hd1500-7 for barrick - direct mining services€¦ · hd1500-7 for barrick ... hd1500-7 530m cat...

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Preliminary and Confidential – 28-SEP-06

HD1500-7for

Barrick

Komatsu America Corporation (GMMD)

Date

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HD1500-7 DUMP TRUCK

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Design Goals Design Goals –– HD1500 Model HD1500 Model ChangeChange

•Reliability Enhancement

- Powertrain (Including Tier 2 development)

- VHMS / ORBCOMM

- New Electronics System

- Front Suspension Improvement

- Frame Enhancements

- Repair & Maintenance Cost Reduction

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Komatsu Truck PopulationKomatsu Truck Population530M / HD1500530M / HD1500

Canada10 Units

United States34 Units

Australia26 Units

Senegal6 Units

Indonesia61 Units

Japan4 Units

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HD 1500-7 Strengths

• Horsepower: faster cycle times• Maneuverability: able to handle variety of

applications• Retarding & Braking: for faster, safer

operations

Performance-

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• 1486 BHP for Speed and Gradeability

• Komatsu 7 Speed Electronic ControlledTransmission

• Heavy Duty FinalDrive Designed for Long Life

Performance

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Komatsu SDA12V160 Engine

• V-12, 4 cycleturbocharged &aftercooled

• 2746 in3, 45 Ldisplacement

• 1486 rated horsepower@ 2000 rpm

• Quantum electroniccontrol

• Prelube is standard

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Cummins CENSE™

• Alerts truck operatorif a potential problemis developing

• Charts trends of vitalengine parametersover time

• Measures lubrication,cooling, fuel & air,crankcase pressure,and individualcylinder performance

Engine mounted electronic module that performs Engine mounted electronic module that performs constant analysis of vital operations:constant analysis of vital operations:

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HD1500 POWERTRAIN IMPROVEMENTHD1500 POWERTRAIN IMPROVEMENT

HD1500 TRANSMISSIONHD1500 TRANSMISSION

To extend overhaul interval:

• Increase lockup clutch diameter

• Added clutch to mid-clutch pack

• Increased transmission cooling oil flow

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Komatsu7-Speed Automatic Transmission

Electronic Transmission Control

HydraulicPumpDrive

Torque Converter

OutputShaft

OilReservoir

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Electronic Transmission Control

The electronics control clutch oil pressure so that the load is shared by the splitter clutch and the main clutch during a shift.

Benefits are:Benefits are:1.1. Longer clutch lifeLonger clutch life2. Improved transmission2. Improved transmission

efficiencyefficiency

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HD1500-7 PERFORMANCE CHART1108KW/7-SPEED/19.15:1/33R51 TIRE

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

0 5 10 15 20 25 30 35 40 45 50 55 60 65

SPEED (Km/h)

RIM

PU

LL (k

gs)

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HD 1500-7 Strengths

• All-hydraulic, fewer components• Access to the engine• Remote-mounted transmission• On-board electronic diagnostics

Serviceability-

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Remote-mounted Transmission

The transmission,torque converter,and the hydraulicpumps are onemodule mountedin between engineand final drivefor excellentserviceability.

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Cast Final Drive Housing

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Heavy Duty Differential

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Planetary Gear Final Reduction

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Hydraulic System

Steering Steering Accumulator assisted twin Accumulator assisted twin cylinders provide constant rate steeringcylinders provide constant rate steering

Oil reservoir Oil reservoir 152 U.S. gal (576 L)152 U.S. gal (576 L)Filtration Filtration InIn--line replaceable elementsline replaceable elementsSuction Suction Single, full flow, 100 meshSingle, full flow, 100 meshHoist and steering Hoist and steering Dual, full flow, in line, high pressureDual, full flow, in line, high pressureTransmission Transmission Dual high pressureDual high pressureBrake component Brake component

cabinetcabinet Above deck, easy accessAbove deck, easy accessHoist Hoist Two 3Two 3--stage cylindersstage cylinders

with new concept designwith new concept designand sealing systemand sealing system

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HD1500-7 RETARDING PERFORMANCE1108KW/7-SPEED/19.15:1/33R51 TIRE

