At Caterpillar’s global articulated truck factory, close to the northern English town of Peterlee, sits an early example of an ADT – articulated dump truck. But this was made by another manufacturer, British mechanical engineer David John Bowes Brown. He created the concept and started his own company in 1972.
Fast-forward to 1984 and DJB Engineering was renamed Artix after 1986 when Caterpillar – seeing a good product with a good future – bought the design rights; all units then had the Cat logo. The company was still owned by the Brown family until Caterpillar purchased the complete business in 1996. As homage to the ADT idea, one of DJB’s trucks, a D35 from the 1980s, was found, cleaned up and now sits proudly atop a raised mound, overlooking the entrance to Caterpillar’s sprawling 24-hectare manufacturing site.
Around 1,500 employees work in the site’s nine buildings where manufacturing is done from the bottom up, from laser-cutting of steel plate to the welding of chassis, from engine and cab installation to final painting and livery applications. The trucks – with the help of around 200 lower tier suppliers that occupy two of the site’s nine buildings – are 100% Caterpillar. On site, apart from manufacturing, are also Caterpillar’s complete R&D outfit, design engineers and marketing departments.
The site also includes a test course. For the first time after being fired up just off the production line, nearly finished trucks are sent out for their post-production checkout to make sure the engine, electronics and hydraulics are operating properly. The machines then come back inside for the application of finishing kits, completed according to the customer’s order.
Off site, about a half-hour drive away and in a former quarry, is Caterpillar’s Articulated Truck Proving Ground. Pre-production units, prototypes, new models and competitors’ vehicles are put through their paces – loading, unloading and running up and down varying grades.
The company’s last celebrated milestone since the site’s first trucks rolled off the DJB production line was at 65,000 units and by this spring, Caterpillar will be celebrating its 70,000th machine – likely one of the latest “Next Generation Smart Articulated Trucks” with built-in automatic features, specifically for the 725, 730, 730 EJ and 735 models. First out of these to roll out of the Peterlee factory was a 730, sometime in early January.
Upgraded interiors put control at an operator’s fingertips. All functions are accessible through a sleek touchscreen or a smooth, responsive keypad. For added convenience, the touchscreen can be effortlessly navigated using the integrated jog dial. New push-to-start with operator ID stores up to 50 operator IDs to quickly get to work and safeguard against unauthorised use.
With the introduction of the Cat C13B engine on the 725, the improved power-to-weight ratio means it is up to 14% more efficient on the Tier 4 Final (and equivalent) machines compared to the previous 725. The Cat C13 has power ratings from 257-316kW and is designed to meet global emission standards, including EPA Tier 4 Final in the US, EU Stage V, Japan 2014 and Korea Stage V. The engine is compact and lightweight with no need for exhaust gas recirculation – available in configurations suitable for all regions worldwide.
Safety is paramount
The Cat 725, 730 and 735 models feature a redesigned dump body that offers easier loading than previous designs and maximises payload. The redesigned body features a rerouted exhaust heat system that helps minimise material carry-back that improves load efficiency and reduces clean-up time. Improved payload technology allows operators to view real-time load weights on the integrated display and the system’s updated software and sensors provide accurate data. External payload indicator lights alert the loading operator when approaching rated payload and when payload is reached.
Caterpillar’s Dynamic Roll Over Protection works alongside the field-proven Stability Assist, which prevents hoisting on uneven terrain. Configurable to material and jobsite conditions, this new feature monitors conditions to detect when the truck is experiencing high lateral acceleration. In critical situations it provides a visual and audible alarm, reduces fuel and applies service brakes automatically. It reduces the risk of machine rollover due to high-speed cornering, helping minimise downtime and safety repairs from rolling the truck. Additionally, Stability Assist software reports information via VisionLink to increase awareness of when an event has occurred.
A new dump-body height limit feature for the 725, 730 and 735 models allows the bed-raise height to be set to meet jobsite conditions. The operator can quickly set the raise height limit by raising the bed to the desired height and holding a button on the keypad. Alternatively, it can be set through the display service mode to meet site-wide limits. This feature helps prevent the dump body from contacting overhead objects and increases cycle time by limiting full-body travel.
