Turn Maintenance Challenges into Innovative, Safer Solutions

Through close collaboration with maintenance teams, Geographe identified one of the industry’s toughest challenges: steering arm maintenance on large Caterpillar haul trucks. Traditional methods such as hammering, grinding, or thermal lancing were time-consuming, hazardous, and often caused costly component damage.

That challenge led to the creation of the Ball Stud Removal Tool (BSRT) and the Ball Stud Bearing Installation and Removal Tool (BSBIRT). Both tools use controlled hydraulic force to replace high-risk manual work, allowing a single operator to complete the task safely and efficiently.

Taking Safety a Step Further

Geographe’s focus on safe maintenance extends well beyond steering arm tooling. The Enhanced Performance (EP) Colleted Pin Assembly (CPA) is another innovation addressing a persistent issue, seized pins in rear strut and suspension locations on Caterpillar and Komatsu haul trucks.

Unlike conventional designs, the CPA uses a tapered collet system that creates a self-wedging effect between the pin and frame bores. This design helps prevent pin seizures, reduces workshop time, and in many cases, removes the need for hot works altogether.

“When we develop EP parts, we’re not just improving the design, we’re improving the whole job,” said Geographe Key Account Manager Brita Phillips. “Our CPA tooling has helped sites eliminate hot works entirely during pin removal, saving hours in maintenance and reducing risk.”

Pictured: the 930E Colleted Pin Assembly next to the Colleted Pin Assembly Installation & Removal Tool 

Proven in Field Applications and Supported Locally

Trials across Tier 1 mining operations have shown measurable results. Crews have reported faster setups, reduced rework, and the complete removal of thermal lancing in some maintenance tasks. For reliability engineers and planners, that means shorter downtime and better asset availability.

“Even if an EP part is installed during the final service cycle of a truck, the savings in time and uptime are significant,” Qadri said. “Those extra hours in production can make a real difference.”

Every Geographe innovation is backed by more than 50 years of local engineering experience. From design through to testing and manufacturing, all work is completed locally by people who understand the daily challenges of mine site maintenance.

“We’re a third-generation Australian manufacturer,” Phillips said. “We understand our customers because we’re on-site with them, listening, learning, and continuously improving our products based on their feedback.”

Redefining Safe and Efficient Maintenance

As mine sites push toward zero harm and greater operational efficiency, Geographe’s Specialised Tooling and Enhanced Performance components continue to set new standards for safety and reliability.

By removing hazards and reducing manual strain, these solutions are not only protecting people but also helping mines achieve measurable productivity gains.

For Geographe, better design means more than superior components; it means better outcomes for maintainers, equipment, and production.

Originally featured in Australian Mining's October 2025 edition, click to read more