North American launch willfocus on its new electric-drive mining trucks with
10-130t and 220t capacities. The BELAZ trucks will
be marketed and service support will be provided by
new subsidiary, BELAZ Trucks Americas, which willbe headquartered in West Bloomfield, Michigan.
Initial efforts will be directed at a group of selectedustomers where the advantages of the BELAZ trucks
nd the capabilities of the support network can beuickly demonstrated.
Semyon Brayman, president of BELAZ Trucks
mericas, tells n ng agaz ne: We recognise that
o penetrate the North American mining market wemust offer trucks that use the latest technology to
provide excellent productivity, and that we must
onstruct a va ue pac age t at nc u es attract veruc pr c ng, so re a ty an an opt m se
perat ng cost per tonne. e ave strong pro ucts,
e ave a strong support networ an we are exc teo e a e to r ng truc s to ort mer ca.
any n t e n ustry w o ave not seen
rucks in action in its stronghold markets of Russia,
hina, Kazakhstan and Ukraine may wrongly considerhem to be outdated. However, todays latest BELAZ
iesel-electric models are equipped with Cummins or
MTU engines and General Electric drives, with a
performance on a par with any other haul truck onhe market.
Almost 1,000 of the latest-design mine trucks fromBELAZ have accumulated over 10.3 million hours of
odels and upgrades from the leading haul-truckanu acturers in 2008, Paul Moore provides exclusive news
o a major new market entry by BELAZ and an in-depthupdate on progress at three other established players
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EQUIPMENT TRUCK UPDATE
peration in some of the worlds most demanding
terrain. They are equipped with state-of-the art
technology, based on highly-engineered designs
rom t e tec no ogy centre, w c asapte components to customer nee s.
e new ort mer can mo e s w e
es gnate - t an t .
The NA designation signifies that the basicdvantages of the trucks have been enhanced with
omponents and materials specifically for Northmerica. Key areas of improvement include:
increased stability of movement while loaded;
tructural protection of vulnerable engineomponents; a rear-axle design that minimises
manual maintenance of brake gears; a heated body
esigned for ease of loading, and high-efficiency
lectro-dynamic brakes. The trucks also offermaintenance labour minimisation through optimal
location of assemblies reduced lubrication points and
the use of maintenance free materials.e stan ar eng n e or t e w e t e
er , an on t e t w e t eer . omp ete - r ve systems
will be standard on both models. Aside from the
re uce emss ons an ncrease orsepower
dvantages of the engine, as well as the proven
tate-of-the-art drive technology, the parts andervice for both are readily available from their
numerous authorised outlets.
In addition, the BELAZ 320t 75600 truck has beeneveloped and is operating in several locations in
Russia. The current plans are that this truck will also
be made available in the North American marketwhen field experience and market conditions dictate.
Wider aftermarket support for the trucks will be
provided by companies that have establishedpersonne an n rastructure at, or near, target m ne
tes. ome o t ese companes a rea y prov e parts
n servce support or ot er pro ucts use n t e
m n ng n ustry.e truc s w n t a y e assem e n e a rus
n s ppe to ort mer ca, ut, at some po nt n
the future, basic truck components may be fabricated
nd sent to North America where they will beombined with the engines, drive systems and perhaps
her components now manufactured in the US.
ATERPILLAR MOVES FORWARDIn a statement in August, Caterpillar said it is moving
rapidly forward with the new large mining truckshowcased at MINExpo 2008, which represent the
ompanys largest-ever investment in new miningechnology. According to the company, the
aterpillar 793F and 797F mechanical-drive trucks,
s well as the 795F AC electric-drive truck, are allchieving milestones.
Caterpillar states that it believes mechanical-drive
mining trucks will satisfy the needs of the vast
majority of mining operations, but as the onlymanufacturer of 181t and larger mining trucks with
both mechanical and electric-drive systems, it will be
e to o er truc s t at a ress a m n ng companypre erences.
t t e t me o t e ugust announcement, t e
an a accumu ate more t an ,f field testing, and proven their per formance
apa t e s an ura ty. e new aterp ar
ngine that powers them had racked up 130,000h of
field testing in mining trucks and more than 120,000hin power systems. Based on the success of these
field-follow programmes, both models will be in full
production and commercially available by the end of
his year, with the 793F available first.The C175 engine meets US EPA Tier 2 emissions
tandards and delivers 4,000hp in the 20-cylinderversion that powers the 797F. The 16-cylinder C175
powers the 795F AC with 3,400hp. It also powers the793F, with 2,650hp. According to Caterpillar, the
175 promises longer life between rebuilds, lower
ound levels, improved altitude capability andimproved fuel consumption compared to the 3500
eries engines it replaces.
By the end of September there were five 793F
ield-follow trucks operating in US copper and goldmines. They have accumulated about 30,000h of
peration and are said to be performing well. An
t ona our s ave een retro tte w t- eng nes an t e eng nes ave accumu ate
more t an , o runn ng t me.
e - o ow s ave a so per orme ver y wet severa app cat on s tes, nc u ng ow er ver
as n coa , t e erta o san s an n a out
merican copper operation. Nine 797F field-follow
rucks have accumulated a combined 50,000h ofperation. In addition, three other 797s have been
retrofitted with C175-20 engines and have
ccumulated more than 12,000h of operation.
According to Caterpillar, test results have shownhe expected increased production when compared
head-to-head with the previous 797B model and the175 20-cylinder engine is said to have performedomatsu 960E, Bingham Canyon
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very well. While no commercial orders have officially
been announced, several orders are in place, most
notably from an operation in South America.
s a ran new p at orm, t encorporates new tec no og es t roug out. n
xamp e s our- corner, en e ra ng an
retar ng us ng aterp ar o - m merse an coo e
sc ra es, as we as e ectr ca r etar ng, w cnhances safety and operator confidence.
