How Specialised Tooling is Redefining Haul Truck Maintenance

At the centre of this evolution is Andre Duckitt, Innovations Project Manager at Geographe. Working closely with mine site maintainers,  Andre and his team have developed a new generation of tooling to suit Caterpillar 785, 789 and 793 haul trucks,  including the Ball Stud Removal Tool (BSRT) and the Ball Stud Bearing Installation and Removal Tool (BSBIRT).

“The motivation behind these tools was really about listening to the maintainers,” Andre said. “We’re committed to developing safer, smarter tooling, and that starts with understanding the realities of the job.”

Pictured: Andre Duckitt, Innovations Project Manager

Rethinking Basics: Making Haul Truck Maintenance Faster, Safer, Smarter

The first-generation BSRT was already a step forward in haul truck maintenance. The second generation, released earlier this year, brings a range of safety and usability upgrades based on direct site feedback.

“One of the biggest improvements is how we’ve secured the hydraulic cylinder to the main tool body,” Andre explained. “It was possible in the first-gen version to accidentally dislodge the cylinder before pressurisation. That’s been eliminated.”

The redesigned latch mechanism allows tool attachment from both sides, reducing setup time and awkward manoeuvring in confined spaces under the truck.

For maintainers, these refinements translate to measurable results. A Truck Maintenance Superintendent from a Western Australian mining company reported that using the BSRT reduces the time to remove ball studs from 12 hours per truck to just one hour, while also removing the risk of damaging jacks.

“It’s a significant cost and time reduction,” they noted. “But more importantly, it improves safety for our maintainers.”

Pictured: Ball Stud Removal Tool (BSRT) 

Addressing Bearing Replacement Hazards

Where the BSRT tackles time-consuming disassembly, the BSBIRT, which is still undergoing field testing, is designed to eliminate risk during bearing replacement on Caterpillar haul trucks, particularly on the 785, 789, and 793 models.

“The BSBIRT came about after a Tier 1 miner shared their frustrations with how difficult and hazardous it was to remove split shell bearings,” said Andre. “We designed a complete toolset that allows a single person to do the job safely and efficiently.”

Traditionally, bearing removal involves brute force techniques such as hammers, heating, and liquid nitrogen, which pose well-documented risks to both personnel and equipment. The BSBIRT replaces these legacy methods with a modular, engineered solution that supports a consistent three-step process: removal, setting, and installation.

“By eliminating the need for hazardous methods, we’ve made the job safer and more predictable,” Andre explained. “It’s also allowed us to provide clear documentation and repeatable steps, which simplifies training and boosts consistency across shifts.”

Pictured:  Ball Stud Bearing Installation & Removal Tool (BSBIRT) (left) and Ball Stud Removal Tool (BSRT) (right)

Built for the Trucks that do the Heavy Lifting

Both the BSRT and BSBIRT have been specifically developed for the 785, 789, and 793 haul trucks, which make up the bulk of large-scale mining fleets in Australia’s iron ore and gold operations.

Geographe follows a deliberate, staged approach to field validation: starting with in-house bench tests, moving to local trials, and culminating in deployment at multiple mine sites across Western Australia.

“Our goal is zero harm,” Andre said. “Every component has to work in real-world conditions reliably, safely, and repeatedly. We don’t cut corners, and we don’t release anything until we’re confident it adds value on site.”

Field validation is particularly important for frontline maintenance personnel working in high-pressure environments.

“We see ourselves as engineering partners, not just tool suppliers,” Andre said. “If a tool isn’t intuitive and safe for someone to use during a night shift in 40-degree heat, then it’s not ready.”

A smarter, safer future for maintenance

At a time when mine operators are seeking every advantage to improve productivity while maintaining rigorous safety standards, Geographe’s tooling innovations highlight the impact of user-driven design.

By simplifying processes, eliminating high-risk legacy methods, and enabling consistent, repeatable maintenance outcomes, Geographe delivers Specialised Tooling solutions that go beyond compliance;  they deliver confidence to maintenance teams.

“We want our tools to empower the people using them,” said Andre. “If we can make the job safer, faster, and easier, we’re not just improving maintenance - we’re helping people go home safe, every day.”