December 2019

ROY HILL: TESTED TO THE LIMIT

Meeting the ever-increasing demand for iron ore and steel worldwide, mining is the main economic activity in West Australia. Most of the continent’s iron ore is mined in the Pilbara region, where Roy Hill runs a 55 million tonne per annum (mtpa) mining, rail and port operation, currently rising to 60 mtpa. Here, Hitachi equipment plays a vital part in supporting the business export to key international markets. As a margin-focused business, Roy Hill aims to maximise the return for each tonne of ore produced. This focus means the operation is not simply concerned with the amount of iron ore dug from the ground, but rather the sustained, low-cost production of iron ore, of consistent quality and grade. Roy Hill’s iron ore travels 344km along its dedicated railway to Port Hedland, where the product is loaded onto ships at the port. Roy Hill’s first shipment was exported in December 2015. A constant supply of cargo has left the two-berth wharf ever since, bound for Japan, Korea, China and beyond.


The bigger, the better

The Roy Hill mine fleet includes 24 of Hitachi’s largest rigid dump trucks, the EH5000AC-3, as well as three of Hitachi’s largest excavators, the EX8000-6. This is in addition to five EX5600-6s, four EX3600-6s and a single EX1200-6 excavator.

All of these models are manufactured to the highest standards at the Hitachi Construction Machinery Co., Ltd factory, Hitachinaka-Rinko Works, in Japan. Here, they are assembled, painted, checked and tested, then disassembled for shipping to customers around the world. The factory is conveniently located next to Rinko port, and delivery to Australia takes approximately one month.

Hitachi dump trucks and mining excavators are designed to work perfectly together and share proven Hitachi technology and components. The dump trucks for example, include an advanced AC drive system developed for Japan’s high-speed bullet trains. Key electrical components are designed and manufactured at Hitachi Ltd’s Omika Works factory, located approximately 15km away. These include the control cabinet, rectifier and IGBT. Travel motors are manufactured at another Hitachi facility, Yamate, also located nearby to Rinko.



"Pink is the new orange..."

Long-term reliability

To ensure Hitachi machines are developed with high levels of quality, safety and durability, they are tested rigorously 24/7. This takes place at the Urahoro test site on the northernmost of Japan’s main islands, Hokkaido, where temperatures can reach -30°C in winter.

A 5km-long track has been specially developed for the dump trucks, with a 1km straight, and varying degrees of slopes to simulate mining conditions. During testing, Hitachi examine aspects such as the brakes and steering to ensure that they conform to the appropriate ISO standards. Tests on the Hitachi Drive Control System (consisting of slip side control, pitch control and side skid control) are designed to ensure stable haul cycle times, and high levels of productivity, safety and efficiency.

Further examples of tests at Urahoro include the peripheral vision system Aerial Angle, and software updates to the machine’s integrated computer systems. Such stringent procedures are a vital part of the development process at Hitachi. They ensure its equipment continues to meet the requirements of customers such as Roy Hill.

At Roy Hill’s mine site in the Pilbara, the process starts with clearing, removing and storing topsoil for progressive rehabilitation once pits have been mined. As part of Roy Hill’s environmental compliance, the land will be returned to its original state once mineral extraction is complete. Once the topsoil is removed, the remaining earth is drilled and loaded with explosives.

After drilling and blasting, an excavator loads the Hitachi AC-3 dump trucks with bulk waste, which is taken to various dumping locations. The ore product is transported to the crushers, where it is screened and sized.

Once processed, the ore is washed, dried and stockpiled ready to be loaded onto train wagons for the 344km journey to Port Hedland. Twenty-six locomotives are used in various driving configurations with up to 236 ore cars hitched together.

At the purpose-built port facility, the ore cars are unloaded by the rotary car dumper, before ore is stacked and loaded onto ships bound for international markets.

An integral role

Up to six of the 2.6km-long trains are loaded with iron ore every day to meet current production requirements. The reliability of the Hitachi dump trucks to move the initial bulk material and satisfy this huge demand cannot be underestimated.

Roy Hill’s Head of Mining, Ian Wallace, explains: “The Hitachi dump trucks are operating in tough conditions, and the fact that they’ve been rigorously tested in Japan gives us confidence.

“We have 24 of the EH5000AC-3s on site and they’re ideally matched to the scale of our operations, and to our EX8000-6 excavators. They provide us with an economy of scale in our bulk waste movement and there is also the benefit of maintaining electric drive machines over conventional mechanical drive models.”

With the mine running 24/7, machine reliability, or ‘asset health’ as it is known in Australia, is paramount, requiring close collaboration between Roy Hill’s specialist technicians and Hitachi representatives. Preventative maintenance and access to operating performance data from Hitachi’s remote monitoring solutions, including Global e-Service and ConSite, is key.

“Since having the EH5000s we’ve had so much support from Hitachi,” says Kevin Weary, Superintendent, Hauling & Ancillary. “We’ve got a couple of Hitachi representatives on site full time and they help with all the asset health. They give us the data we need as and when required.

