730E Product Presentation

Team expert Big dump truck

Jakarta, 20-24 Juni 2011
 Agenda
• Product Overview
– Commitment to Quality- Improvements along the way
– Drive System overview
– Engine overview
– Frame structure- “The backbone of the Product”
– Hydraulic Components- Steering, Hoist and Brakes
– Operator Environment- Cab improvements
– Tires and Tire options
– Dimensional Information

• VHMS- Vehicle Health Monitoring System

• PLM 3- Payload Meter system and Payload Policy

• Electric vs. Mechanical drive system comparisons

• Closure- Questions
Komatsu 730E Product Summary

Standard Specification

GVW = 715,000 lbs (324,317 kg)

Gross Power = 2,000 hp (1,491 kW)

Payload = 202 s ton (183 m tonne)

Tire Size = 37.00 R57

 Komatsu 200 Ton Class Truck Population 730E
OVER 440 UNITS WORLD WIDE!
Canada
8 Units China
51 Units

Japan
2 Units
United States
45 Units
Australia
150 Units
South America Indonesia
32 Units
61 Units

Africa
105 Units
 730E Walk Around Highlights
GE 200 Ton
DC Control System
Bladder
Accumulators

14 Element Retarding
Grid Package
Komatsu Hydrair II
Front Suspensions

Rod Down Rear

Suspensions

Komatsu SSA16V159
2,000 hp engine

Rear Armature Speed

Dry Disc Brakes
Hydraulically
Actuated Front
Dry Disc
GE 788 FS Brakes
Wheelmotors
FGR = 26.825:1

Standard 37.00 R57

GE GTA22 Mature, Reliable Frame
Tires
Alternator
 Dimensions

Based on Standard Configuration and Body

 Dimensions

Based on Standard Configuration and Body

DC Drive System Overview
Engine Specifications

Standard
• Komatsu SSA12V159 (Cummins K2000)
• Gross Power: 2,000 hp (1,492 kW)
• Tier 1 Emissions Certified
• 16 Cylinders
• Weight: 12,603 lb (5,717 kg)
 Engine Features
CENTRY – ELECTRIC ENGINE
MANAGEMENT
Continuously monitors engine
conditions and automatically
adjusts for peak operation
PRELUBE SYSTEM
Eliminates wear from cold
and hot starts, for longer
engine life.
DUAL STAGE TURBO
CHARGING
The two-stage design delivers
high performance at altitudes
(up to 8,000ft)
OPTIONS
 C.E.N.S.E. – Engine
Diagnostic system (Real-Time)
 ELIMINATOR- Dynamic full-flow
and centrifugal system that incorporates
a permanent core. This optional feature
eliminates up to 90% of lube system
maintenance costs while increasing
vehicle uptime.
 Alternator

G.E. GTA-22 alternator

• Three phase AC generator

mounted to the diesel engine
driven by the engine
crankshaft

• Provides cooling air through

an inline dual impeller to the
rectifier and both wheelmotors
Wheelmotors

General Electric – GE788 FS

• Force ventilated DC motor that converts

electrical energy into mechanical
energy.

• Maximum Motor Speed = 2350 rpm

• Designed, in general, for 10% equivalent

grades

• Standard Gear Ratio = 26.825:1

• Optional Gear Ratio = 22.354:1 (cont

man)
Statex III Control System

DC Control Group – Statex III

• Monitors operator input and system

feedback signals and calculates a
response and initiates an appropriate
action

• Over 20 years of operating

experience

• Fuel Saver

• Retard Speed Control

• Spin-Slide Control
 Statex III Control System
Electronic Linking and controlling of all Power Module
Components Retarder

Throttle
Centry
GE Statex III
Engine
Control System

Alternator

Wheelmotor
Statex III Downloads
• Truck Identification • Truck Speed

• Truck Model • Fault Data Storage and Snapshot

• Component Operating Hours

• Engine HP Counter
• Engine Speed
 Airless Control Cabinet
Airless Reverse Contactor GE Diagnostic Panel Main Control Cards

Hinged 24 V
High Voltage Airless Wheelmotor and Main Alternator Relays and
Contactors Field Control Cabinet Control Circuit
Panels
Retarding
DC Dynamic Retarding Assembly

• Primary Braking System

• Maximum 3,700 hp retarding

capability

• Continuously rated blown

grids

• Reverse Retarding and Auto

Retard Speed Control

• NO Mechanical Brake Wear!

