When loading large haul trucks, hydraulic excavators offer a high level of mobility
When it comes to loading machines for ultra-class haul trucks, open-pit mine operators have options: electric rope shovels, hydraulic excavators and large wheel loaders. Each has its strengths and weaknesses that are inversely proportionate. Rope shovels can load the largest trucks in three passes, but they lack mobility. Wheel loaders have high mobility but lack capacity. The hydraulic excavator is in the sweet spot for mines wanting mobility, and with the introduction of the PC9000, the capacity is edging closer to that of a rope shovel.
In May, Suncor’s Fort Hills oil sands mine became the first site to operate the largest hydraulic mining shovel, the PC9000. Komatsu’s western Canadian distributor SMS Equipment delivered the gigantic machine and commissioned it with help from the experts at Komatsu’s German Mining Division (KGM). The sheer size and capabilities of this new shovel are expected to significantly boost productivity and performance at Fort Hills.
In other news, Caterpillar announced updates for its 6020 Hydraulic Mining Shovel. Hitachi Construction Machinery, which also has many machines operating in coal, is making a transition. This article provides details on those announcements and more.
The 900-mt PC9000 has a 46-m3 bucket. (Photo: Komatsu)
Transforming the Future
The 900-metric-ton (mt)-class PC9000 has a larger bucket (46 m3), longer reach and higher digging forces compared to PC8000-11, which has an operating weight of 773 mt and a 42-m3 bucket. Designed as a five-pass match for Komatsu’s 980E ultra-class haul truck, it enables double-sided loading for autonomous operations, which could significantly improve cycle times and lower the cost-per-ton of material moved. Suncor has the world’s largest fleet of 980E ultra-class haul trucks.
“The PC9000 is set to transform the future of mining,” said Ansgar Thole, president and managing director, Komatsu Germany GmbH. “This new class of hydraulic mining excavator raises the bar for productivity, efficiency and performance, while enhancing operator comfort and safety.”
The handover event in May celebrated the industry-leading collaboration that led to the PC9000’s development. The new model was designed based on feedback from Komatsu’s international customer base and refined in partnership with SMS Equipment and Suncor.
“In addition to the engineering excellence behind this machine, the PC9000 is a shining example of what true collaboration can achieve,” Thole said. “It stands as the embodiment of an extraordinary partnership between KGM, SMS and Suncor — three forces united by trust, expertise and a shared vision for operational excellence.”
“At SMS Equipment, we say we’re ‘Partners in Your Possibilities,’ a sentiment brought to life through this collaboration,” said Dennis Chmielewski, executive vice president-mining for SMS Equipment. “In our role as equipment dealer, we’ve had the unique ability to bring together Komatsu and Suncor to create an incredible machine that has the potential to optimize our customers’ operations.”
Komatsu, SMS Equipment and Suncor have worked together for decades to advance mining operations, introducing innovations to Canada like the coun-
try’s first autonomous haulage system, the 980E haul truck, the first PC7000 front shovel and now the PC9000.
In the mining business, efficiency drives everything — and in the oil sands, bigger is better, explained Peter Zebedee, executive vice president — oil sands for Suncor. “Suncor is always exploring ways to enhance our operations by adopting the latest advancements in equipment and technology,” said Zebedee. “Our shared passion for excellence with Komatsu and SMS, along with the tangible value the shovel offers to our mining operations, made our decision to invest in the PC9000 clear.”
Initial discussions with KGM and and SMS about the potential of the PC9000 quickly revealed the new shovel could bring tangible value to Suncor’s mining operations.
“Our collaboration with Komatsu and SMS is built on years of trust, transparency and a shared vision,” Zebedee said. “What started as early conversations quickly turned into something much bigger — proof of what’s possible when industry leaders come together. We had a unique opportunity to be a first mover in the sector with a product that is new to the ultra-class market and designed to further enhance our operations.”
The shovel is more powerful, with a higher digging force and an extended arm reach. It also moves on a pivot to load trucks from either side, reducing repositioning time and increasing overall loading efficiency.
“I am extremely excited about the PC9000,” Zebedee said. “I really believe that my role as a leader isn’t to repeat what was delivered yesterday, but to deliver results that go beyond the status quo. Launching the PC9000 at our site and working it into our operations to drive scale and efficiency is really something special.”
The Cat 6020 is more fuel efficient with faster cycle times. (Photo: Caterpillar)
Cat 6020 Delivers a Productivity Advantage
Caterpillar said its 6020 Hydraulic Mining Shovel delivers the consistent and reliable performance mining that operations expect. It’s more fuel efficient than other shovels in its class, and its fast cycle times and high reliability deliver the productivity levels that miners want.
The Cat 6020 is powered by the high-performing C32B engine, which is more reliable and durable than its predecessor, the C32.
