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930E-4

Product Presentation

930E-4 Product Presentation 1


November, 2006
Development History – Focus on Success
1980’s 1990’s 2000’s

 Large Truck Studies Began


• 830E Introduction – DC Electric Drive

 Drive System Investigation


• Mechanical
• DC Electric
• AC Electric

 North American Locomotive Development


• DC to AC Electric Drive
 1992 – 930E Development Begins

 1995 – 930E-1 Prototype

 1996 – 930E-1 Field Test

930E-4 Product Presentation 2


November, 2006
Development History – Focus on Success

1980’s 1990’s 2000’s

 Large Truck Studies Began  1996 – 930E-1 Introduction


• 830E Introduction – DC Electric Drive • The World’s First Ultra Class Truck

 Drive System Investigation


• Mechanical  1999 – Dash 2 Model Change
• DC Electric
• AC Electric

 North American Locomotive Development  2003 – Dash 3 Model Change


• DC to AC Electric Drive

 1992 – 930E Development Begins

 1995 – 930E-1 Prototype

 1996 – 930E-1 Field Test

930E-4 Product Presentation 3


November, 2006
Komatsu Ultra Class Truck Population
930E & 930E SE
Canada
930E-1 11
467 UNITS WORLD WIDE!
930E-2 37 China
930E-3 27 930E-4 3
930E-4 24

South America
930E-1 21
Australia
930E-2 61
930E-2 19
United States 930E-3 101
930E-3 11
930E-1 71
930E-2 49
930E-3 31
Indonesia
930E-1 9
930E-2 16
930E-4 Product Presentation 4
November, 2006
930E Market Success

Customer Location Fleet Size Commodity Application


Codelco Chile 117 UnitsCopper Deep Pit
Barrick United States 38 Units Gold Deep Pit
Suncor Energy Canada 31 Units Oil Sands Severe RR
Freeport Indonesia 25 Units Copper Wet – Deep Pit
Massey Energy United States 23 Units Coal Contour Mining
Elk Valley Coal Canada 15 Units Coal Uphill/Downhill
Arch Coal United States 16 units Coal Flat Hauls
930E-4 Product Presentation 5
November, 2006
930E Evolution
1996 1999 2003
Specification
Specification Engine SSDA16V160 Tier 1
Engine DDC 16V4000/ GE Wheel GDY 106
SSDA16V160 GE Alter. GTA 41
GE Wheel GDY 85 Control AC Torque Control (GTO)
GE Alter. GTA 34 Retard 20 elem. @ 3300HP
Control AC Torque Control (GTO) GVW 1,100,000 lbs.
Specification Retard 18 elem. @ 3300HP Rear Susp. Inverted Sus. W/ larger
Engine MTU-396/DDC16-4000 GVW 1,100,000 lbs. piston
/QSK 60 Rear Susp. Std. Susp. W/4” Eye Tire 53/80R63
GE Wheel GDY 85 Tire 53/80R63
GE Alter. GTA 34 Improvements Improvements
Control AC Torque Control (GTO) 1. Improved pinion/carrier – GDY85 1. Improved Propulsion and Retarding
Retard 16 elem. @ 3300HP 2. Control system improvement Rimpull
GVW 1,039,000 lbs. 3. Tire – 53/80R63 2. High-Altitude Deration Impr.
Rear Susp. Std. Susp. W/4” Eye 4. Improved Frame Casting 3. Longer wheel base
Tire 50/90R57 4. Target Operating Cost

930E 930E-2 930E-3


Units 1 - 120 Units 120 - 296 Units 296 - 461
930E-4 Product Presentation 6
November, 2006
930E Evolution
2003 2006
Specification Specification
Engine SSDA16V160 Tier 1 Engine SSDA16V160 Tier 2 Certified
GE Wheel GDY 106 GE Wheel GDY 106
GE Alter. GTA 41 GE Alter. GTA 41
Control AC Torque Control (GTO) Control AC Torque Control (IGBT)
Retard 20 elem. @ 3300HP Retard 20 elem. @ 3300HP
GVW 1,100,000 lbs. GVW 1,106,670 lbs.
Rear Susp. Inverted Sus. W/ larger Rear Susp. Inverted Sus. W/ larger piston
piston Tire 53/80R63
Tire 53/80R63
Improvements
Improvements 1. Drive System Improvement to IGBT Based
1. Improved Propulsion and Retarding Control System
Rimpull 2. Tier 2 Certified QSK60
2. High-Altitude Deration Impr. 3. Cab Improvements
3. Longer wheel base 4. Access System Improvements
4. Target Operating Cost 5. Minimal Empty Vehicle Weight Change

