Caterpillar Prepares 22-Tonne Diesel-Electric Loader for Underground Mining

Caterpillar is preparing to launch the R3200, a 22-tonne-class underground load-haul-dump (LHD) loader designed to move more material per cycle while improving fuel efficiency in underground mining operations.

The new machine will sit above the company’s R2900 XE, which has an 18.5-tonne payload. According to preliminary specifications reported by International Mining on 19 October, the R3200 offers a 19% increase in payload capacity, 28% more tonnes moved per hour and 8% more tonnes moved per litre of fuel compared with the R2900 XE.

The R3200 will use a diesel-electric drivetrain, building on the technology already deployed in the R2900 XE. Instead of relying on a conventional mechanical transmission and torque converter, the system converts power from the diesel engine into electricity to drive the machine.

Caterpillar will equip the R3200 with a larger C18 engine, compared with the C15 engine in the R2900 XE. An EU Stage V emissions-compliant configuration is expected to be available as an option.

Higher Payload and Faster Loading

Caterpillar’s reported performance figures also include an 11% improvement in speed on gradients. Faster acceleration, improved machine response and shorter cycle times are expected to contribute to the increase in material moved per hour.

The loader is designed to work with Caterpillar’s AD63 underground mining truck in a three-pass loading configuration. This allows the loader to fill the truck in three bucket passes, helping coordinate loading and hauling operations.

Caterpillar has also made design refinements intended to improve durability and reduce maintenance and repair costs, including redesigned axles. The electric drivetrain has fewer moving parts than a conventional mechanical transmission, potentially reducing component wear and servicing requirements.

Automation and Remote Operation

The R3200 is expected to support Cat MineStar Command for Underground, Caterpillar’s system for remote and automated operation of underground load-haul-dump machines.

The technology allows operators to control equipment remotely, with options ranging from line-of-sight operation to full autonomy. Moving operators away from the machine can reduce their exposure to underground hazards, while automated loading and tramming can help improve consistency across operating cycles.

The launch will add another high-capacity diesel-electric option to an underground equipment market that also includes battery-electric and cable-electric loaders from competing manufacturers such as Sandvik and Epiroc.

Caterpillar has not yet formally launched the R3200, with further details expected in the coming months.