Hydraulic shovel operators at O’Neal Quarry in Calera, Alabama, USA, have one primary job: Remove overburden to expose the mineral reserves underneath. These reserves are used by owner Lhoist North America to provide aggregates and heavy building materials that are used to build the infrastructure on which we depend every day.

The more productively these operators work, the more quickly these reserves become available. And in the last year, shovel operators at O’Neal Quarry have been uncovering more than ever before – thanks in part to a new Cat® 6015B Hydraulic Shovel.

“We’ve had the Cat 6015B on site since December of 2014 and have seen about a 20 percent increase in production, which for us is a significant step up,” says Rob Massengale, operation supervisor at O’Neal.

O’Neal Quarry was one of four sites selected to validate the power, efficiency and capacity of the new 6015B. “We placed them in the subarctic and we’ve placed them in semi-tropical locations,” says Arthur Milkowski, Caterpillar platform manager for the new shovel model. “We have seen this machine in temperatures from 100 degrees to minus 40 degrees (Fahrenheit) and we’ve had very harsh conditions. We also chose customers that essentially have very high duty applications, running 20-plus hours a day.”

Productivity advantage

Building on the robust and productive Cat 5110B, the 6015B delivers a productivity advantage over other 100-tonne shovels thanks to the most powerful engine in its class, a large standard bucket and payload capacity of 14.6 tonnes (16 tons). The shovel delivers a pass match advantage over leading standard-equipped shovels in its class when loading trucks of 55-, 65- and 90-tonne capacities.

The 6015B has been designed to fill a Cat 773 mining truck in four passes, a 775 in five passes and a 777 in seven passes using an 8.1 cubic-meter (10.6 cubic-yard) bucket.

“We’ve been able to go from a five- and six-pass down to a four-pass with the 6015B with the increased bucket size,” says Massengale. “The machine seems to handle a little bit faster as well.”

To keep up with the shovel’s productivity, an additional truck was added to the cycle. “They had to put a fifth truck on us to keep up with the machine,” says shovel operator Dale Riffe. “I don’t see a problem keeping up with five trucks. I mean, that’s just total production digging right there.”

Increased power and performance

The 6015B is equipped with a single Cat C27 ACERT™ engine that provides 606 kW of rated power. As with all hydraulic shovels, the greater the engine power, the greater the digging power and the faster the digging cycles. The large, 8.1 cubic-meter (10.6 cubic-yard) standard bucket, outfitted with Cat C70 hammerless GET, further boosts production capability.

“WE’VE HAD THE CAT 6015B ON SITE SINCE DECEMBER OF 2014 AND HAVE SEEN ABOUT A 20 PERCENT INCREASE IN PRODUCTION, WHICH FOR US IS A SIGNIFICANT STEP UP.”

“It’s got plenty of power,” says John Harris, shovel operator. “It’s loading four or five passes on the 775—and they’re (fully) loaded.”

The 6015B front is sturdy and strong, yet light enough to enable fast cycle times. It’s built upon the robust 5110B platform, which is proven durable and reliable, and the entire machine benefits from extensive use of proven Cat components. An improved filtration system ensures consistent oil cleanliness and hydraulic system performance.

“It’s like a mule. It never quits,” says Riffe. “It’s always productive. (For) a 10-, 12-hour shift; it’s awesome.  You couldn’t ask for a better machine.”

Fuel efficiency

Caterpillar’s proprietary integrated engine control technologies, a boom float feature that regenerates boom oil for reduced engine demand, an oil cooling system that’s independent of engine cooling, and regeneration of swing energy via its closed-loop swing system, all increase fuel efficiency.

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