930E-3 930E-4
Units 296 - 461 Units 462 

930E-4 Product Presentation 7


November, 2006
Komatsu 930E-4 Product Summary

General Specification

GVW = 1,106,670 lb (501,974 kg)

Gross Power = 2,700 hp (2,013 kW)

Payload = 320 s ton (290 m tonne)

930E-4 Product Presentation 8


November, 2006
Komatsu 930E-4 Product Summary
Manufacturer Komatsu Komatsu Komatsu
Truck Model 930E - 4 Tier 2 930E - 4 Tier 1 930E - 3
Nominal GVW lbs 1,106,670 1,106,670 1,106,670
kg 501,974 501,974 501,974
Axle Spilt (FT / RR) % 33 / 67 33 / 67 33 / 67
EVW (wet) lbs 466,283 466,784 466,672
kg 211,501 211,729 211,678
Axle Spilt (FT / RR) % 47 / 53 47 / 53 47 / 53
Weight
Rated Payload short ton 320 320 320
metric ton 290 290 290
Standard Body Weight lbs 66,936 66,936 66,936
kg 30,362 30,362 30,362
Typical Tire Weight (6) lbs 57,600 57,600 57,600
kg 26,127 26,127 26,127

930E – 3 EVW 466,672 lbs


112 lbs
930E – 4 EVW Tier 1 466,784 lbs 389 lbs
930E – 4 EVW Tier 2 466,283 lbs

Same Rated Payload


930E-4 Product Presentation 9
November, 2006
What’s New?
TIER II ENGINE

GE IGBT CONTROLS
Cab QSK60 2 STAGE
-New Engine Diagnostic TIER II
PRODUCT IMPROVEMENT Connectors AT 2700 HP
-New Diagnostics
-New coolant level
sensor
-New water pump

New Radiator
-Narrower Cores
-New port locations

GE IGBT Control
Grp common with
830EAC and 960E

Cab commonization
with 830EAC,
860E, & 960E

New access system


meets SAE &
Australian
Standards
- New Auto Lube New Common New LED
930E-4 Product Presentation Controller Battery Box Lights 10
November, 2006
Engine Specifications

• Komatsu SSDA16V160 (Cummins QSK60)


• Tier 2 Emissions Certified
• Tier 1 Emissions Optional Outside of North
America

• Gross Power: 2,700 hp (2,013 kW)

• Flywheel Power: 2,550 hp (1,902 kW)

• Weight: 21,182 lb (9,608 kg)

930E-4 Product Presentation 11


November, 2006
Achieving Tier 2 Emissions
Unregulated
15
NOx + HC (g/kW-hr)

Tier 1 (2000)
EPA MOH >751 HP
10
For Tier 2 the emissions
‘box’ gets smaller and
Tier 2 (2006) combustion trade-off gets
more difficult i.e.
High temperature = higher
5
NOx + HC
Tier 4 Interim (2011)
Low temperature = higher
PM
Tier 4 Final (2015)

0 0.5
0.1 1.0
PM (g/kW-hr)

930E-4 Product Presentation 12


November, 2006
Tier 2 Development Goals

Customer Targets
• Power Rating
• Fuel Efficiency
• Reliability

Manufacturer Targets
• Minimize Installation Impact
• World-wide Utilization
• Robust for Tough Duty Cycles

Technology Targets
• Achieve Tier 2 Emissions
• Utilize Proven Platforms
• Enhance Performance

930E-4 Product Presentation 13


November, 2006
Tier 2 Engine Design
Quantum advanced in-cylinder combustion is the key
High durability FCD piston
technology enabler for maintaining or improving ratings becomes common across
without increased displacement the range

Modular Common Rail fuel


system with improved power
delivery

Enhanced engine
sensor package

Fully sealed
High-pressure wiring harness
fuel pump generates system
1600 bar becomes
common across
the range

Upgraded ECMs with


930E-4 Product Presentation over two times faster 14
November, 2006 processing power
Tier 2 Engine Design
Tier 2 engines have near identical
envelopes to that of Tier 1 No change in air No change in exhaust
inlet connections outlet connections
70-75% common part numbers with
Tier 1 engines