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

0 5 10 15 20 25 30 35 40 45 50 55 60

SPEED (Km/h)

4 6 0 m

C O N T IN U O U S

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Service Brakes Front/Rear

Braking SurfaceEmergency Brakes

Retarding

Parking Brakes Komatsu oil cooled, all hydraulic actuated, Komatsu oil cooled, all hydraulic actuated, disc brakes, front and rear.disc brakes, front and rear.24,668 in24,668 in22 (159 144 cm(159 144 cm22))Automatically applied prior to hydraulicAutomatically applied prior to hydraulicpressure dropping below level required topressure dropping below level required tomeet secondary stopping requirements.meet secondary stopping requirements.

Hand operated lever provides modulatedHand operated lever provides modulatedengagement of both front and rear brakes.engagement of both front and rear brakes.

Spring applied, oil released, dry caliper discSpring applied, oil released, dry caliper discmounted on input shaft to differential.mounted on input shaft to differential.

Brakes

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Brake Design

• Simplicity & lowrebuild cost

• Hydraulic apply• Oil cooling flow

back pressurereleases brake

• Retarding horsepower:Continuous = 2150 hp vs. Cat’s 1865 hpIntermittent = 5080 hp

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Electronic Control

• Service brake is activated by hydraulic valve (foot pedal)

• Retarder system is activated by electronic control (control on steer column)

• The retarder control module sends electric signal to hydraulic brake control

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ARSC (Automatic Retard Speed Control)ARSC (Automatic Retard Speed Control)ARSC- Constant downhill speed- Able to set speed from 6 through 35 mph- Precise adjustment ±1 mph - Overheat caution- All 4 wheel control

Decrease speed

Increase speed

Set speed display

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Emergency Braking System

• 3 Systems:- Front brake and accumulator- Rear brake and accumulator- Spring-applied park brake (24” disc, 3 calipers)

• Manual emergency brake switch- Will apply front & rear service brakes

and parking brake• Automatic emergency brake

- When either accumulator drops to 1750 psi,the operator is warned by warning light & buzzer

- At 1650 psi, the accumulators apply service brakes

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Steering Circuit

• Pressure compensated piston pumps charge steering accumulators

• Low pressure steering valve in cab with a flow-amplifier mounted low on the frame rail

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Emergency Steering

• Emergency steeringwarning is activatedat 1850 psi.

• Accumulators providehydraulic power to meetSAE J1511requirements.

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Emergency Steering

Bleed-down manifold has ports for towingthe truck (good truck-bad truck connection or APU).

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Hydraulic Tank

• Split tank, with commonfluid for steering, hoistand cooling.

• Divider plate with strainer(at bottom of tank) whichallows flow between the steer section and hoist/brake cooling section

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Filtration

•• 1 high pressure filter after steering pump1 high pressure filter after steering pump•• 1 low pressure filter after front brakes1 low pressure filter after front brakes•• 2 low pressure filters after rear brakes2 low pressure filters after rear brakes•• 2 low pressure filters after 2 low pressure filters after

transmission pumptransmission pump

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HoistThree Stages

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Frame

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Frame Castings

Castings are 45% of frame weightCastings are 45% of frame weightand are used in highand are used in high--stressstress--areas.areas.

• Allow use of variablethickness when needed

• Castings can use largeradii at transition points(to dissipate stresses)

• Allow weld joints to beused in low stress areas

Benefits:Benefits:

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Full welded, box-section frame with special alloy steel

•Plate material•Casting material•Rail width•Rail depth•Top and bottom plate thickness•Side plate thickness•Slope•Drive axle mountingDrive axle alignment

50,000 50,000 psipsi (344.5 (344.5 mPamPa) yield strength steel) yield strength steel50,000 50,000 psipsi (344.5 (344.5 mPamPa) yield strength steel) yield strength steel8.80” (225 mm)8.80” (225 mm)28.75” (730 mm)28.75” (730 mm)1.25” (32 mm)1.25” (32 mm)0.75” (19 mm)0.75” (19 mm)13°13°One high mounted and two low mounted driveOne high mounted and two low mounted drivelinks with sealed and lubed spherical bearing links with sealed and lubed spherical bearing jointsjointsSwinging link between frame and axle housingSwinging link between frame and axle housing

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Fabricated Frame Sections

The frame box-section (betweenhorse collar &rear castings)uses flush-buttweld of sidemember to topmember. Backerbar provides full-penetration weld.