Caterpillar engineers have also been testing two795F AC prototypes, including the truck shown at
MINExpo, at the Tinaja Hills testing site in Arizona.
The development programme has provided input forthe construction of a new 795F AC in Decatur, Illinois.
This new truck was recently shipped to a copper
mine in North America where it will serve as the first
field-follow 795F AC. The 313t-capacity 795F ACrepresents a new size class for Caterpillar, and, as a
result, the primary focus of the Caterpillar AC electric
programme has been on the 795F AC. Late 2010 ist e e y commerc a aunc ate, a t oug tests at
m ne s tes w n uence t e na ec s on.e eve opment programme as now
een suspen e , arge y ue to t e ownturn n t e
wor economy an ecause test ng s owe t at t e
- r ve mo e w not ave an a vantage n cost
per tonne over the mechanical-drive model. Futureinput from customers who have a preference for
lectric-drive trucks will drive the decision on the
restart of the 793F AC programme.
LIEBHERR MINING EQUIPMENT LME2009 has been a year of highs and lows for Liebherrstruck business, as it has for the whole large mining
truck industry. Due to the economic downturn and
its effect on the forward orderbook, the workforce atewport ews was re uce y emp oyees ear er
t s year. ccor ng to e err, t e wor ers were
ss ste w t n ng emp oyment e sew ere, suc as
t t e ort rop rumman s pyar , a so ocate newport ews. e company te s n ng agaz ne
g y tra ne an s e we ers t at e err
utilises for frame fabrication are always welcomewhen looking to use their skills towards local
hipbuilding.
Despite this, Liebherr is continuing to ship modelsf its highly successful T282B 363t-capacity diesel-
lectric AC-drive truck. Recent order announcements
have included news that Asarcos Ray copper mine
near Phoenix, Arizona, has purchased four new T282Btrucks, boosting its fleet to 13 units. The 363t-payload
trucks will be phased in as older and smaller-capacity
auage equ pment s gra ua y ta en out operat on. e new truc s are equ ppe w t
ese eng n es an c e n
ow-pro e tyres. e err s o er ng tec n caupport, a parts warehouse and an on-site office as
part of its customer care package for Asarco, as well
s an a t ona t ree servce truc s to support
the fleet.Elsewhere, Liebherr announced that it is in the
process of delivering seven T282B trucks to Codelcos
Radomiro Tomic mine by the end of this year. This
pen-pit mine produces oxidised copper ore at over3,000m above sea level, some 1,670km north of
Santiago, Chile. The order will take the total numberf Liebherr trucks in the Codelco Norte Division to 48;
truc s are at uqu camata an at a omro
Tomic. There is a further order for 12 new T282B
rucks, which will be shipped to BHP Billitons Mountrthur Coal in Australia at the end of 2009 and
nto .
Overall, the company says it believes the outlookfor 2010 is promising with various projects coming
nline, including supplementing existing customer
fleets with new trucks, but also developing andmanufacturing prototype/pre-series models for mine
ite testing.
On this subject, the much-discussed TI 274, firstown n a prototype orm at t e auma s ow
n un c , s cont nu ng m ne-s te test ng an w
ave a secon prototype un t s ppe or p acement
n m ne pro uct on towar s t e en o t s year.e err states t at t e pro uct- eve opment
imeline at this point looks to 2011 for this truck to be
ommercially available. The standard TI 274 engineill be an MTU 16V4000 Tier 2, rated at 3,000hp,
but it will also be available with a Cummins QSK60,
rated at 2,850hp.
ys ca y, t e truc oo s t e same as t e one
presente n , ut, accor ng to t e company,
here have been numerous developments from theesting process that have been incorporated into the
esign of both prototype trucks. Future test results
ill warrant additional improvements. But thereremains significant interest.
Jonathan Baucom, product manager, mining
rucks, at LME comments: More and moreustomers are requesting information on the TI 274,
anting to run their own cost-per-tonne scenarios to
ompare truck options against the innovative lowan g -pay o a es g n t at t e mo e emp o ys.
so on t e or zon s t e new generaton o t e
, t e , w c w rep a ce t e current
truc . ase on t e pro uct re ease ate o t eT282C and the number of orders at the time, the first
ruc s w t er eng nes may e e vere as ear y
s the December quarter of 2010. The T282C will haven MTU Tier 2, 20V4000 engine, rated at 3,750hp, as
tandard.
Mr Baucom tells n ng agaz ne: A number ofproduct enhancements have been made to the
T282C from the original T282B. The main areas are: a
new frame with more robust castings in high-stress
reas; a new axle box with greater brake and wheelmotor cooling, with improved service access; and the
Liebherr drive system being incorporated into the
new truc eatur n g e err- es g ne an u tontro ca net, coo ng system, w ee motors an
p anetary gears. co s on-avo ance pac age w
so e an ava a e opt on.The firm adds that while the drive system, engine
performance and payload rating are not designed
o substantially improve truck performance, instead
he focus of the T282C is achieving increasedreliability and availability by vertically integrating
ruck components within the Liebherr group. This
ertical integration of major components allows
rapid design changes for safety, reliability andfficiency, as opposed to working with a third-partyruck-component supplier where making such changes
ould be much more difficult.
tru c operat ng n uss a. e company w o er ts t an t truc n t a y on t e mar et
erex , no ron
EQUIPMENT TRUCK UPDATE
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