Ejector unloading option
The Cat 730 EJ Articulated Truck ejects the load without raising the body. This allows load dispersal on inclines, side slopes and in very soft underfoot conditions such as those found on landfill sites. The ejector system virtually eliminates the possibility of material sticking to the body. In doing so, the ejector system increases productivity; the truck can eject in areas with low overhead clearance, such as around overhead lines or in tunnelling and underground operations. Delivering faster cycle times, the versatile 730 EJ can eject and spread material on the go to reduce the need for additional spreading and dozing equipment.
For front and rear proximity detection, all Next Generation Articulated Trucks offer an optional object-detect and multi-view camera via a separate secondary monitor. The system’s radar sensors, mounted fore and aft, provide visual and audible alerts when objects are within the truck’s travel path. Four discrete camera views, configurable to the operator’s preference, are mounted at the front, rear and sides.
Coaching advice
An optional onboard interactive training tool, Operator Coaching, measures and reports on individual operator behaviour that impacts efficiency, safety and machine health. Operator Coaching identifies opportunities to improve operating behaviour for the inexperienced, as well as experienced operators alike, by monitoring 14 activities. Tips can be viewed on a summary page on the main touchscreen display, while animated video tutorials provide operator instructions. For fleet managers, the GPS function includes maps to show the location of where tips are triggered on the work cycle.
Among the 14 coaching tips are hoisting without articulation, with transmission in neutral and on level ground. There are also tips on reducing cornering speed, using lower gear when retarding, reducing speed in rough conditions and when approaching a grade in a lower gear
In the jump seat with Scott
Recent downpours had made the ground at Caterpillar’s Conforth Proving Ground extremely muddy and heavy, just the sort of conditions in which articulated truck drivers love to show off their skills. Traditionally, these behemoths have needed drivers with a lot of skills honed over time.
As with any heavy construction equipment, mistakes – no matter how skilled a driver is – can be costly, even fatal. Caterpillar’s newest generation of articulated trucks has the most advanced and sophisticated safety systems of any such vehicles. It’s about safety first, second and last, according to Scott Thomas, Caterpillar’s US-based market professional for articulated trucks.
Thomas is behind the wheel as the Cat 730 pre-production machine makes its way around the old quarry, executing tight turns, backing into loading positions to receive 30 tonnes of mud and dirt. The machine then crawls up various 25% grades to come down the other side and eventually dump its load. Thomas provides a running commentary about safety features, at times taking his foot completely off the accelerator to show how the truck’s automatic features kick in according to the conditions in which the vehicle finds itself.
This speed reduction feature is the advanced automatic traction control. It requires no operator input to prevent wheel slippage in poor underfoot conditions for maximum traction and productivity. The new engine-overspeed control works seamlessly with Automatic Retarder Control (ARC) to manage braking and automatically adjust engine speed; this enhances truck handling, improves steering response and, importantly from a safety perspective, builds confidence for newer operators in challenging conditions.
Meanwhile, machine speed limiting supports safe operation by allowing ground speed to be set by the operator or in service mode. This is ideal for uneven terrain, high-traffic areas or sites with strict speed regulations. Additionally, the integrated body height limiter promotes safety by helping ensure the machine operates within jobsite standards and height restrictions.
In order to reduce operator fatigue, the new Auto Wait Brake (AWB) automatically applies service brakes when the shift lever is in any position other than park and ground speed reaches 0kph, a complete stop. The service brakes apply in less than one second after the machine has stopped. Then after eight seconds, the transmission shifts to neutral with AWB engaging. When the operator needs to start his journey, he or she simply applies the accelerator which will re-engage the transmission and release the service brakes.
In short, Auto Wait Brake eliminates the need to shift to park for short duration stops and saves fuel when shifting to neutral. This feature also works with the machine Hill Assist, by applying the service brakes to prevent rollback.
Caterpillar began manufacturing articulated trucks under its name in 1985 at its facility in Peterlee, northern England. The first model to roll out of the plant was the D400, a 36-tonne machine. Over the years, the line-up has expanded to include multiple three-axle models, including innovations such as the 740 EJ for efficient unloading. Continuous design improvements in power, capacity and operator comfort have been a hallmark of the facility which produced its 50,000th Cat Articulated Truck in 2018. More information on the new Cat 725, 730, 730 EJ and 735 Articulated Trucks can be found by contacting a Caterpillar dealer or visiting www.cat.com.