Side Rail Side Rail 0.75 in0.75 inTop & Bottom Rail Top & Bottom Rail 1.25 in1.25 in

Continuous Backer Bar

at 4 Corners

Flus

h-B

utt J

oint

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Integral 4 Post ROPS

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Suspension

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Front Suspension

Variable rate hydroVariable rate hydro--pneumatic withpneumatic withintegral rebound control.integral rebound control.

Max front strokeMax front stroke 14.76” (375 mm)14.76” (375 mm)

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Caterpillar

Komatsu

Suspension Comparison

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Maneuverability

80’ Turning CircleSAE (24.38 m)

Cat 785 circle is 90’

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Rear Suspension

Max rear strokeMax rear stroke 5.51” (140 mm)5.51” (140 mm)Max rear oscillation Max rear oscillation +/+/--9.2°9.2°

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Loading Heightof

16’ 3” (Standard Rock Body)

16’3” (4.965 m)

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CHARACTER DISPLAYCHARACTER DISPLAY

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Tires33x51 Tire Rating

Bias Ply Tire

78,500 lb35 608 kg

90,275 lb40 949 kg

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541,650 lb245 692 kg

Single TireSingle TireRating (100%)Rating (100%)



Max. Load forMax. Load forTruck (6 Tires)Truck (6 Tires)

Radial TireRadial Tire

85,500 lb85,500 lb38 783 kg38 783 kg

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91,485 lb 91,485 lb 41 498 kg41 498 kg

548,910 lb548,910 lb248 986 kg248 986 kg

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Body

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Struck capacity 71 yd3 (54 m3)Heaped capacity 102 yd3 (78 m3)

Bottom plate

Sides and front

body plate

175,000 175,000 psipsi (1207 (1207 mPamPa) tensile strength steel,) tensile strength steel,0.75” (19 mm), two piece construction0.75” (19 mm), two piece construction

175,000 175,000 psipsi (1207 (1207 mPamPa) tensile strength steel,) tensile strength steel,0.50” (12 mm), front wall, 0.38 (9 mm) side wall.0.50” (12 mm), front wall, 0.38 (9 mm) side wall.Rugged bolster and sill construction.Rugged bolster and sill construction.Body is rubberBody is rubber--mounted on frame.mounted on frame.Exhaust heated body is standard.Exhaust heated body is standard.

All body plate is 400 All body plate is 400 BrinellBrinell (nominal) steel(nominal) steel

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HD1500-7 Specification Comparison

HD1500-7 530M Cat 785CEngine Komatsu SDA12V160 KTA50 3512B

Horsepower 1,486 1,450 1,450

Transmission 7-Spd Auto 7-Spd Auto 6-Spd Auto

EVW (lbs.) 227,347 220,440 211,000

Max GVW (lbs.) 550,000 550,000 550,000

Rated Payload (Tons) 150 150 150

Body Capacity (Heaped yds./Struck yds.) 102/71 102/71 102/74

Continuous Retarder Rating (HP) 2,150 2,150 1,865

Service:Engine Oil Change 500 Hrs. 250 Hrs. 250 Hrs.

Dimensions:Wheel Base 17’ 9” 17’ 9” 17’ 0”Overall Width 20’ 0” 20’ 0” 20’ 7”Load Height 16’ 3” 16’ 3” 16’ 4”

Tires 33R51 33R51 33R51

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HD 1500 SUCCESSHD 1500 SUCCESSTEXAS UTILITIES 5 UNITS 9000/2500 HRS.

HORIZON COAL 4 UNITS 6000 HRS.

SABINE MINING 4 UNITS 30,000 HRS.

SENEGAL 6 UNITS 8000 HRS.

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SpecificationsSpecifications

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The EndThe End

hd1500-7 for barrick - direct mining services€¦ · hd1500-7 for barrick ... hd1500-7 530m cat...

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