Same Options:
Virtually no change • Fan Drives
to dimensions • Alternators
• Flywheels
• Oil Pans
• Aux. Drives
• Filters
• Prelub
• Centinel
• Eliminator
• Ether Injection
No change in jacket water No change in mounting
inlet / outlet connections locations
930E-4 Product Presentation 15
November, 2006
Tier 2 Engine Design
Emissions certified engines achieve Tier 2 with a marginal fuel
consumption increase of approx.1% averaged across the range
BSFC fuel comparison shown (highest ratings at rated power)

Tier 2 QSK19 QST30 QSK50 QSK60


Fuel System MCRS PLN MCRS MCRS
Consumption 1.7% 0.0% 5.1% 1.4% 0.59%
difference reduction neutral increase increase increase
lb/hp-hr 0.344 0.349 0.348 0.341

Tier 1 QSK19 QST30 K2000E QSK45 QSK60


Fuel System HPI PLN PT/STC HP HPI
lb/hp-hr 0.350 0.349 0.331 0.343 0.339

930E-4 Product Presentation 16


November, 2006
Engine Features
CENTRY – ELECTRIC ENGINE DUAL STAGE TURBO
MANAGEMENT CHARGING
Continuously monitors engine The two-stage design delivers high
conditions and automatically performance at altitudes (up to
adjusts for peak operation 12,000ft)

PRELUBE SYSTEM OPTIONS

Eliminates wear from cold and  C.E.N.S.E. – Engine Diagnostic


hot starts, for longer engine system (Real-Time)
life.
 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.

930E-4 Product Presentation 17


November, 2006
Tier 2 Engine Comparison
Manufacturer Komatsu Komatsu Komatsu
Truck Model 930E - 4 Tier 2 930E - 4 Tier 1 930E - 3
Type (SSDA16V160 TIER 2) (SSDA16V160 TIER 1) (SSDA16V160 TIER 1)
# of Cylinders 16 16 16
Engine Weight (Wet) lbs 22,309 21,207 21,207
10,119 9,619 9,619
Bore x Stroke mm 159 X 190 159 X 190 159 X 190
Displacement liter 60.2 60.2 60.2
Gross Power HP 2,700 2,700 2,700
Engine RPM 1,900 1,900 1,900
Flywheel Power HP 2,550 2,550 2,550
RPM 1900 1900 1900
Power/Displacement HP/l 44.9 44.9 44.9
Net Power/Payload HP/s ton 8.4 8.4 8.4
Net Power/ Ton GVW HP/s ton 4.9 4.9 4.9
Altitude w/o Derate ft 12,000 12,000 12,000
m 3,659 3,659 3,659

Power Rating

Displacement

Altitude Rating

Engine Weight 500 lbs


930E-4 Product Presentation 18
November, 2006
GE 320AC Drive System

930E-4 Product Presentation 19


November, 2006
GE Invertex AC Control Group

AC Control Group

» High Capacity Rectifier – longer diode life

» Only two high-capacity retard contactors –


less maintenance

» GE InvertexTM AC control with spin-slide


control and thermal self-protection
algorithms

» Packaged for easy access

» GTO   IGBT Inverter Technology

930E-4 Product Presentation 20


November, 2006
GE Invertex AC Control Group

Comparison GTO-IGBT technology

• IGBT and GTO drive system block diagrams are identical.


• Three phase alternator output is rectified to DC.
• DC input to Inverters which provide Three Phase “Variable Voltage
Variable Frequency” for Traction Motors.

GTO or IGBT

930E-4 Product Presentation 21


November, 2006
GE Invertex AC Control Group
GTO IGBT
PHASE PHASE
MODULES MODULES

DC + DC +

GATE
DRIVER
0 - 15V
GATE
DRIVER
0 - 100V

AC
R
AC

GATE
DRIVER
GATE
0 - 15V
DRIVER
0 - 100V

SNUBBER

DC - DC -
930E-4 Product Presentation 22
November, 2006
GE Invertex AC Control Group

Comparison GTO – IGBT Technology


IGBT GTO
EFFICIENCY Efficiency of Inverter Module
Snubber N.A. Needed X
Gate Drive Complexity X
Higher Switching Frequency (Motor Efficiency) X

