Welcome

Project History

Large Truck Study - Late 80s

Drive System Investigation
- Mechanical
- Direct Current (DC)
- Alternating Current (AC)
North American Locomotive Development
Project Start-up - Late 92
Prototype - Early 95
Field Test - 96
Market Introduction - September 96

Development Goals

Increased Productivity
Decreased O&O Costs
Better Performance
- Speed-on-grade
- Maximum Speed
- Continuous Gradeability
- Retarding Capability
- Horsepower Utilization Across
Speed Range
Improved Driveability

Big Is Better Philosophy

OK If?
Infrastructure Can Support:

- Haul Road Width

- Service Bays
- Maintenance Handling Equipment
- Crusher Capacity
- Shovel Match

Big Is Better Philosophy

OK If?
Cost Per Ton is Reduced

- Higher Production
- Fewer Trucks
- Better Reliability & Availability

930E

930E Specifications

Conventional Configuration
- Rigid Frame/Single Engine/Two Axles/Six Tires
Approximately 50L X26WX24H
1,059,000 pound Gross Vehicle Weight
400,000+ pound Empty Vehicle Weight
320 Short Ton Payload
40 mph Maximum Speed
50/90 R 57 Tire Size
Oil-cooled Service Brakes
2700 hp DDC 16V4000 Engine
AC Drive System

AC Electric Truck Performance

High speed

Superior retarding

Deep pit capacity

High efficiency/
high horsepower
utilization
Long component
life

320 Ton Componentry

MTU/DDC 16V4000
engine

G.E. drive system

GTA-34 alternator

AC traction torque
regulation

GDY-85 motorized
wheel

Bridgestone 50/90
R57 VELS tires

930E Systems

Drive System

Engine

Specifications
Make and model MTU/DDC 16V4000
Fuel Diesel
Number of cylinders
16
Operating cycle 4 Cycle
Rated brake power2700 hp (2014 kW) @ 1900 rpm
Flywheel power
2500 hp (1865 kW) @ 1900 rpm
Weight (dry) 15,419 lb (6994 kg)

320 Ton Capacity

20-30% more
than
240 ton trucks

Up to 10% lower
cost per ton

Braking System

Electric retarding
5400 hp (4026 kW)

Oil-cooled,
multiple
disc service
brakes

Economics

Fuel savings
Time cost control
Maintenance cost
advantage

- Lowest life-cycle
cost per ton

Reliability Advantage

UNI-ECS electronic
control

5-10% fuel economy

improvement

12,000+ hours
to overhaul

Main Alternator Cutaway

Control Cabinet
Alternator 3-phase Voltage
Measuring Module

Inverter Phase
Module 1 + or -

Link Voltage
Measuring
Module

Control
Panel

Chopper GTO
Phase Module
1 and 2

Inverter Phase
Modules 2 + or -

Electrical Interface Cabinet

Truck Control
Interface

Circuit
Breakers/Switches

Lincoln Lube
System Timer

Engine Drive
System

Diode Board

Relay Boards

G.E. GDY-85 Electric Wheel

AC Drive System
Blower

Motorized
Wheels

Controls

Pumps

Alternator

Retarding
Grids

Engine

AC Control System
IGBT Aux.
Inverter

D.I.D.

Truck
Control
Interface
(TCI)

Serial
Comm.
Link

Propulsion
System
Controller
(PSC)

Blower

Cooling
Air

Inverters
#1

#2

Rectifier

Alt.

Retarding Power Circuit

BM1

Inverter

M1

Inverter

M2

BM2

Chopper
Module
1
RP1

RP2

RP3

Chopper
Module
2

Gradeability Comparison in Retarding

930E vs Cat 793C

Grade in Percent

15

930E
930E GVW
GVW == 1,059,000
1,059,000 lb
lb

930E

793C
793C GVW
GVW == 830,000
830,000 lb
lb

930E

10

793C
Cont.
Cont.

3-min
3-min

5
Continuous
Continuous

mph
km/h

0
0

10

15

20

25

30

35

40

45

5 10 15 20 25 30 35 40 45 50 55 60 65 70
Speed

Cooling

AC Drive

Induction motors no commutator,

no brushes

Integral outboard
planetary final drive

Proven GTA-34
traction alternator

Electric Retard Advantage

High-density air
cooled grids

5400 hp (4028 kW)

3-minute retarding
effort

3300 hp (2460 kW)

continuous retarding
effort

0.7 sec propel-toretard transition time

KMS
Quality Confirmation Attitude
Past Practice Design, Release, Produce. . .
hope for the best in the field

Current Practice - Design, Test, Re-design,

Re-test, Produce
. . . know what the field
results will be

KMS Joint Technology Projects

930E

D575A

USA

H655S

Japan
Modular
Mining

Vital Signs
Monitoring

Germany

Quality Confirmation Activity

Application of K.E.S. Techniques

Advanced technology, full butt-welded box sectional laddertype frame with integral ROPS supports, integral front
bumper, rear tubular
cross members,
steel castings at all
critical stress
transition zones,
rugged continuous
horsecollar.