“Moving forward with the remote monitoring system, we’ll get the data daily and be able to improve our maintenance packages as a result. Since the trucks have been on site, they’ve performed really well, we’re very happy with them.”

View from the cab

Operator safety and comfort are also vital. Shifts are long, conditions are always challenging, and the sheer size of the trucks is significant. The operator sits high above ground level and commands a 500-tonne machine capable of speeds up to 56km/h, carrying loads up to 296 tonnes.

Fortunately, the Hitachi trucks have been designed and developed with safety and performance in mind. Ergonomics play a key part in the cab design, which offer superior operator comfort and a great field of view. Another benefit is the Aerial Angle system, which provides the operator with all-round vision of what’s happening outside of the truck.

Ancillary Operator Tarra Ninyette explains: “The Aerial Angle is a fantastic safety system that’s fitted to the Hitachi trucks. It provides us with object detection and collision avoidance technology that allows the trucks to operate in a safe and productive manner.

Pink is the new orange

All the Hitachi EH5000AC-3 dump trucks owned by Roy Hill have their trays painted bright pink in support of breast cancer patients and research, and to honour the large number of women working alongside the men in these often tough conditions.

“Our Executive Chairman, Mrs Gina Rinehart, actively supports breast cancer patients and research, having started back in the early 1990s Australia’s then first breast cancer foundation, and the pink trucks campaign continues this initiative,” confirms Ian.

“Many of the trucks are named after people in the company who’ve been affected by and battled breast cancer, or partners of Roy Hill. This has touched many of our staff who are also champions of the cause. We have five pink locomotives, 130 pink ore cars and will soon have a pink WHIMS (wet high intensity magnetic separator) plant. In addition, our Chairman is also Godmother of the world’s first pink bulk ore carrier ship, the Berge Toubkal, the newest in the Berge Bulk fleet, and the largest ship to carry the Roy Hill ore.”

While the colour of the equipment sends a clear message, the performance of the Hitachi dump trucks and excavators also speaks for itself. As a result of high-quality manufacturing and engineering in Japan, and proven in-house technology from the Hitachi Ltd. group, as well as rigorous testing and continuous after-sales support, the Hitachi machines at Roy Hill are delivering long-term reliability in arguably the toughest conditions on the planet.





Related stories
  • New Team. Reliable Service.

    We are excited to announce growth in our Canberra region ...

    Read more
  • A powerful machine in a compact ...

    Discover the ZW80-5B: A compact, powerful wheel loader ...

    Read more
  • RJV Expands Operations

    RJV has recently taken delivery of a substantial order of ...

    Read more
  • ZAXIS-7 Compact Excavators

    The ZAXIS-7 series has been engineered to maximise operator productivity ...

    Read more
  • Aidan
    Seaton

    Our People: Major Accounts Manager - Aidan Seaton, South Australia...

    Read more
  • Electrifying Anric

    In a pioneering move toward a more sustainable future in ...

    Read more

#TheOrangeFamily

💧 Another 4 for the fleet!
Wormall Civil have just taken delivery of four brand-new Bell 2806E water carts, further strengthening their capacity to deliver civil projects across WA.

We’re proud to continue supporting @wormall_civil with reliable, high-performance machinery that keeps the job moving. Thanks for choosing us again, team!
Head to Head in Laverton!

A powerhouse delivery to @genesisminerals — the EX2000-7 and EX2600-7 standing tall at the Laverton Operations site. 💪🧡
These two mining giants are ready to move serious dirt and get to work.

Big thanks to the team at Genesis for choosing Hitachi.

#HCA #OrangeFamily 🍊#HitachiConstruction #HitachiMining #EX2000 #EX2600 #GenesisMinerals #HeavyMachinery #MiningLife #BuiltToPerform
📡 Maximise performance across your fleet—no matter the size.

LANDCROS Connect delivers operational, health, and location data, giving you the visibility and control to:

✅ Monitor mixed fleets from a single platform
📊 Track job site productivity at a glance
📍 Pinpoint performance with location-based insights
🔧 Stay ahead with daily machine alerts 
📱 Mobile Access Anywhere 

Smarter decisions start here.
👉 Learn more: https://hitachicm.com.au/landcros-connect
Missed us at DDT? No worries — we’re hitting events across the country all year long. Come chat with our reps, get hands-on with the latest machines, and stay up to date on what’s new.

📍Check out the wrap-up video and keep an eye out for where we’ll be next!
🚨 Applications are now open! 🚨

Are you ready to dare to be epic? 👷‍♂️💥
We're looking for motivated individuals to join our Apprenticeship Intake for 2026 across Australia!

Whether you're passionate about heavy machinery, love working with your hands, or want a future in a growing industry — this is your shot.

👊 Earn while you learn
🧠 Gain hands-on skills and formal training
🤝 Become part of the Orange Family

👉 Tag someone who should apply
👉 Share this post and spread the word
👉 Apply today at: https://hitachicm.com.au/orange-family/ai2026/

📣 Let’s build the future together!
📣 Exciting News! Foxleigh Mine has welcomed a brand-new EX1200-7 to their Mining Fleet!