RELIABILITY Overcurrent Fault Protection X

COST System Cost X

AVAILABILITY Device Availability X

EQUAL
SUPERIOR
INFERIOR X

IGBT drive systems are a future oriented technology that


offer lower cost, lower complexity and higher reliability

930E-4 Product Presentation 23


November, 2006
GE Traction Alternator

G.E. GTA-41 Alternator

» Three phase AC generator mounted to the


diesel engine driven by the engine crankshaft

» Provides cooling air for main controls and


wheel motors

» Advanced excitation system


Enable fast response to power demands

» Also used in the 830E AC

930E-4 Product Presentation 24


November, 2006
GE AC Motorized Wheel

G.E. GDY106 Wheel Motor

» Continuous motoring capability up to 12%


equivalent grade

» Maximum Speed: 40 mph (64.5 kph)

» Standard Gear Ratio: 32.62:1

930E-4 Product Presentation 25


November, 2006
GE AC Motorized Wheel

GDY106 Design Improvements (930E-2  930E-3 / 930E-4)

930E-4 Product Presentation 26


November, 2006
GE AC Motorized Wheel Design Features

24,000 hr MTBO transmission


@ nominal GVW 1,106,670 lb and
10-10-20 loading practice

• larger gearing

• new material sun pinion

• larger low speed bearings

• stiffer carrier assemblies


• ground ring gear
• increased frame coupling – and
frame coupling bushing thickness

• removable inboard thrust washer retainer


• enhanced ability to drain gear case
930E-4 Product Presentation 27
November, 2006
GE AC Motorized Wheel Design Features

24,000 hr MTBO transmission


@ nominal GVW 1,100,000 lb and
10-10-20 loading practice

• larger gearing

• new material sun pinion

• larger low speed bearings

• stiffer carrier assemblies


• ground ring gear
• increased frame coupling – and
frame coupling bushing thickness
Outside diameter 85B/D 106
LS sun pinion
LS planet gear
7.7”
13.6”
9.2”
15.5”
• removable inboard thrust washer retainer
LS ring gear (inside minor) 31.6” 36.7
• enhanced ability to drain gear case
LS gearing face width 9.0” 11.83”
930E-4 Product Presentation 28
November, 2006
GE AC Motorized Wheel Design Features

24,000 hr MTBO transmission


@ nominal GVW 1,100,000 lb and
10-10-20 loading practice

• larger gearing

• new material sun pinion

• larger low speed bearings

• stiffer carrier assemblies


• ground ring gear
• increased frame coupling – and
frame coupling bushing thickness

• removable inboard thrust washer retainer


• enhanced ability to drain gear case
930E-4 Product Presentation 29
November, 2006
GE AC Motorized Wheel Design Features

24,000 hr MTBO transmission


@ nominal GVW 1,100,000 lb and
10-10-20 loading practice

• larger gearing

• new material sun pinion

• larger low speed bearings

• stiffer carrier assemblies


• ground ring gear
• increased frame coupling – and
frame coupling bushing thickness
LS Planet Bearing dimensions
outside diameter 240 mm
85B/D
260 mm
106
• removable inboard thrust washer retainer
Inside diameter 110 mm 120 mm

• enhanced ability to drain gear case


Width 92 mm 106 mm
Dynamic Capacity 190,000 lbs 232,000 lbs

930E-4 Product Presentation 30


November, 2006
GE AC Motorized Wheel Design Features

24,000 hr MTBO transmission


@ nominal GVW 1,100,000 lb and
10-10-20 loading practice

• larger gearing

• new material sun pinion

• larger low speed bearings

• stiffer carrier assemblies


• ground ring gear
• increased frame coupling – and
frame coupling bushing thickness

• removable inboard thrust washer retainer


• enhanced ability to drain gear case
930E-4 Product Presentation 31
November, 2006
GE AC Motorized Wheel Design Features

24,000 hr MTBO transmission


@ nominal GVW 1,100,000 lb and
10-10-20 loading practice

• larger gearing

• new material sun pinion

• larger low speed bearings

• stiffer carrier assemblies


• ground ring gear
• increased frame coupling – and
frame coupling bushing thickness

• removable inboard thrust washer retainer


• enhanced ability to drain gear case
Allows for easy, on board
930E-4 Product Presentation
replacement of thrust washer
32
November, 2006
930E-4930E – 4 Motoring
LOADED MOTORING PERFORMANCE
Performance
2,700
2,700hp /HP
32.62:1 FGR / 53/80R63
/ 32.62:1 FGR Tires / Loaded Travel
/ 53/80R62 TIRES
20%

