What’s your quarry?

To this end, we were gripped by an event called MineExpo held in Las Vegas in the latter part of last year. There was far too much equipment on display to detail each and every piece, so we picked out a few items that could bring greater productivity to a quarry site near you.

Wheel loaders

There were many large loaders on display, with products from brands such as Liebherr, Komatsu and LeTorneau. However our attention turned to the latest offering from Caterpillar, the 993K.  Launched at the show, the item is available by special order from the region’s Cat dealers. The all new model offers a new size class in the Caterpillar line-up. The 25-ton capacity loader features Z-bar linkage, hydraulics and power train that deliver high breakout forces—20 percent more than the 992G. The increased performance and capacity result in a 15 to 20 percent improvement in productivity compared to the 992G, according to the manufacturer.

The new loader at the show also features the Cat C32 ‘Acert’ engine. It produces net power of 950 horsepower (708 kW). The makers also say that the newcomer offers solutions to ease maintenance and boost reliability.

For example, an improved design eliminates the need for daily greasing of the front linkage. To lower life cycle costs, the 993K is designed to meet mining customer rebuild requirements and have an estimated 45,000-hour structure life.

Power train

The power train and hydraulics are designed to deliver high productivity and low cost per ton. As compared to the 3508B engine used in previous mining loaders, the C32 engine delivers 19 percent more power and a 5 percent increase in fuel efficiency. The proven C32 also powers several other Caterpillar mining machines, which simplifies parts inventory management.

The 993K features a new design of modular radiator which has copper fins for improved heat exchange capabilities. The design and construction minimizes space required for the cooling package and allows enhanced sight lines to the rear. 

Positive flow control hydraulics is the next generation of load-sensing hydraulics. Additional sensors at the pumps provide enhanced responsiveness that the operator can feel and use. The full return flow filtration system filters 100 percent of the implement oil return flow to 6 microns for extended component life and increased uptime. The optional deluxe filtration system prevents downstream contamination in case of a failure.

The Cat planetary power shift transmission is electronically controlled and features three forward and three reverse speeds. The impeller clutch torque converter allows the operator to match rimpull to the application and underfoot conditions through the use of a foot pedal and adjustments made through the rimpull control system.

The all-wheel drive design features four planet carrier gears with planetary double reduction in each wheel. Double reduction final drives significantly reduce power train stresses and effectively extend power train life and durability.  

Options for reduced maintenance include the Oil Renewal System (ORS). By regularly burning small amounts of engine oil and automatically adding makeup oil to the crankcase, ORS offers a means to reduce or eliminate engine oil changes and to increase machine availability. Another interesting option is zip-in zip-out glass. This feature provides rubber-mounted glass, which does not require adhesives to retain the glass. The system enables fast changes of damaged glass.

Volvo A35E Articulated Hauler

Few quarries operate without a fleet of dump trucks to take away the rubble, and a flexible and highly efficient way of doing this is with an articulated hauler.

Volvo claims to have invented the concept back in the 1960s.

The current E-series haulers have a long list of features that set them apart from their predecessors including a payload of 33.5 tonnes,while the patented planetary transmission features smooth shifting providing maximum rimpull (which loosely is the amount of power the truck can transmit between the tyre and the contact patch of the ground.)

The maker says that electronic monitoring of fluid levels means enhanced reliability as well as no need for daily service.

Downtime during service is short, thanks to fewer service points on a new suspension design.

A fully loaded body is raised in only 12 seconds, and lowered in only 9 seconds, while the new design of the cabin leaves plenty of room for personal items such as a lunchbox and the seat features air-suspension.

Visibility around the machine is improved even more over predecessors with the large rearview mirrors, large windscreen and windows.

Giant Excavator

Even in quarry pits, really big excavators and mining shovels are a rarity in this region. That said, there is now at least one more to chose from, with the launch of a massive new 800-ton machine at the Vegas show. 

Liebherr announced the R 9800 mining excavator. Rated at 800 tons of service weight the R 9800 provides a nominal bucket capacity of 38 to 42 m³ at a material density of 1,8 t/m³. This new flagship of the German firm’s mining excavators’ range is targeting bucket loads of 75 tons in both versions, as a backhoe and a shovel execution.

