Komatsu · Feature
Arctic to the Equator
Spanning frozen Arctic frontiers and sun-scorched African mines, the journey of the Komatsu HD785 dump truck reveals more than just engineering resilience — it tells a story of human determination and global extremes.
Awesome Earthmovers recently travelled to two of the most challenging mining locations on the planet. The purpose of both trips was to see some of Komatsu's impressive mining equipment in action and to meet some of the female operators who drive them on a daily basis. One common machine, two very different locations, and two differing — but similarly impressive — stories about their highly skilled operators.
When Komatsu proposed the idea of telling the story of two female operators, both using similar machines, we didn't expect the locations to be so different. From the icy cold northern tip of Swedish Lapland to the sweltering heat of Ghana, our team couldn't say no.
The common denominator on both sites was Komatsu's HD785-7 mining truck. One of the Japanese manufacturer's most popular models, the 100-tonne-class truck sits roughly in the middle of their impressive array of mining trucks, which is topped off by the 363-tonne-capacity 980E-5SE.
The Cold
Gällivare, Sweden, in the province of Lapland — as far north as any human dares to live. Temperatures in December (conveniently when the Awesome Earthmovers visit was scheduled) regularly reach −16°C, dropping to −30°C as winter bites harder. With around three hours of daylight per day at this time of year, cold temperatures and almost constant snowfall, Gällivare is one of the most difficult places for a human being to survive, let alone operate a busy, safe and productive mining operation.
The mine site at Gällivare is operated by Göran Eriksson Maskintjänst AB (GE Maskintjänst), a family-owned business for over 65 years. GE Maskintjänst is one of the oldest contracting companies in the Swedish ore fields, undertaking a range of projects and employing over 270 staff throughout their operations, mainly in and around the Gällivare region.
The company's extensive fleet of mainly Komatsu machinery includes several HD785-7 models. The particular machine we were going to look at was working alongside a huge PC8000 mining excavator and was being loaded with iron-rich rock for the journey to the site's processing plant.
Behind the wheel of the HD785-7 was experienced operator Caroline Landström. Having trained initially as an assistant nurse, Caroline found the challenge of construction machinery enticing, especially when coupled with the supportive environment at Göran Eriksson Maskintjänst AB. Caroline has been working within the Swedish construction industry for three and a half years, with the past two years spent in the employment of GE Maskintjänst.
"Many people think only men operate big machines like this, but we girls can do it just as well," Caroline commented. "I feel very comfortable with the Komatsu HD785 — it is quite easy to operate, the visibility from the cab is great thanks to the mirrors and cameras. It feels safe."
"Many people think only men operate big machines like this, but we girls can do it just as well." Caroline Landström · Operator, GE Maskintjänst AB
At glass-cracking temperatures, the site in Gällivare requires only the strongest of machinery. Komatsu was able to step up to the plate with the simplicity and outstanding build quality of their mining machinery.
The Hot
Our second visit took us to the total opposite in terms of weather conditions. Ayanfuri, in central Ghana, sits close to the equator with hot and humid conditions regularly nudging 40°C.
The Komatsu HD785-7 we were visiting here is owned and operated by Rocksure International. Whilst many mining companies are internationally owned, Rocksure International is a 100 per cent Ghanaian-owned mining corporation, investing profits from their operations back into the local economy, employing local operators and ensuring the region in which they operate benefits from their work.
Rocksure International is currently operating across three of their own sites and also in a joint venture with another mining company. Operating over 150 pieces of heavy equipment and employing over seven hundred people, our location was the Edikan mine — a large-scale, low-grade, multi open-pit operation managed by Perseus Mining Ghana. Perseus commenced commercial production at Edikan in 2012, and the mine has since produced more than two million ounces of gold.
With daily temperatures regularly exceeding 30°C, the ground is baked dry, making extraction work harder on operators and their machines. To allow them to productively manage the extreme conditions, Rocksure International has invested heavily in building a substantial fleet of Komatsu machinery, which includes two PC2000 excavators and a staggering forty-one HD785 trucks.
We met up with operator Ruth Ofori, one of the many female operators working in the vast mining operation. Ruth had previously worked as a financial analyst and moved into operating construction equipment several years ago.
"I love operating the HD785," Ruth said. "It's such a comfortable place to spend a long day in. The controls are easy to use, and the air conditioning makes it more comfortable in the hot temperatures we see here. It is a powerful truck making it so easy to operate. The automatic transmission is so smooth — even when loaded, you can't feel it change gear."
The Machine
With an empty weight of around 74 tonnes and an all-up loaded weight of over 160 tonnes, the HD785-7 is designed to deliver productivity and reliability over a long operating life for its owners. Powered by a fuel-efficient, reliable Komatsu SAA12V140E-3 engine delivering 1,178 hp at just 1,900 rpm, the HD785-7 has an advanced transmission with seven forward and two reverse gears providing smooth and effortless gear changes in any operating condition.
The transmission includes an electronically controlled clutch modulation system — K-ATOMiCS — which controls both the engine and transmission to optimise clutch engagement. Combined with a new 'skip-shift' function that automatically matches the travel speed to the incline the truck encounters, this system ensures smooth gear shifting and responsive acceleration. The powerful and efficient engine provides impressive acceleration, low fuel consumption, and a top speed of 65 km/h.
To optimise performance and fuel consumption, the engine is fitted with a variable horsepower control (VHPC). This system sets the maximum engine power to one of four levels to match the job being carried out and the working conditions. The operator chooses between power and economy mode, and the VHPC automatically detects whether the machine is loaded or unloaded. Consequently, the HD785-7 delivers excellent climbing ability when required and can reduce fuel consumption.
The HD785-7 also has several features to improve operational safety, such as an advanced retarder braking system. With a capacity of 1,464 hp for continuous descent — the largest in its class, and more than the engine power — this system ensures the safest downhill travel. It includes Komatsu's anti-pitching 4-wheel oil-cooled multiple-disc retarder, AP-FOUR, which shares the retarding force between all four wheels to reduce tyre-lock and allow smooth downhill travel. In addition, the auto-retard speed control (ARSC) allows the operator to pre-select a constant downhill speed so they can concentrate on steering.
For even greater safety, the HD785 can be optionally fitted with an anti-lock braking system (ABS) and an automatic spin regulator (ASR) that prevents the rear tyres from slipping on soft ground, improving traction and braking. With a heaped capacity of 60 m³, the HD785-7 is ideally matched to Komatsu's PC1250 and PC2000 excavators, and to WA800 and WA900 wheel loaders.
Komatsu
The HD785 dump truck is a perfect example of Komatsu's engineering brilliance. Aside from the machine's ability to work in almost any conditions — be that extreme cold or extreme heat — the HD785 represents simplicity and downright toughness. Two attributes Komatsu are known for across the world. The reliability of the HD785 is one of the central reasons operations like GE Maskintjänst and Rocksure International buy Komatsu machines.
Downtime is never a concern thanks to the machine's simplicity, and operational difficulties are avoided thanks to its complete capability as a load-bearing tool.