Equipped with outstanding reach and bucket capacity this stunning 120 tonne mechanical marvel will get straight to work maximising  production.

💪 Refined Engineering and Proven Reliability #Hitachi Excavators are the go-to solution to meet the demanding needs of Coal seam mining!

Pictured: Peter, Maintenance and Engineering Manager at Foxleigh

#HCA #OrangeFamily 🍊#HitachiConstruction #Earthmoving #Productivity
Perth Tradie Expo 2025 – We're ready, are you?
Get up close with Hitachi’s game-changing machines this weekend and see how they can revolutionise the way you work.
💪 Built for performance. Come check us out!
🎉 Congratulations to Whitehaven Coal on the addition of their 2nd Hitachi EX5600-7 excavator to their Daunia Mine Operation.

Standing tall and poised to meet head on the demanding landscape of Queensland's Bowen Basin by embracing the Hitachi design philosophy of balanced reliability and productivity, the EX5600-7 optimises machine performance, providing a consistent and dependable solution to meet the demands of our customers in the Coal Mining industry.

Pictured from (left to right): Ben, Matt, Scott, Priscilla, Aaron and Heath.

#HCA #OrangeFamily 🍊#HitachiConstruction #Hitachi #Earthmoving #Whitehaven #Productivity
💧 Another 4 for the fleet!
Wormall Civil have just taken delivery of four brand-new Bell 2806E water carts, further strengthening their capacity to deliver civil projects across WA.

We’re proud to continue supporting @wormall_civil with reliable, high-performance machinery that keeps the job moving. Thanks for choosing us again, team!
Head to Head in Laverton!

A powerhouse delivery to @genesisminerals — the EX2000-7 and EX2600-7 standing tall at the Laverton Operations site. 💪🧡
These two mining giants are ready to move serious dirt and get to work.

Big thanks to the team at Genesis for choosing Hitachi.

#HCA #OrangeFamily 🍊#HitachiConstruction #HitachiMining #EX2000 #EX2600 #GenesisMinerals #HeavyMachinery #MiningLife #BuiltToPerform
📡 Maximise performance across your fleet—no matter the size.

LANDCROS Connect delivers operational, health, and location data, giving you the visibility and control to:

✅ Monitor mixed fleets from a single platform
📊 Track job site productivity at a glance
📍 Pinpoint performance with location-based insights
🔧 Stay ahead with daily machine alerts 
📱 Mobile Access Anywhere 

Smarter decisions start here.
👉 Learn more: https://hitachicm.com.au/landcros-connect
Missed us at DDT? No worries — we’re hitting events across the country all year long. Come chat with our reps, get hands-on with the latest machines, and stay up to date on what’s new.

📍Check out the wrap-up video and keep an eye out for where we’ll be next!
🚨 Applications are now open! 🚨

Are you ready to dare to be epic? 👷‍♂️💥
We're looking for motivated individuals to join our Apprenticeship Intake for 2026 across Australia!

Whether you're passionate about heavy machinery, love working with your hands, or want a future in a growing industry — this is your shot.

👊 Earn while you learn
🧠 Gain hands-on skills and formal training
🤝 Become part of the Orange Family

👉 Tag someone who should apply
👉 Share this post and spread the word
👉 Apply today at: https://hitachicm.com.au/orange-family/ai2026/

📣 Let’s build the future together!
📣 Exciting News! Foxleigh Mine has welcomed a brand-new EX1200-7 to their Mining Fleet!

Equipped with outstanding reach and bucket capacity this stunning 120 tonne mechanical marvel will get straight to work maximising  production.

💪 Refined Engineering and Proven Reliability #Hitachi Excavators are the go-to solution to meet the demanding needs of Coal seam mining!

Pictured: Peter, Maintenance and Engineering Manager at Foxleigh

#HCA #OrangeFamily 🍊#HitachiConstruction #Earthmoving #Productivity
Perth Tradie Expo 2025 – We're ready, are you?
Get up close with Hitachi’s game-changing machines this weekend and see how they can revolutionise the way you work.
💪 Built for performance. Come check us out!
🎉 Congratulations to Whitehaven Coal on the addition of their 2nd Hitachi EX5600-7 excavator to their Daunia Mine Operation.

Standing tall and poised to meet head on the demanding landscape of Queensland's Bowen Basin by embracing the Hitachi design philosophy of balanced reliability and productivity, the EX5600-7 optimises machine performance, providing a consistent and dependable solution to meet the demands of our customers in the Coal Mining industry.

Pictured from (left to right): Ben, Matt, Scott, Priscilla, Aaron and Heath.

#HCA #OrangeFamily 🍊#HitachiConstruction #Hitachi #Earthmoving #Whitehaven #Productivity

Use of cookies

This website stores cookies on your computer. These cookies are used to improve your website experience and provide more personalised services to you, both on this website and through other media. To find out more about the cookies we use, see our Privacy Policy. We won’t track your information when you visit our site.

Find a dealer

Search by location
Search by dealer name
It appears you're using an old version of Internet Explorer for safer and optimum browsing experience please upgrade your browser.