The maker is providing for the machine two engine options, two Cummins QSK 60 with a installed power of 1,492 kW / 2,000 hp each or two MTU 12V4000 with a installed power of 1,425 kW or 1,910 horsepower.

Whilst the backhoe digging envelope and bucket width remain similar to the previous Liebherr flagship, the R 996, the R 9800 in backhoe configuration provides a break out force of 1,840 kN with a digging force of 1,750 kN. In shovel configuration, the machine is achieving crowd forces at ground level of 2,980 kN and breakout forces of 2,350 kN. These values ensure superior digging capabilities even in toughest mining conditions.

The first units of the new flagship are currently in the final stages of factory testing and the first machine is soon due for operation in Australia.

Although the mining giant was launched at the show, it wasn’t actually on display. The accolade for the largest machine was the Hitachi EX5500-6, which broke the record (as far as we could tell) for the largest machine ever bought to a trade show, tipping the scales as it did at 570 tons. The newcomer features a choice of buckets up to 40 cubic yards, and is powered by two Cummins QSK50-C engines totaling 2,800 HP.

Bulldozers

Komatsu are no strangers to the world of super-large bulldozers. For the last ten years, several examples of the super-large D575a have grazed their way around the region. More common, however is the slightly smaller D475, and it was the latest incarnation of this, the D475a-5 Super Dozer that was on display at Minexpo.

This machine has an operating weight of about 125 tons. With 890 hp, it is pitched to compete with the equally large Caterpillar D11T. Also of interest on the Komatsu stand some enormous rigid-body mining trucks. At the top of the range was the new diesel/electric 860E. The maker has teamed up with electronics company Siemens for the development of new electric drive system.

 It consists of a generator, AC motor, inverter, final gear and other components. The 860E integrates Siemens’ leading-edge electric components and Komatsu-developed and manufactured mechanical components, such as the final gear. Needles to say, the firm suggest that this new tech will go towards improving productivity and reduce operating and maintenance costs.

A factory installed trolley-cable option is also available for the 860E. Pantograph-mounted dump trucks receive electric power from the trolley cable extended over their travel routes to drive their AC motors. The trolley system supports high-climbing performance. Also, dump trucks use electricity generated at the mine instead of electricity generated by their own engines, which can extend their engine life to a great extent and cut down fuel expenses. We hope to see one in the region soon.

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Cat 993k Specifications	Standard	High Lift
Engine model	Cat C32 ACERT	Cat C32 ACERT
Gross power	1,050 hp (782 kW)	1,050 hp (782 kW)
Flywheel power	950 hp (708 kW)	950 hp (708 kW)
Operating weight*	294,670 lb (133 637 kg)	296,800 lb (134 603 kg)
Payload	25 tons (23 mt)	25 tons (23 mt)
Bucket capacity range	16-19 cu yd (12.2-14.5 cu m)	16-19 cu yd (12.2-14.5 cu m)
Dump height	15 ft 3 in. (4654 mm)	17 ft 4 in. (5299 mm)
Reach at full lift	8 ft 2 in. (2503 mm)	8 ft 6 in. (2612 mm)
Static tipping load, full turn	161,687 lb (73 327 kg)	134,639 lb ( 61 016 kg)
Breakout force*	159,562 lb (709.2 kN)	159,416 lb (708.5 kN)

•  With 17-cu-yd (13-cu-m) bucket

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Volvo CE A35E	Specifications
Engine	D12D AFE3*/AEE3**
Max power at	30 rs (1800 r/min)
SAE J1995 gross	313 kW (426 hp)
ISO 9249, SAE J1349 net	309 kW (420 hp)
Max torque at	20 r/s (1200 r/min)
SAE J1995 Gross	2100 Nm
ISO 9249, SAEJ1349 Net	2056 Nm
Max. speed	57 km/h
Load capacity	33 500 kg
SAE 2:1 heap	20,5 m3
Net weight	28 100 kg
Gross weight	61 600 kg
* Meets Europe (EU) Stage IIIA.** Meets US (EPA) Tier 3, California (CARB) Tier 3 and Europe (EU) Stage III. Table from FAMCO website.