Heavy haul retrofit
ABB’s retrofit solutions for diesel haul trucks deliver a fast and cost-efficient path to electrification. By upgrading existing vehicles, operators can reduce their cost per ton moved — without the need for full fleet replacement.
Modernizing Mining Fleets for the Electric Future
ABB’s haul truck retrofit solutions combine advanced traction converters and high-performance energy storage systems to transform existing haul trucks into efficient, low-emission machines.
Built for the harsh conditions of mining environments, ABB’s solutions increase productivity, lower maintenance costs, and support a step-by-step transition toward fully electric operations.
Whether through hybridization or full electric conversion, ABB enables operators to increase performance today while building the foundation for tomorrow’s zero-emission mining fleet.
Key Benefits
ABB’s retrofit solutions transform diesel-powered haul trucks into efficient, reliable, and sustainable assets. By electrifying and hybridizing existing fleets, operators benefit from improved performance, lower operating costs, and safer, cleaner mining operations — all while extending vehicle lifetime and reducing environmental impact.
Lower cost per ton moved
ABB’s retrofit solutions improve vehicle efficiency and performance, enabling operators to transport more material with less energy consumption—reducing overall cost per ton moved.Proven Reliability
Based on field-proven technology, ABB's haul truck retrofit solutions minimize downtime through high efficiency and reduced maintenance needs.Lower Total Cost of Ownership (TCO)
ABB’s hybridization and full electrification solutions significantly reduce fuel consumption, directly lowering Total Cost of Ownership (TCO).Enhanced Safety & Health
Improved on-site working conditions through quieter and cleaner operations with reduced exposure to noise and heat.Simplified Maintenance
ABB's retrofit solutions lower maintenance needs, reduce service intervals and cut overall maintenance costs.Sustainability
Retrofitting heavy haul trucks helps to reduce CO₂ and emissions, supporting customers to meet global decarbonization goals.Thinking about going hybrid? Give your haul truck a hybrid muscle
Learn how hybrid retrofits can reduce costs and emissions without replacing your fleet.
Upgrade Solutions for Diesel-Electric Haul Trucks
Hybridization
ABB’s hybridization solution combines a new form-fit IGBT traction converter with an advanced energy storage system, enabling partial electrification of diesel-electric haul trucks. This upgrade significantly improves energy efficiency, reduces fuel consumption by up to 30%, and lowers emissions — while maintaining the reliability and power required for demanding heavy-haul operations. Other benefits include regenerative braking, diesel engine load optimization, maintenance cost reduction as well as a boost mode delivering up to +1.5MW of extra power, speeding up cycles and improving throughput, all while delivering a short term ROI.
Full electrification of haul trucks
ABB’s full electrification solution enables complete transition to zero-emission operation. By combining a high-efficiency traction converter with an advanced energy storage system and trolley connection, this upgrade delivers 100% diesel-free performance, maximized energy efficiency, and significant reductions in total cost of ownership by up to 60%.
Traction Converter Replacement
ABB’s traction converter replacement solution introduces the latest IGBT-based technology to enhance performance, efficiency, and reliability. This form-fit converter is designed for seamless integration into existing systems and prepares vehicles for future upgrades, such as hybridization or full electrification. This upgrade delivers initial fuel savings of 5-8% through optimized efficiency and solves the main obsolescence issues with your current fleets.
Upgrade Solutions for Diesel-Mechanical Trucks
Down Hill Upgrade Solution
ABB’s Downhill Haul Upgrade Solution enables fully electric operation by converting the truck’s braking energy into usable power. Equipped with an IGBT traction converter, AC traction motor, and high-power energy storage system, the solution allows loaded trucks to regenerate energy during downhill runs — achieving up to 100% fuel savings and zero-emission operation.
Flat or Uphill Haul Upgrade Solution
ABB’s Flat or Uphill Haul Upgrade Solution enables efficient, zero-emission operation for demanding haul profiles. Featuring an IGBT traction converter, AC traction motor, and static charging system, it integrates with third-party energy storage solutions to deliver up to 50% total cost savings while ensuring reliable performance across all application profiles.
Parallel Hybrid Upgrade Solution
ABB’s Parallel Hybrid Upgrade Solution combines a high-efficiency traction converter, AC traction motor, and power-optimized energy storage system with a mechanical drop box for hybrid connection. This configuration reduces fuel consumption by up to 20% and enables regenerative braking, lower emissions and maintenance costs while enhancing overall vehicle performance for all application profiles.
Video highlights
See how ABB's haul truck hybridization solution supports customers