HD1500-7 for Barrick - Direct Mining Services€¦ · HD1500-7 for Barrick ... HD1500-7 530M Cat...
Transcript of 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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
Komatsu Truck PopulationKomatsu Truck Population530M / HD1500530M / HD1500
Canada10 Units
United States34 Units
Australia26 Units
Senegal6 Units
Indonesia61 Units
Japan4 Units
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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
• 1486 BHP for Speed and Gradeability
• Komatsu 7 Speed Electronic ControlledTransmission
• Heavy Duty FinalDrive Designed for Long Life
Performance
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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
Komatsu7-Speed Automatic Transmission
Electronic Transmission Control
HydraulicPumpDrive
Torque Converter
OutputShaft
OilReservoir
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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
HD1500-7 PERFORMANCE CHART1108KW/7-SPEED/19.15:1/33R51 TIRE
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10,000
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SPEED (Km/h)
RIM
PU
LL (k
gs)
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Preliminary and Confidential – 28-SEP-06
HD 1500-7 Strengths
• All-hydraulic, fewer components• Access to the engine• Remote-mounted transmission• On-board electronic diagnostics
Serviceability-
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Preliminary and Confidential – 28-SEP-06
Remote-mounted Transmission
The transmission,torque converter,and the hydraulicpumps are onemodule mountedin between engineand final drivefor excellentserviceability.
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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
HD1500-7 RETARDING PERFORMANCE1108KW/7-SPEED/19.15:1/33R51 TIRE
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SPEED (Km/h)
4 6 0 m
C O N T IN U O U S
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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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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Maneuverability
80’ Turning CircleSAE (24.38 m)
Cat 785 circle is 90’
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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
Loading Heightof
16’ 3” (Standard Rock Body)
16’3” (4.965 m)
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Preliminary and Confidential – 28-SEP-06
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%)
Single TireSingle TireRating (115%)Rating (115%)
Single TireSingle TireRating (107%)Rating (107%)
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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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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Preliminary and Confidential – 28-SEP-06
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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Preliminary and Confidential – 28-SEP-06
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.