18%

16%

14%
Total Resistance (%)

10% Grade + 2% RR = 12% Total Resistance


12%
930E – 4 Speed = 6 mph
10% No Performance Change from Dash 3 to Dash 4

8%

6%

4%

2%

0%
0 5 10 15 20 25 30 35 40 45
930E-4 Product Presentation 33
Speed (mph)
November, 2006
Dynamic Retarding Assembly

AC Dynamic Retarding Assembly

» Primary Braking System – NO Moving


Parts or Brake Wear

» Maximum 5,400 hp retarding capability

» Continuous 3,300 hp retarding capability

» 14 Element - Continuously rated blown


grids

» Two-speed over speed retarding

» Short Term Retarding

» Reverse retarding

930E-4 Product Presentation 34


November, 2006
Dynamic Retarding Performance
32.62:1 FGR / 53/80R63 Tires / Loaded Travel
930E-4 RETARDING PERFORMANCE
18%

930E-4 Continuous
16%
930E-4 Short Time

14% Cat 797


Total Resistance (%)

12% -10% Grade + 2% RR = 8% Total Resistance


930E – 4 Continuous = 15 mph
10% 930E – 4 Short Time = 23 mph
797 Continuous = 12 mph
8% No Performance Change from Dash 3 to Dash 4

6%

4%

2%

0%
0 5 10 15 20 25 30 35 40 45
930E-4 Product Presentation 35
November, 2006 Speed (mph)
Existing Frame Design

Komatsu’s Reputation for Reliability Begins With The Frame!

Casting Used In High Stress Areas


Material Tensile Strength:
Plate 482.6 mPa / 70000 psi
Fabricated Box Section Frame Casting 620.5 mPa / 90000 psi

Rails

Integral ROPS / Front Bumper

Six Point Drive Axle Mounting

Rail Width – 305mm / 12”


Continuous Horsecollar Rail Depth – 864mm / 34”
Top/Bottom Plate – 45mm / 1.77”
Side Plate – 25mm / 0.98”

930E-4 Product Presentation 36


November, 2006
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

930E-4 Product Presentation 37


November, 2006
Existing 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
 Treadle Operated, Dual Circuit Brake Valves
Allow Superior Operator Control / Feel
 Filtration – In Line Replaceable Elements

Pumps
Hoist and Brake Cooling – Tandem Gear Type, 1022 l / 246 US gal per min @ 1900 rpm
Steering and Brake – Piston Type, Pressure Compensated, 246 l / 65 US gal per min @ 1900
rpm

Relief Pressures
Hoist/Brake – 17237 kPa/2500 psi
Steering/Brake – 27549kPa/4000 psi
930E-4 Product Presentation 38
November, 2006
Existing Suspension
HYDRAIR® II (Komatsu Exclusive) Provides
Smoothest Ride and Best Protection In
Industry for Operator and Truck

Inverted Rear Suspensions


Variable Rate Hydro-Pneumatic with Integral Rebound Control

Max Stroke
Front - 328mm / 12.92”
Rear – 239 mm / 9.4”

930E-4 Product Presentation 39


November, 2006
Existing Hoist System

Dual Acting, 3 Stage Cylinders

Internal Cushion Valve

Over Centre Damping

Power Up (Loaded): 21 Sec

Power Down: 23 Sec

Float Down (Empty): 24 Sec

930E-4 Product Presentation 40


November, 2006
Existing Steering System

• Accumulator-assisted twin
cylinders provide constant
rate steering. 29.7m / 97.4’

• Emergency power steering


automatically applied by
accumulators

• 97.4 ft (29.7 m) Turning


Diameter

930E-4 Product Presentation 41


November, 2006
Existing Braking System

Service Brakes
Hydraulically Actuated
Front / Rear – Oil Cooled, Multiple Disc At Each Wheel
Total Friction Area Per Brake – 97025 cm2 / 15038 in2
Emergency Brakes
Automatically Applied Prior To Hydraulic System Dropping Below Acceptable
Level
Park Brake
Multiple Disc Dry Brakes, Spring Applied, Hydraulically Released, Located On
Inboard End Of Each Wheel Motor Rotor Shaft. Rated To Hold Max GVW 15%
Grade
Loading Brake
SAE: 101m / 331’ Komatsu 57m / 188’
Switch Activated, Locking Rear Service Brakes
58% of Required Stopping Distance!