 Mature and Reliable Frame Design

Fabricated Box Section Frame Castings Used in High Stress Areas

Rail Width – 279 mm / 11” Plate Tensile Strength – 70,000 psi (482.6 mPa)
Rail Depth – 813 mm / 32” Casting Tensile Strength – 90,000 psi (620.5 mPa)
Top/Bottom Plate – 32 mm / 1.25”
Side Plate – 16 mm / 0.62”

Integral ROPS
/Front Bumper
Six Point Drive
Axle Mounting

Continuous Horsecollar Design

 Frame Rail Ultrasonic
Inspected By Model
11”
(279 mm)

0.62” (16 mm)

32” (813 mm)

Top / Bottom Bar

1.25” (32 mm) Length of Rejected Indications (IN)

200
180
160
140
120
100
80
IMPROVED TESTING = 60
40
IMPROVED PRODUCT! 20
0

18
Hydraulic System
 Hydraulic System Features
• Common tank for steering, hoist and brake systems
• Common fluid for all systems
• Fewer components, less hydraulic hose and tubing
• Reduced maintenance, simple servicing
• Externally mounted filter keeps system clean, easy to service
• Brake control valves limit oil flow, save horsepower and fuel
(when brakes are not in use)
• Vane-type pump for steering and braking - saves fuel, increases
component life
• Gear-type pump for hoist
 Hydraulic System
 Simple Design With Fewer Parts and Piping Than Other OEM’s
 Commons Tank (Divided) For Steering, Hoist, and Brake System
 Common Fluid For All Systems
 Externally Mounted Filter
 Brake Control Valves Limit Oil Flow When Not in Use
 Filtration – In Line Replaceable Elements

Pumps
Hoist and Brake Cooling – Tandem Gear Type, 513 l / 136US gal per min @ 1900 rpm
Steering and Brake – Vane Type, Pressure Compensated, 235 l / 62 US gal per min @ 1900 rpm

Relief Pressures
Hoist/Brake – 17237 kPa/ 2500 psi
Steering/Brake – 18960 kPa/ 2750 psi
Hydraulic tank

Hydraulic System
193 U.S. gal (731 L)
 Suspension Systems
HYDRAIR® II (Komatsu Exclusive) Provides
Smoothest Ride and Best Protection In
Industry for both Operator and Truck.
Front Suspensions
 Forged Front Suspension Rod and Housing Tube
 Large Casting Steel Mounts
 Extra-length Bronze Bearings
 Maximum Stroke = 13.2” (335 mm)
 Suspension Systems

Rear Suspensions

Rod Down Rear Suspension Pin and Clevis

Variable Rate Hydro-Pneumatic with Integral Rebound Control

Maximum Stroke = 11.5 “ (292 mm)

 Hoist System Features

Dual Acting, 3 Stage Cylinders

Internal Cushion Valve
Over Centre Damping
Power Up Loaded 21 sec
Power Down 15 sec
Float Down 22 sec
 Steering System
• Accumulator-assisted
twin cylinders provide
constant rate steering.

• Emergency power
steering automatically
applied by accumulators

• 92 ft (28.0 m) Turning
Diameter – Excellent
Maneuverability

• Six point Articulation

Linkage
 Braking System
• All-hydraulic, dry-disc
mechanical service brakes
are designed to stop the
truck anywhere within its
performance envelope
• Electric retarding is primary
means of controlling speed
and deceleration
• Service brakes primary
means of stopping truck
• Mechanical service brakes
will stop the truck
Front Service Brakes
• Front inboard-
mounted 46” (1168
mm) diameter
wheel speed disc
brakes with a 3-
caliper design on
each brake
Rear Service Brakes
• Rear armature
speed brakes
feature dual
25” (635 mm)
diameter disc
with a single
caliper per disc
 Emergency Brakes
• Front, rear, and
parking - apply
automatically
when hydraulic
system pressure
drops below the
level necessary to
meet secondary
stopping
requirements
 Braking System

Emergency Brakes
Automatically Applied Prior To Hydraulic System Dropping Below
Acceptable Level
Park Brake
Spring applied, Hydraulically Released

SAE: 101 m / 331’ Komatsu 58 m / 190’ Brake Testing and Certification

1. Truck tested at max. GVW
58% of Required Stopping Distance!
2. Dynamic Retarding
Disconnected
3. Tested on 8-10% grade
4. 5 consecutive stops from 30
Komatsu mph (48 km/h)

SAE Requirements 5. Maximum 20 minutes between

stops
6. Additional stop simulates
worst-case
single brake failure
31
 Operator Cab
Ergonomically Designed, Incorporating Advanced Technology, For
Paramount Operator Health and Comfort

