While there is no doubting that the build quality and standard of components used in Chinese mining equipment, including large mining trucks, has been increasingly markedly in recent years, one major difference remains – how they are operated. In Australia, carrying out four or five mining truck rebuilds is becoming the norm – and as a result, many trucks running with over 100,000 hours.
In China, it is still common for mines to run equipment to initial end of life and then invest in new machines – with the original fleets often remaining idled on the minesite indefinitely without being sent to scrap which causes its own environmental issues.
But there is a realisation among the leading Chinese OEMs that they need to get better at the remanufacturing and rebuilding of equipment – partly to meet increasing customer expectations on ROI but also to be able to compete with their offering in the overseas market. It is also a way to introduce the latest technology for customers during the rebuild process without them having to buy a new truck.
This trend is being reflected in project cases being released by the major players. Recently, Baotou based Inner Mongolia North Hauler (NHL), a rigid mining truck leader in China, successfully completed all maintenance and modification of its first NTE240 remanufactured vehicle for Dexing Copper Mine in Jiangxi.
NHL: “This complete vehicle remanufacturing project was successfully completed, not only achieving a full performance recovery for old mining trucks but also solving complex pain points in mining areas through customised technology upgrades, providing benchmark solutions for reducing mining equipment costs, increasing efficiency, and promoting green circular development.”
Since the first NHL diesel electric drive NTE240 mining trucks began operation at Dexing Copper Mine, they have performed well, exceeding expected performance and uptime levels. But after years of intensive service, they are showing their age with wear and tear. “To revitalise existing equipment, reduce procurement and maintenance costs, and ensure on-site safe production, NHL and Dexing Copper Mine officially launched a complete vehicle remanufacturing project.”
NHL’s technical team spent time at the mining area, to better understand the working environment on site and connect with the needs of operators and maintenance personnel This has allowed precise tailoring of the work to the conditions of the mining area, establishing a complete set of remanufacturing technical standards, and simultaneously implementing a number of equipment technical upgrade and renovation plans.
After comprehensive disassembly and maintenance, structural reinforcement, component replacement, and electronic control optimisation, the remanufactured NTE240 mining truck fully meets the standard of a new machine in terms of MTBF, MTTR, and other core operation and maintenance indicators.
To address special conditions such as heavy rainfall, bumpy roads, and long-distance downhill hauls in the mining area, the project team in particular made special upgrades in structural strength, corrosion resistance, and robustness of electrical systems. Applying NHL’s independently developed control system contactor replacement solution further enhances equipment operational safety.
NHL: “The successful delivery of the remanufacturing project is a model example of NHL and Dexing Copper Mine working together to promote equipment repair, reduce waste, cut costs, improve efficiency improvement, and ensure safe production. In the future, NHL will continue to deepen its presence in the field of large-scale mining vehicle remanufacturing, tap into potential market value, build a comprehensive technical service system, and enhance full lifecycle service capabilities. With higher-quality maintenance capabilities and ongoing technological innovation, it will help mining users achieve safe, efficient, and green development.”
Looking at another example, in the high-altitude open-pit mining areas of southwest China, XCMG is simultaneously progressing in two directions: first, systematic remanufacturing of old mining dump trucks that have been in service for many years, giving existing equipment a second life. Second, mass deployment of battery electric mining trucks it says is opening new space for cost reduction through new energy solutions. “Both lines are advancing in parallel, with only one goal…reducing overall operating costs.”
The XCMG XDE130 mining truck fleet has already had a long operation time far exceeding industry norms. With ageing equipment and pressure to maintain and increase production, the mine had originally planned to replace the vehicles in bulk with new machines. However, XCMG tailored a system solution covering technical consulting, remanufacturing execution, spare parts supply, and equipment management – to revitalise the old equipment.
The core of the solution XCMG says lies in standardisation, moving from non-standardised on-site overhauls to a standardised operating procedures. After the overhaul and rebuild, the power and performance of the old mining trucks was fully restored, with key component lifespans extended by 15%, and the full lifecycle operation and maintenance cost per unit dropping by over 20%.
Beyond hardware upgrades, service models are also being reshaped. A dedicated service team is stationed in the mining area, carrying out regular maintenance, proactive inspections, and predictive maintenance. The project has executed over 300 preventive work orders, responded to more than 30 emergency responses, reduced unplanned downtime by more than 400 hours, and increased equipment availability to over 95%.
XCMG: “The value of equipment is not limited to their value at the moment of delivery, but also spans the entire lifecycle from production operation and maintenance, major overhauls, and reengineering. XCMG’s circular business has been deeply embedded across the entire chain of maintenance, repair, overhaul, remanufacturing, and technological upgrades, maximising the existing equipment asset value.”
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