The advanced features that come with Cat 785, 789 and 793 next-generation trucks are improving productivity and safety in the Australian mining industry.
The Caterpillar, or Cat, 125–240-tonne productivity class mining trucks – Cat 785, 789 and 793 next-generation models – have been upgraded with multiple new product developments.
Cat mining trucks general manager David Rea said they’re built on an advanced platform with common electronic architecture, cab and controls.
“These next-generation mining trucks feature a flexible technology platform and optional configurations to help each mining operation meet their goals,” Rea told Australian Mining.
All models are direct mechanical drive and boast the latest electronically controlled transmission with advanced electronic control strategy.
The transmission offers smooth gear shifts for a smoother ride and delivers productivity and efficiency improvements.
There are more than 30 new or improved features with the next-generation truck design, focusing on safety, productivity and operator confidence.
These include a productivity-boosting cab, an operator-focused environment that ergonomically accommodates a wider range of drivers, and confidence-building controls that advance safety and operator confidence.
“The walkthrough cab offers 34 per cent more space than the D series,” Cat 793 product applications specialist Rob Shea told Australian Mining.
This results in more room for the operator and trainer, increased storage, and added space for third-party or dealer-installed options.
The new trucks also feature cutting-edge connectivity that offers increased data transfer speed, power of electronic control modules and advanced underlying architecture.
New enhanced automatic resistive braking control takes speed control to a new level by automatically selecting truck speed on declines based on the grade, weight and brake oil temperatures.
Previously, Cat trucks applied resistive braking based on a selected gear limit.
The operator now leaves the gear in the ‘D’ position, and enhanced automatic resistive braking control uses the truck’s full decelerator capabilities without requiring manual gear selection, enabling drivers to run at three to six per cent higher speeds on average during resistive braking.
“Field data shows operation speed during resistive braking can increase up to 25 per cent, elevating the average skill level of all operators to that of an experienced operator, while protecting the asset,” Shea said.
Next-generation trucks now offer hill start assist with anti-rollback – two separate features that work together.
Anti-rollback stops the machine with automatic brake application when the truck rolls in the opposite direction of the selected gear.
If drive is selected, the truck won’t roll backward, and if reverse is selected, it won’t roll forward.
Hill start assist uses grade and payload to determine the necessary rimpull to keep the truck stationary on a hill, simplifying truck movement in the selected direction.
The next-generation trucks also include Cat’s AutoHoist, which helps simplify body dumping to provide lower cycle time.
Integrated with the transmission control, AutoHoist consolidates four continuous operator hand and foot inputs into two simple hand inputs.
On previous models, the operator shifted the truck into park, applied the park brake, moved the hoist lever in the raised position and held the accelerator to dump, increasing the opportunity for inconsistency and inefficiencies.
With AutoHoist, the operator moves the truck into park, holds up the lever and pushes the up button on the gear shifter, and the truck takes over.
“It can reduce typical dump cycle times in some instances by up to 12 seconds and potentially reduces fuel burn during the cycle,” Shea said.
Significant safety advancements, a new dynamic stability control system and an anti-lock brake system, or ABS, provide operators with better truck control to improve cycle time and safety in poor underfoot conditions.
The four-wheel, oil-cooled brakes in Cat mining trucks have always allowed for four-wheel braking at any speed to enhance truck controllability and safety. Now, when a locking wheel is detected, ABS regulates the brake pressure to maintain traction and truck control, so the truck keeps tracking forward.
The new dynamic stability control modulates the brakes while braking and turning.
It monitors operator steering intention through the brake and throttle inputs – plus the inertial measurement unit informs the system of the truck’s travel direction – and modulates the brakes to keep the machine tracking with the operator’s steering inputs.
This brings the truck back under control and keeps it travelling straight if a locked wheel or slide is detected.
This feature appeared in the August 2024 issue of Australian Mining.
