ning operation is indeed interesting. How they got there
is simply fascinating.
I doubt theres anybody else doing it this way, said Greg
Sutton, general mine manager. So I would imagine in that
regard, we are unique.
Sutton is speaking of the method used to lower these
massive Volvo A40D haulers - each capable of
transporting 41 tons of rock and ore - through the
relatively narrow mine shafts deep into the earth.
Because these shafts are much narrower than the trucks
are wide, it would appear a magicians trick would be
required to make it work.
Steve Batts, Doe Run maintenance manager, said its
elbow grease rather than magic that gives Doe Run crews
the ability to fit the haulers down the shafts.
After each of the eight A40D haulers was delivered to the
mine from Rudd Equipment Co., Rudd technicians were
dispatched to Doe Run to disassemble the trucks,
separating the cab from the rear frame, removing the body
and tires, and detaching the hood, Batts said. These
sections were then carefully lowered down the mineshaft
and were reassembled underground by the Rudd team.
According to Sutton, other hard-rock mining operations
use A40D haulers underground. But, most of those mines
have ramps for the trucks, he said. I believe we are the
only ones who lower Volvo haulers through the shaft.
The Doe Run Company, North Americas largest
integrated lead producer, operates six mines and four mills
in the ore-rich Viburnum Trend, which begins about 100
miles south of St. Louis. Doe Run mining operations
supply lead for auto batteries, computer screens,
televisions and other products.


Lowering the A40D rear body into the mine shaft


Doe Run crews mine using the room and pillar method,
during which rooms are cut into the hard rock, leaving
a series of pillars, or columns, to help support the mine
roof. As the mining advances over a period of time, a
grid-like pattern of rooms and pillars is formed.
The mineral-rich ore - which contains lead, zinc, and
copper - is drilled, blasted and then loaded by wheel
loaders into articulated haulers. Sutton said the ore is
either crushed underground and taken to the surface
through an ore shaft or brought directly to the surface for
primary crushing and further processing at one of four
Doe Run mills. The firms four mills have an aggregate
production
capacity of about
25,000 tons of ore
per day.
Doe Run has
operated Volvo
haulers in its lead
mines for the past 10
years, with the first
of the D-Series
haulers being put to
work about three
years ago.
The A40Ds are
doing quite well,
Sutton said. About
one half of Doe
Run's hauler fleet is
Volvo.
In addition to the
haulers, Batts said
equipment being
operated
underground includes wheel loaders, remote-controlled
loaders, pillar drills, roof bolters, scaling rigs, man lifts and
tractors for crew transport.

continued
Reassembly underground

Its amazing how much equipment is down there, he
said, noting that Doe Run employs about 600 workers
in its Missouri mining operations. Batts said that Doe
Run recently took delivery of a specially equipped
Volvo L220E wheel loader, and he noted that the
buying decision was based in large part on the
excellent performance of its Volvo haulers.
Because the A40D haulers are running in the
underground passageways of the Doe Run mines,
equipment emissions and their impact on mine workers
are of major concern.
Rudd Equipment salesman Bob Voss said Doe Run
considered emissions when deciding to purchase the
Volvo machines. Rudd Equipment Co., St. Louis, is the
Volvo dealer serving Doe Run.
Thats especially critical when youre working 1,000 feet
underground, said Voss, who was working as a geologist
for The Doe Run Company when the first Volvo haulers
were purchased from Rudd.
The A40D haulers in use by Doe Run are equipped with
new Volvo D12CAAE2 engines, which have been
engineered for lower emissions and meet Tier 2 emission
regulations. These turbo-charged, high performance
diesel engines feature
electronically controlled injection
and intercooler, which help
provide for lower emissions.
The Volvo inline 6-cylinder
engines are equipped with
overhead camshafts and unit
injectors and wet replaceable
cylinder liners.
The Volvo A40Ds run very
clean, Sutton said. Of course
thats of interest to us. It means
that our guys down there have
better working conditions.
The A40D haulers in service at
Doe Run are equipped with 6x4
drive, which results in less tire
wear and better fuel economy, and 100% lock-up
differentials, operator-selectable while on the move.
These haulers operate in Doe Run mines on two 10-hour
shifts per day, six days a week, Batts said.
Traveling across these rough underground thoroughfares at
speeds up to 29 mph while carrying nearly 41 tons of rock
and ore pushes these trucks to their limits.

Batts said
vibration has strained previous hauler models used by Doe
Run, causing metal fatigue in key stress points that led to
cracks in areas such as fenders and hood assembly.






Voss reports that Rudd technicians servicing the A40Ds
said these units have been running clean, showing no
signs of stress or cracking.

Were really high on Volvo, he said. Volvo engineers
did a good job of addressing the structural issues that
have been a problem with other trucks.

Batts credits the Volvo design, calling Volvos D-Series of
haulers the new generation of trucks. With Doe Runs
first Volvo A40D fast approaching 10,000 hours of
service, Batts said he has been pleased with the overall
performance and durability of the unit.
Like all Volvo D-Series haulers, Doe Runs A40D units
are equipped with computerized diagnostics, which
monitors all operational data.
Voss said Rudd technicians use MATRIS, Volvos
exclusive Machine Tracking System, to collect and
analyze this data to help Doe Run reduce its overall
operating costs.

While Rudd technicians are assisting with the
diagnostics, Batts said Rudd Equipment and Volvo have
been providing operator and service training to Doe Run
technicians so that they will become able to perform
their own diagnostics on the
D-Series haulers.
They have been very good
to us, he said.
Batts said he anticipates
Doe Run will also
experience greater uptime
as a result of Volvos
extended service
schedules.
He said that Doe Run
technicians are looking to
take advantage of the
Volvo-recommended oil
change intervals of 500
hours, adding that other
models of haulers used by Doe Run had called for oil
service at 250 hours.
Right there, were already saving money on the cost of
oil and filter changes and from the productivity we
would lose while the truck was down for service.
Batts also pointed to the easy access to routine service
checks and fewer lube points on Volvos D-Series haulers
as being another cost-saving benefit. It really makes
service more efficient, he said.
Issued: 7/26/04



A40D hauler awaits disassembly at ground level
� 2004 Volvo Construction Equipment North America, Asheville, NC
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