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MINEXPO HIGHLIGHTS New in the underground hard rock area is the R3000H LHD and AD60 mine truck. The new LHD maintains the R2900G's XTRA profile, provides 20-ton truck load- ing capacity, and has performance improvements that include 25% more lift and tilt breakout, 12% more dual stall rim- pull, 26% higher speed on 1:7 grade (loaded) and a 42% reduction in ventila- tion rate (CANMET). It is targeted for pro- duction in early 2014. The AD60 truck replaces the AD55 and offers engine/power train durability improvements, better cooling capabilities, and structural improvements and en- hanced operator comfort, according to Cat. Production is scheduled to begin in the first quarter of 2013. Finally, according to Paschedag, Cat is developing a prototype for a continuous miner-style, hard-rock cutting machine and plans to begin trials of the unit within a few months. Large Mining Trucks—It's been an eventful four years since MINExpo 2008 for Cat's mining truck business, said Ed McCord, segment manager, and the acquisition of Bucyrus' Unit Rig electric- drive truck lifted the truck group's level of activity even higher than usual. In the years following the last MINExpo, said McCord, Cat began production of the 793F, 797F and 795F AC; designed, test- ed and began producing the 789D; start- ed field tests on the 793F AC; and went 'live' with the MineStar Command for Hauling system. It also initiated develop- ment of Liquified Natural Gas (LNG) engine development for its largest mining trucks (see article on p. 48). The company's long-term strategy for its mining truck business, said McCord, includes "extending our leadership posi- tion," continuing to increase manufactur- ing capacity and footprint, improving prod- uct-line power train efficiency, and estab- lishing Cat as a technology pioneer—a new stance for the company. Even so, McCord also noted that Cat is not currently plan- ning development of any truck larger than its 797F without a significant advance in necessary technology. Cat is intent upon "building on its foun- dation" in further development of the Unit Rig brand, said McCord, taking advantage of Unit Rig's long history in the industry, its unique technology in certain areas, and its distinction as being the only mining truck line with AC drive throughout the entire range. There was also, he noted, value in capitalizing on Unit Rig's name recognition in certain markets such as China and Russia. Cat will continue to increase vertical integra- tion of the Unit Rig line in conjunction with its EMD operations; i.e., customers will see more EMD components in the Unit Rig line in the future. Support for the line will be pro- vided by Cat's worldwide dealer network. Cat will move assembly of the large Unit Rig mining trucks from Mexico to its Decatur plant, leaving the Acuña, Coahuila, plant to focus on "large fabrica- tions" needed for truck production. Although it will continue to produce other MT models, development money will be spent mostly on the larger rigs. The flagship of the Unit Rig line will be the new MT5300D AC, a 320- ton-capacity, AC-drive hauler powered by a Cat C175-16 diesel with 2,750- and 3,500-hp options. Cat redesigned the frame to handle 320-ton payloads and equipped the new model with what, in essence, is a 795F AC drive system—all part of an accelerated development sched- ule that began in 2011 and had the truck up and running late in August 2012. Although the MT5300D AC is, in many ways, similar to the 795F AC, it won't have certain features included in the Cat-branded truck, including the unique blended retard- ing system built into the 795F. Production is expected to begin early in 2014. Large Loading Tools—With an eye toward the changing requirements of the global mining industry, Cat designed and intro- duced the 6120B FS, which it touts as the industry's first hybrid, ultra-class hydraulic shovel. The 120-ton-bucket-payload shovel employs new diesel-electric technology that makes it a very attractive alternative to other shovels at short-term operations, non-electri- fied mine sites and greenfield development projects, said Surface Extraction Product Segment Manager Joe Helfrich. The Cat 6120B hydraulic front shovel features hybrid technology. 30 E&MJ; • NOVEMBER 2012 The 6120B—first in a planned line of B series machines, according to Helfrich—features hybrid technology with energy-recovery capabilities that involve quick, efficient reversal of flow in the shov- el's hydraulic circuits, in the process reducing fuel costs by at least 25% while providing the capability to three- to four- pass match with ultra-class haul trucks. The company is currently assembling a pilot machine in Milwaukee, Wisconsin, and then expects to ship the unit to its Tinaja Hills test facility in Arizona before the end of the year. Offering performance similar to Cat's 7495 rope shovel, Helfrich said the 6120B would, in fact, make a "great back- up machine" to traditional rope shovels, while giving Cat capability to address the "full space" of ultra-class truck loading requirements demanded by its customers. Cat's 7495 rope shovel now utilizes some of the technology developed in the 6120B project, said Helfrich, and is capa- ble of running on one-third the power required by traditional shovels. This capabil- ity, he said, has the potential to change the way mines are planned and started in areas where off-grid power is the early—or only— choice. Cat currently has a test version of the upgraded 7495 running at Tinaja Hills, powered by two 3512 diesel gensets. www.e-mj.com