Frame

Frame Specs

Rail width

Side plate
thickness

12 (305 mm)

Rail depth 34 (864 mm)

Top and bottom
plate thickness

Plate material

Casting material

70,000 psi (482.3 mPa)

tensile strength steel

90,000 psi (620.1 mPa)

tensile strength steel

1.77 (45 mm)

0.98 (25 mm)

Fabricated Rails
12
(305 mm)

.98 (25 mm)

Outside / Inside Sidesheet

34 (864 mm)
Top / Bottom Bar

1.77 (45 mm)

180

5080
4572

160

4064

140

3556

120

3048

100

2540
2032

200

80
40

1574
1016

20

508

60

Date and Unit

Length of Rejected Indications (mm)

Length of Rejected Indications (in)

Frame Rail Ultrasonic Inspected By Model

Brake System

Service Brakes
2500 psi (17 229 kPa)

Service Brakes

Oil cooled, hydraulic-actuated, multiple disc brakes at

each wheel. Traction system wheel slip/slide control.
Max. service apply pressure ........ 2500 psi (17 229 kPa)
Total friction area per brake ........ 15,038 in3 (97 025 cm3)

Parking Brakes

Multiple disc
Spring-applied,
hydraulically
released

Wheel Brake Locks

Switch-activated
Rear brake only
2000 psi

Electric Dynamic Retarder

Brake Codes
Safe and Reliable Service Brakes
SAE = 331 ft

Actual = 188 ft

58%
Actual
SAE J1473

Emergency Braking Tests

Truck 101
GVW = 1,023,200 lb (464,124 kg) -- EVW = 430,800 lb (195,411 kg)
Loaded
on
Level

Loaded
8.7%
Grade

Empty
on
Level

Empty
8.7%
Grade

Bumper to
bumper

589
(17.9 m)

815
(24.8 m)

Did not
run

Did not
run

Skid

437
(11.8 m)

654
(19.9 m)

Did not
run

Did not
run

Radar
gun

23 mph 25.5 mph

(37 k\m/h) (41 km/h)

All-welded steel flat floor body with horizontal bolsters

and full canopy. Left and right canopy spill guards,
eyebrows, rear wheel
rock ejectors, body
tilt cable, and rubber
mounts on frame are
standard. Pivot
exhaust heating
optional.
Struck capacity
Heaped capacity
Loading height

Body

182 yd3 (139 m3)

241 yd3 (184 m3)
2111 (6.68 m)

Canopy Sheet & Bolster

Front Sheet

0.19 (5 mm) 100,000 psi (690 mPa)

0.35 (9 mm)
400 BHN Nominal

Floor Sheet
0.63 (16 mm)
400 BHN Nominal

Side Sheet
0.31 (8 mm)
400 BHN Nominal

Bolster
0.31 (8 mm)
100,000 psi (690 mPa)
tensile strength steel

Heated Exhaust

930E & 830E Body Impact Plate

930E & 830E Body Impact Plate

Advanced Analog Operator Environment with integral 4-post

ROPS/FOPS structure (meets J1040 Apr88), adjustable
Isringhausen seat w/ lumbar, passenger seat, R-12 insulation,
thermopane windows, tilt steering wheel, electric windshield
wipers w/ washer, tinted
safety glass, Komatsu
Payload Weighing System,
55,000 Btu/hr heater and
defroster, 21,600 Btu/hr
air conditioning
(HFC-134 refrigerant).

Cab

Hydraulic System

Hydraulic Tank

Hydraulic System
350 U.S. gal (1325 L)

Hydraulic Pumps
Hoist & Brake Cooling Pump
Tandem gear-type with
output of 270 gpm
(870 liters/min) at 1900 rpm
and 2500 psi (17 240 kPa)

Steering & Brake Pump

Pressure-compensating
piston with output of 60 gpm
(227 liters/min) at 1900 rpm
and 2750 psi (18 961 kPa)

Steering
Steering Cylinder
Bore diameter
Rod diameter
Stroke
Extended
Retracted

6.50
3.00
27.29
74.41
47.12

Accumulator
Bore
Length
Working
Pressure

8.00
85.75
27.50 psi

Steering Diameter
Maneuverability

974 (24.72 m)
Turning Circle

930E

SAE Steering Course

Corridor 3

Finish 2
Finish 1

Corridor 1

10 m

Corridor 2

20 m

A = 1.10 x the tire track circle or 14 m,

whichever is larger.
B = 1.75 x the tire track circle or 22 m,
whichever is larger.
C = 2.00 x the maximum axle spacing
or 15 m, whichever is smaller.