Komatsu

SAE J1473
930E-4 Product Presentation 42
November, 2006
Operator Cab
Ergonomically Designed, Incorporating Advanced Technology, For Paramount
Operator Health and Comfort

Logically Arranged Controls Maximize Productivity and Minimize Training


Time

Simple and Effortless Monitoring of Critical Machine Functions

ROPS/FOPS Certified

Full Size Passenger Seat

A Work Environment Designed For


Productivity and Operator Satisfaction

930E-4 Product Presentation 43


November, 2006
Existing Tires & Rims

Rock Service, Tubeless Tires


Forged Flange
Lock Ring
O-Ring
53/80-R63 Sizing Bead Seat Band

Back Section Centre Band


Gutter Band
Standard 5 Piece Rim
(914 mm x 1600 mm x 127 mm / 36” x 63” x 5”)

Patented Rim Assembly with Forged Centre Bolt Flange

Rated at 758 kPi / 110 psi Cold Inflation Pressure

930E-4 Product Presentation 44


November, 2006
Dimensions

Based on Standard Configuration and Body

930E-4 Product Presentation 45


November, 2006
Dimensions

Based on Standard Configuration and Body

930E-4 Product Presentation 46


November, 2006
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

930E-4 Product Presentation 47


November, 2006
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
930E-4 Product Presentation 48
November, 2006
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 download WebCARE
Distributors
- Monitoring Support Support Database
- Abuse control Data flow
- Correct maintenance
930E-4 Product Presentation- Proactive repair 49
November, 2006 - O/H timing
ORBCOMM

After Planned
GES Installations

Direct Gateway
Near-Real-Time Service

Store and Forward


Globalgram Service

930E-4 Product Presentation 50


ORBCOMM PROPRIETARY 12
November, 2006
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

930E-4 Product Presentation 51


November, 2006
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

930E-4 Product Presentation 52


November, 2006
VHMS Example
 Overrun , over load = shorter life of engine, power line, and axle due to excessive load
 Retarder overheat = brake premature wear, seizing
 Cooling radiator clogging = shorter life of engine due to heat damage to rubber parts
Correct operation  Excessive shoe slip = premature wear on grouser of shoes on bulldozer
 Insufficient warming up = engine seizure, pump cavitation
 Excessive T/C stall = shorter life of T/C
 Sudden shift F/R = 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
930E-4 Product Presentation 53
November, 2006
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
SOFTWARE CAPABILITIES:
reduce the total cost of ownership for
Komatsu equipment. » 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
930E-4 Product Presentation 54
November, 2006
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.

930E-4 Product Presentation 55


November, 2006
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
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930E-4 Product Presentation 56


November, 2006
Payload / Overload Policy
10-10-20
Four (4) Main Criteria;
1. Payload Up To 110% Of Rated Payload Must Not Account For More Than 90% Of Total Loads

2. Payloads Between 110% and 120% Of Rated Payload May Occur No More Than 10% Of The Time

3. No Single Load Shall Exceed 120% 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


Loads Loads 0% of Total Loads

930E-4 Product Presentation 80 85 90 95 100 105 110 115 120 125 130
57
Actual Load As % of Rated Load
November, 2006
AC 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
2) Electric Drive Systems Have No Mechanical Gear Shifting
• Eliminates Shift Shock
• Improves Operator Comfort
3) Dynamic Retarding vs. Mechanical Retarding
• No Brake Wear
• In Some Downhill Applications – Brakes Represent the Largest Budget
Item for Mechanical Drive Trucks!
4) 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
930E-4 Product Presentation 58
November, 2006
ELECTRIC VS. MECHANICAL SURVEY
HAULAGE CONFERENCE RESULTS
AUDIENCE COMMENTS
» More versatility
» Fewer parts Opinion Poll - Haulage Conference
» Better component replacement
» Better acceleration
» Less capital cost 80
» Better tire life 60
» Better braking 40
» Lower life cycle costs 20
» Less fuel 0
» Faster on grade Mechanical Electric Depends
» Extended life of components
» Trolley efficiency
» Availability still high as truck ages
» More commercial competition
930E-4 Product Presentation 59
November, 2006
930E-4 Product Presentation 60
November, 2006
930E-4 Product Presentation 61
November, 2006