The C32B offers improved power and performance thanks to:
A higher flow oil pump and higher baffles in the oil cooler to keep the engine core cooled and lubricated;
A new cylinder head with an optimized water jacket to maximize heat transfer;
Increased piston compression height to enable higher power for some applications.
An updated crankshaft and connecting rods with larger journals increase durability by reducing contact pressure and optimizing bearing performance, while a new cylinder block helps increase structural capability. In addition, all valves are equipped with oil metering stem seals and reduced contact pressure geometry for maximum life.
The C32B is also more reliable. Updates include a thicker shim gasket to increase head-to-block sealing, and more durable exhaust valves, especially at higher power. The new Dual Sensor Coolant Protection feature detects potential coolant leaks sooner to avoid costly downtime.
For 6020 shovels in the field, Caterpillar offers an affordable option to upgrade to the C32B engine core. With closed lube and fuel systems, the Long Block Plus (LB+) minimizes the risk of contamination during rebuilds and saves time, versus a full rebuild.
In addition, Caterpillar offers a new-with-core (NWC) offering, which allows the return of a C32 core for Cat Reman credit, reducing the cost of a new or remanufactured engine.
Key to the 6020’s high efficiency is Hydraulic Optimization, which dynamically assigns individual pumps or groups of pumps to deliver the exact flow and pressure that each hydraulic function requires. An intelligent pump managing system continuously evaluates actual engine and hydraulic operating values against set values and adjusts pump output accordingly. This results in efficient use of the engine for greater productivity, less energy and fuel consumption, and reduced component wear. Hydraulic Optimization also cuts down on waste, eliminates metering losses and reduces excess heat.
The Independent Oil Cooling system is a more efficient means of cooling that protects and extends the life of hydraulic components. The system is independent of return oil, achieving efficiency through the utilization of dedicated pumps that provide cooling capacity as needed, whether the engine is idling or under load.
The 6020 features highly durable structures designed to withstand the toughest loading conditions, and is designed for reliability — from robust tracks and an enhanced undercarriage to a highly reliable crawler and extended swing component life. The result is the uptime needed to keep operations moving.
High reliability and durability are hallmarks of the 6020. Downtime is reduced thanks to a heavy duty undercarriage with a longer life and increased crawler life made possible by three carrier rollers that eliminate unnecessary wear and assist in easier track tensioning.
Features that contribute to easier serviceability also reduce downtime. The spacious walk-through power module provides exceptional component accessibility, as does the swing system, which features a boom-mounted hydraulic valve block, ground-level accessible service fluid fill points and jump start receptacle.
The power module can be quickly swapped out for a spare, then transported for repair in a safe, convenient and clean environment. Undercarriage service is simplified with an automatic track tensioning design that requires no manual adjustment.
The 6020 features a next generation cab that provides better visibility than competitive shovels, with 40% window area of outer cab surface.
Operators enjoy excellent visibility to digging and loading areas thanks to a large windshield and in-floor window. Visibility is further enhanced by strategically positioned and high-powered LED lights. The result is optimized operator situational awareness and safe machine positioning and truck loading.
The quiet and fully pressurized cab offers an ergonomic operator seat and controls, superior insulation, extensive in-cab air distribution via a powerful HVAC unit and multiple optimally positioned vents.
Fatigue is reduced by the Electronic-Hydraulic Servo Control, which delivers fast and precise machine reactions. No hydraulic lines are present in the cab or the cab module, ensuring a clean arrangement with less noise emission.
HCM recently launched a mining innovation challenge.
Hitachi to Transition to LANDCROS
Hitachi Construction Machinery Co., Ltd. (HCM) recently announced its intention to change its trade name to LANDCROS Corp. and its corporate brand to LANDCROS, effective April 1, 2027. The consolidated subsidiaries of HCM will also unify their brands under LANDCROS to enhance recognition in global markets.
“The new LANDCROS corporate brand combines the word LAND, representing our vision, with Customer, Reliable, Open and Solutions, which are all words that are important to us, to express our commitment to society to provide innovative solutions to all of our customers,” said Masafumi Senzaki, president and CEO, Hitachi Construction Machinery. “We aim to cultivate LANDCROS into a brand that will make our customers feel that they made the right choice when selecting our machinery or services, our shareholders confident about their decision to invest in the company and our employees feel that their work is meaningful.”
The LANDCROS name was first announced in July 2024, and the company began gradually offering innovative solutions under the new name during April. This is a new concept, a neologism which symbolizes a new direction for the company to pursue, that has been widely discussed within HCM since becoming independent from the Hitachi Group.
The construction and mining industries are currently facing complex and serious social challenges, including labor shortages, environmental regulations, operating cost increases and aging infrastructure, HCM said. To adapt to a rapidly changing market environment, the company said it is essential to break away from its traditional hardware-
centric business structure and evolve into a solutions provider that helps solve customer issues with integrated support that includes services and digital solutions throughout the machinery lifecycle, in addition to developing next-generation construction machinery combining AI, robotics, sensing and communication technologies.
