WORLD PROSPECTS
The next generation of productive hauling
Caterpillar is leading the way in the next
generation of productive hauling through
game-changing efficiency advancements
with the Next Generation of Cat ® Mining Trucks.
The 785 large mining truck was Caterpillar’s
first entry into the mining industry more than
three decades ago and, the company says, has
been a top performer on sites around the world
ever since. It’s fitting, therefore, that it is the
first of a new generation.
Designed by operators, for operators
“Where does the next generation of productive
haulage begin? It all starts with operators, who
work in an environment designed for them by
other operators,” Cat says.
Truck operators provided input, worked
alongside Cat’s large mining truck design team
and shared feedback to help create a state-ofthe-art
environment on board the 785 designed
for efficiency and ergonomics, and equipped
with features that increase comfort, automate
functions and boost confidence, from the
smallest operator to largest operator around the
globe, the company said.
The next generation operator experience is
safer, more consistent, more predictable and
more intuitive, shortening the learning curve
and boosting productivity of less experienced
operators, according to the company.
The new speed coaching feature gives
operators real-time feedback on how to operate
the truck to maximise its productivity, Cat told
IM. In field trials, the new AutoHoist controls,
meanwhile have shown reductions of up to 12
seconds in the dumping cycle. “This feature can
also reduce fuel burn during this portion of the
haul cycle,” the company said.
Features such as Hill Start Assist, Anti Roll
back, Enhanced Traction Control, Dynamic
Stability Control, Anti-lock Brake System,
Machine Speed Limiting and Cruise Control
improve machine responsiveness and
controllability, while improving cycle times and
reducing operator fatigue, the company added.
Serviceability and reliability
In addition to enhancing the operator
experience and efficiency, the next generation
truck platform delivers significant improvements
in serviceability and reliability, according to Cat.
“We’ve worked to reduce key contributors to
downtime with features like the new modular
HVAC (heating, ventilation and air condition)
system, which improves reliability and
consolidates components so the entire system
can be removed and replaced quickly,” Cat said.
Field studies have shown this modular
element alone can improve physical availability
by up to 0.5%.
New “Remote Flash” and Remote
Troubleshooting capabilities reduce downtime
and maximise machine availability, according to
Cat, providing the ability to troubleshoot the
machine remotely or
update the software of an
electronic control module
on an engine or machine
through cellular service.
“A manager in the back
office can securely push
machine software updates
over the air to the truck,”
Cat explained. “This
feature reduces machine
downtime and technician
time, allows updates to be
performed when most
convenient, and keeps the
machine up to date with
the most recent software.”
Connectivity and
technology integration
Mine sites have access to real-time information
and analytics that improve their total cost of
ownership, the company claims, with these next
gen pre-production machines “quantifying the
full value of new features” at multiple customer
sites right now ahead of the start of
manufacturing in the March quarter of 2021, Cat
says.
Cat says it will be easier to integrate
Caterpillar and certain third-party current and
future technology solutions on the next
generation platform, with offerings such as Cat
MineStar™ – which includes fully autonomous
haulage with Command – able to deliver a step
change in productivity, efficiency and safety.
This integration can provide valuable data
and analytics to enable near real-time decision
making, maintenance troubleshooting, and the
ability to predict and proactively prevent
failures, according to the company.
Included on the truck is an improved payload
monitoring system that comes with more
accurate measurements, improved monitoring
and an improved interface, according to Cat.
“Information is more accurate and the system
provides access to more data,” the company
said of this system. “The new system also
provides accurate dipper counts, reduces false
loading triggers and overload detection, while
carryback calculations are more accurate.”
The system also provides detailed haul cycle
segmentation and remote access through
telematics, Cat added.
The backbone of advanced connectivity on
the Next Gen truck platform is the ability to
communicate through dual mode cellular
4G/LTE and Satellite, or local Wi-Fi networks –
“whatever benefits the mine plan”, Cat says.
“Next generation connectivity delivers faster
data transfers, better access to data, consistent
and reliable data communication, more
insightful and actionable data, improved data
analytics and new diagnostic capabilities,” the
company explained.
The next gen 785 pre-production machines are
“quantifying the full value of new features” at
multiple customer sites right now, Cat says
“The NextGen telematics systems can collect
and transmit information securely into locallyhosted
or cloud-hosted applications, such as
Cat MineStar Fleet, MineStar Edge, and Health
Equipment Insights. These applications boost
productivity and improve maintenance and
machine life.”
Built on a solid foundation
With nominal rated payload of 138 t or higher
with optional larger tyres, the 785 has delivered
lowest cost per tonne in a wide range of mining
applications ranging from flat hauls to deep
pits, and solid roadways to challenging
underfoot conditions, the company said.
Its 3512E engine offers selectable power
options so miners can either match the speed of
their current fleet or speed up their cycle times,
according to the company. The optional Tier 4
engine has shown a reduction in fuel usage by
as much as 9%, while advanced electronic
transmission controls deliver faster cycle times,
faster acceleration, less spillage and reduced
haul road maintenance, on top of improved
engine and powertrain life. Longer-life
components, extended service intervals and
easier maintenance contribute to higher
mechanical availability.
“The individual features, components,
software and systems that make up the Next
Generation 785 have one very important thing in
common: they are all manufactured by
Caterpillar and supported by the Cat dealer
network.
“This integration ensures that the entire
truck, from tyres to transmissions, engines to
electronics, can be fully optimised to deliver the
lowest cost per tonne in any manned or
autonomous site applications in the world.”
www.cat.com/785
14 International Mining | SEPTEMBER 2020