C
30 m

40 m

Corridor 4

25 m

5 x max width over tires

Start 1
Start 2
1.25 x max width over tires

Steering meets
SAE J1511 standards

Suspensions

Front Suspension

Maximum stroke 12.92 (328 mm)

Long length bearing
Forged rod and housing
Large cast mounts

Rear Suspension

Variable rate hydro-pneumatic with

rebound control

Maximum stroke - 9.0 (229 mm)

Maximum rear axle oscillation - 6.5

Rear Hitch Pin

High Mounted Rear
Axle Hitch Pin

Maximum rear axle

oscillation 6.5

Hoist Cylinders
Extended
169.07 pin to pin
Retracted
65.07 pin to pin
Bore diameters
1st stage
14.00
2nd stage
11.75
3rd stage
9.50
All stages sealed
Quill for deceleration at
frame-standard
Stroke each stage
34.88

Hoist
Cylinders

Rock service, tubeless, radial tires

Standard tire 50/90 R57

Tires

Tire Rating
Bridgestone 50/90 R57 VELS

Load and inflation

165,000 lb at 102 psi

176,000 lb at 116 psi

Specifications

Specifications
308 9.35 m

128 3.86 m

459
13.94 m
RAISED

2111
6.68 m
EMPTY

2310
7.26 m
EMPTY

41
1.25 m

140
4.27 m
LOADED

45
511
1.80 m
EMPTY
1310 4.21 m

31 0.94 m
2010 6.35 m
500 15.24 m

148 4.47 m

47
1.40 m
LOADED

Specifications
278 8.43 m

260 7.92 m

152
4.62 m

75
2.26 m

198 5.99 m

172 5.23 m

242 7.37 m

2610 8.10 m

Weight Distribution
Empty Vehicle
Front axle
Rear axle
Total (wet, 50% fuel)
Loaded Vehicle
Front axle
Rear axle
Total

lb
204,289
215,181
419,470

kg
92 664
97 604
190 268

%
48.7
51.3

lb
353,000
706,000
1,059,000

kg
160 120
320 239
480 359

%
33.3
66.7

Service Capacities
Cooling system
Crankcase *

205 U.S. gal (776 L)

58 U.S. gal (220 L)

Hydraulic system

350 U.S. gal (1325 L)

Motor gear box (each)

25 U.S. gal (95 L)

Fuel 1200 U.S. gal (4542 L)

* Includes lube oil

930E World Population

Total 100
10
67

12
11

KMS 930E AC Drive Truck

In The Dirt
Customer
A. T. Massey
Arco
Asarco Mission
Asarco Ray
Barrick
Chuquicamata
Fording River
Freeport
PD Chino
PD Morenci
Peabody
Peoria
Pipeline
Syncrude
100 Units

Hours
Location
10,193
W. Virginia
3,050
Wyoming
22,650
Arizona
8,389
Arizona
9,950
Nevada
11,163
Chile
13,522
Canada
18,790
Indonesia
99,580
New Mexico
235,883
Arizona
9,600
Wyoming
4,000 Peoria Proving Grounds
7,318
Nevada
30,050
Canada
484,138 Hours

Meeting the future global

mining

Thank You
For Visiting
KMS Peoria

Fuel Savings

UNI-ECS electronics
engine control

Separate circuit
charge air cooling

Fluid coupling fan drive

Fuel Savings

Matched engine
drive system

Engine speed
managed by AC
traction control

Drive matched to
sweet spots on
fuel map

Engine at idle
speed in retarding

Control Cabinet
AC Traction Torque Regulator

Torque regulator

Built in diagnostics/
diagnostics display
panel

Fault and statistical

data recording

Wheel slip/slide
control in propel
and retard

Rims

Standard five (5) piece

rim 32 x 57 x 6.5
(813 mm x 1448 mm x
165 mm)
Patented Phase II New
Generation Rim
assembly with forged
center bolt flange and
62 (1575 mm) center line dual spacing
Rated at 120 psi (827 kPa) cold inflation pressure