• Fully Adjustable Operator’s Seat

• Tilt-telescopic steering wheel
• Air suspension seat
• Tinted, safety glass windows
• Heating and air conditioning
• Acoustical insulation
• Double sealed doors
• Pressurized cabin

ROPS / FOPS Certified

Standard 2 Point Seat Belt Optional 4 Point Seat Belt

 Operator Cab
Logically Arranged
Controls and Simple
Monitoring of Critical
Machine Functions
Easy to Reach Dump
Lever
Automatic Windows
Alarm System Warning
Lights
AM/FM Cassette Radio
Digital Tachometer and
Speedometer
Retard Speed Control
Easy to Reach Engine
Stop Switch

33
 Tires & Rims

Rock Service, Tubeless Tires Forged Flange

Lock Ring
O-Ring
Bead Seat Band
Standard 37.00 R57
Back Section Centre Band
Gutter Band
Standard 5 Piece Rim
(686 mm x 1488 mm x 152 mm / 27” x 57” x 6”)

Patented Phase II New Generation Rims

Rated at 827 kPi / 120 psi Cold Inflation Pressure

 Tires & Rims
Ground Bearing Pressure
Loaded Travel Empty Travel
Truck Tire GVW Load per Bearing EVW Load per Bearing
Model Ident. Weight (lbs.) Tire (lbs.) Pressure (psi) Weight (lbs.) Tire (lbs.) Pressure (psi)

730E 37.00R57 715,000 119,200 81.9 315,100 77,200 69.2

TMPH Ratings
Source: Michelin

Pattern Photo

Pattern Name XDM XDR

Size Available 37.00R57
Tread Class E3 E4
A = 464
B4 = 581
Tire TMPH
B = 697
C4 = 784
 Vehicle Health Monitoring System
(VHMS)

• Combination of Hardware, Software and

Communication Systems

• Tool to Provide Critical Operating Information on

Mining Equipment

• Allow the Remote Diagnosis of Equipment Condition

• Provide Pro-Active Support to Lower Operating Costs

and Raise Availability
 VHMS Features
• VHMS Controller
– Gathers Critical Information Via Sensor Network

• Orbcomm Communication System

– Transmits Data Using Satellite

• WebCARE
– Analyzes Data, Provides Tools to Make
Recommendations

• MyKomatsu.com
– New Access Point for Customers and DBs to Review
VHMS Reports
 VHMS with Orbcomm
Orbcomm

Customer
Jobsite
Gateway

Technical support
Remote monitoring by Factory
engineer & H.O.

Data is sent by E-mail that

is not real time.

Komatsu Komatsu H.O.

Subsidiary & Factory

KCC (Komatsu Computer Center)

PC WebCARE
download Distributors
- Monitoring Support Support Database
- Abuse control
- Correct maintenance Data flow
- Proactive repair
- O/H timing
38
 ORBCOMM

After Planned
GES Installations

Direct Gateway
Near-Real-Time Service

Store and Forward

Globalgram Service

ORBCOMM PROPRIETARY 12
 Benefits of VHMS Utilization
• Reduce or Stop Unexpected Major Failures

• Reduce and Shorten Downtime Events

• Keep Repair Cost at Lowest Possible Level

• Keep Machine Highly Productive through Performance and

Availability
 PAYLOAD METER III
Benefits

• Simple method to track production

• Integrates easily with mine management systems (IE Dispatch)
• Provides feedback to loading operators for better control of
overloads
• Unique Speedometer/Payload gauge give the truck operator
critical information from one source on the dashboard
• Better loading management is the key to reduced wear and tear on
equipment producing longer life and lower maintenance costs for
the long haul.
 VHMS Example
 Overrun , over load
 Retarder overheat
 Cooling radiator clogging
Correct operation  Excessive shoe slip
 Insufficient warming up
 Excessive T/C stall
 Sudden shift F/R
= shorter life of engine, power line, and axle due to excessive load
= brake premature wear, seizing
= shorter life of engine due to heat damage to rubber parts
= premature wear on grouser of shoes on bulldozer
= engine seizure, pump cavitation
= shorter life of T/C
= premature wear on clutch discs

Service meter = correct periodic maintenance(oil, coolant and filter)