One of the new initiatives announced this year was LANDCROS Connect Insight, which provides an added layer of support for operations where uptime is critical and safety is non-negotiable. The platform enables HCM dealers to support customers with actionable insights that enhance the productivity, reliability and safety of their Hitachi mining machines.
LANDCROS Connect Insight is powered by an IoT device that is installed on HCM mining machinery. The device encrypts and transmits more than 200 points of machine sensor data securely to the LANDCROS Connect Insight cloud platform for analysis.
It lets trained dealers remotely monitor a machine’s health without stopping operations. They can quickly diagnose issues, inform on-site maintenance teams and share data with factory experts to find root causes faster. The system also has a predictive analysis feature that identifies anomalies that may indicate an impending failure. It can help to identify operator behaviors or haul road conditions that are reducing efficiency or reliability, as well.
During November, HCM launched the LANDCROS Innovation Studios Mining Challenge, a project which solicits ideas from startup companies around the world. This year’s challenge will target the field of mining, and the application deadline is January 20, 2026.
The challenge will solicit ideas for three mining-related themes: Smarter Machines, Smarter Mine Sites and Low Impact & Sustainable Mining. Successful applicants will be invited to a pitch event to be hosted on April 16, 2026, in Brisbane, Australia. The application can be found at: www.hitachicm.com.
Ian Dobson is retiring, but the last operating 995 is not. (Photo: Liebherr)
Taking Pride in Every Machine
After more than 20 years as part of Liebherr-Australia’s Mackay team, with 14 of those years spent embedded at Yancoal’s Yarrabee coal mine in central Queensland, Ian Dobson is getting ready to hang up the hard hat and head into retirement. He will be leaving behind a legacy of knowledge, high standards and a reputation for treating every machine like his own.
For Dobson, who has worked as a site fitter with Liebherr-Australia since 2005, the key to keeping heavy mining equipment running smoothly is simple: take ownership. He worked on every machine he came into contact with as if they were his own, and he taught those around him to treat them with the same care and precision.
This mindset has helped set the quality standards at Yarrabee, where Dobson’s standard of care, eye for detail and ability to mentor the next generation of fitters has earned him a strong reputation within the Liebherr community. Dobson spoke proudly about an R 996 excavator on site that has stood the test of time.
“Digger 12’s got about 76,000 hours on it and it’s clean as a whistle. Not a leak on it. That’s a testament to the digger crew, not just me,” he said.
Dobson’s journey to Liebherr wasn’t a straight line; he worked in a range of industries, from farming and forestry to IT and automotive. He also served as a proud member of the RAAF (Royal Australian Air Force) for five years as a fitter for specialised equipment.
“I’ve done all sorts of jobs. But when I saw what Liebherr did — engines, hydraulics, electronics — I thought, ‘this is everything I’ve done all rolled into one. I can do this.’”
Over the course of his career, Dobson has worked with a wide range of Liebherr machines: older models like the R 994, R 996 and the last operational R 995 in the world — which is still working hard at Yarrabee — all the way through to the R 9600, one of Liebherr’s latest generation of excavators. To this day, Dobson still has a soft spot for the R 996 and its successor as he’s been able to see how far it’s come through the years.
“The first time I climbed into the R 9600, I thought, ‘they’ve even thought of a fridge.’ It blew me away,” he said.
But the excavator he ranks highest? The 300-mt R 9350.
“The R 9350 is a great little machine. Easy to work on and smooth to operate. If I could find a place with four or five of them, I’d go tomorrow.”
Above all else, Dobson’s favorite thing about working with Liebherr for all these years has been the people. The excavator crew, site team and even former colleagues who still call him for advice have all shaped his experience at Liebherr.
“I’ll miss the camaraderie the most. That’s what’s kept me around all these years,” he says.
Of course, working on excavators comes with its pressures. But when high pressure situations arose on site, Dobson credits the camaraderie and strength of the people around him with his being able to stick it out and get the job done. That incredible teamwork extended to mentoring young fitters, something Dobson found especially rewarding in the later years of his career.
“Knowledge not shared is wasted. You might lose a day chasing a fault, but you walk away knowing more than you did before. And that knowledge? That’s gold.”
This team environment is something Liebherr actively fosters in its teams all around the world. Through strong collaboration and mutual respect, employees are empowered to support each other, solve challenges together and grow as a team. It’s a culture Dobson has helped shape at both Yarrabee and Liebherr-Australia’s Mackay branch, and one that will continue long after he leaves.
As Dobson prepares to retire, he’s looking forward to travelling with his wife, who is also retiring, and spending time working on his six — soon to be seven — motorbikes.
