Cooling System for Retrofitted Electric Mining Truck (EPCA-E100 project)

The Challenge 

Retrofitted electric haul trucks must operate reliably in extreme mining conditions, including very high ambient temperatures. Batteries and power electronics have narrower temperature limits than diesel engines, so a purpose‑designed cooling system is essential to maintain performance, safety and component life.

Proposed Solution 

EPCA developed and tested a cooling system and control strategy for a retrofitted 100‑tonne electric Caterpillar 777D truck. Mine‑site testing demonstrated that coolant flow distribution (via orifice settings) can keep inverter temperatures below first‑derating thresholds. Results also showed that a battery thermal management chiller is not well suited to sustained high heat loads from motors/inverters, with cooling effectiveness reducing over time as thermal load exceeds chiller capacity.

Proposed Benefits to WA 

The work supports lower‑emissions mining by enabling retrofit pathways for heavy haul trucks using a circular‑economy approach. Improved thermal management helps electric haul trucks operate more reliably in WA’s hot mining environments, accelerating electrification uptake and strengthening local METS capability and innovation.

Report DOI

DOI: 10.71342/359794298652