Correct Lower level (oil,coolant) & alarm = correct maintenance, cleaning clogged filter archangel element
maintenance
- Engine
Monitoring machine
Speeds…engine, hydraulics condition oil press….volume efficiency of Lub. Pump
condition Blow-by…wears on piston , valve coolant temp…cooling system condition
Boost press….turbocharger condition oil temp….lubrication & cooling system
Exhaust gas temp….air/fuel ratio, combustion condition( difference LH/RH, 123 & 456)
Fuel injection amount…load factor for engine life estimation
- T/M, power line (brake)
caution Fill time…disc wear oil press….gear pump volume efficiency
Shift frequency…disc premature wear brake oil temp….brake premature wear
- Hydraulics & work equipment
Hyd. Press….difference among pumps
- Bulldozer…traveling distance, shift frequency to estimate undercarriage wear
alert
Not too early, not too late Critical
OV timing predict Recommend schedule OV / Repair cost / Reduce down time Caution

Feedback Engine Load Factor = = = OV Life

component life T/ M Shift Change Frequency = = = OV Life Ｈ OV

Don’t wait for failure signal but detect real cause and take preventive action to avoid unnecessary failure. Cure to CARE
 PAYLOAD METER III
General Summary
REDUCE OVERLOAD…OPTIMIZE PAYLOADS..MAXIMIZE PRODUCTIVITY!

• PLM III is an electronic system that

monitors and records payload information
for Komatsu’s family of Off-Highway
mining trucks. It was released in June
2001. (200 Units: 730E, 830E & 930E)
• PLM III offers improved accuracy of
payload measurement and reliability. This
information can be used as a tool to
reduce the total cost of ownership for
Komatsu equipment.
SOFTWARE CAPABILITIES:
PLMIII Dash Display
• Count each shovel pass
• Record segment times for the entire
haul cycle (loading, hauling, etc)
• Provide repetitive accuracy of payload
measurement
• Report the details of each haul cycle
• Saves and stores up to 5,208 payloads
in memory
 PAYLOAD METER III
Benefits

• Simple method to track production

• Integrates easily with mine management systems (IE Dispatch)
• Provides feedback to loading operators for better control of
overloads
• Unique Speedometer/Payload gauge give the truck operator
critical information from one source on the dashboard
• Better loading management is the key to reduced wear and tear on
equipment producing longer life and lower maintenance costs for
the long haul.
 PAYLOAD METER III
PC Software
Connect to the PLM III
Monitor pressures, record haul cycles and download

Graphs & Reports

Quickly produce reports

Export & Integrate

Payload data can be exported to Excel for detailed
analysis and integration with other data sources

Quickly Analyze & Review

Fleet data is stored in local database for
comprehensive comparison and analysis
 Payload / Overload Policy
10-5-10
Four (4) Main Criteria:
1. Payload Up To 105% Of Rated Payload Must Not Account For More Than 90% Of Total Loads

2. Payloads Between 105% and 110% Of Rated Payload May Occur No More Than 10% Of The Time

3. No Single Load Shall Exceed 110% Of Rated Payload

4. Average Of All Payloads, Measured Monthly, Shall Not Exceed The Rated Payload
Number of Loads

90% of Total 10% of Total 0% of Total

Loads Loads Loads

90 95 100 105 110 115 120

Actual Load As % of Rated Load
 Electric Drive Advantages
1) Maintenance and Operation
• Fewer Gears and Bearings (Mechanical Components)
• Less Maintenance Intensive – Higher Availability
• Easier Maintenance – Less Components
• Less Complex Drive System

1) Electric Drive Systems Have No Mechanical Gear Shifting

• Eliminates Shift Shock
• Improves Operator Comfort

1) Dynamic Retarding vs. Mechanical Retarding

• No Brake Wear
• In Some Downhill Applications – Brakes Represent the Largest
Budget Item for Mechanical Drive Trucks!

1) More Hours of Field Experience

• Electric Drive Has Been in Off-Highway Applications Longer Than
Mechanical Drive Trucks
• Electric Drive Systems Are Continually Used in the Locomotive
Industry – The Number 1 Transportation System Worldwide
 Electrical vs. Mechanical
MECHANICAL DRIVE:
•TORQUE CONVERTER
•DRIVELINE
•UNIVERSAL JOINTS
•TRANSFER CASE
•TRANSMISSION
Mechanical Drive Total •BEVEL SET
48 Gears
•AXLE SHAFTS
148 Bearings
•PLANETARIES

ELECTRIC DRIVE:
•ALTERNATOR
•CONTROL CABINET
•POWER CONTROL
•ELECTRIC WHEELS
•RETARD GRIDS

3 LESS
COMPONENT
GROUPS TO
MAINTAIN!!