831168 Truck - Komatsu HD1600M Y. Kato Product Development and Design Dept. Technical Center Kawasaki Plant Komatsu Ltd. Japan West Coast International Meeting Vancouver, British Columbia August 8-11, 1983 Downloaded from SAE International by North Carolina State Univ, Tuesday, September 18, 2018Copyright 1983 Society of Automotive Engineers, Inc. Downloaded from SAE International by North Carolina State Univ, Tuesday, September 18, 2018ABSTRACT As a direct result of the Mining Industries need to im­ prove efficiency and production in Open Pit type operations, the size of haulage units have increased dramatically. This trend has continued such, that the majority of dump trucks operating in Open Pit operations are in the 170 ton class. Continued mining in existing locations has meant that the increase in vertical lift and resultant grades, and increases in hauling distances are making electric drive systems unsuitable. This is largely due to the electric drive systems heat limitations on major propulsion components. With these mining requirements in view and the present limitations on electric drive systems in mind, Komatsu have been developing the Komatsu HD1600M. A diesel powered mechanical drive dump truck capable of operating in deep pit operations. This presentation introduces: Komatsu HD1600M Dump Truck BACKGROUND The maximum hauling capacity of Off Highway Dump Trucks used in mines today is in excess of 300 tons per unit. However, the vast majority of hauling units of the larger capacity can be divided into two categories, those of 170 ton, and those of 120 ton and below. Generally the hauling units of less than 120 ton, are of mechanical drive, those of above 120 ton being electric drive and the 120 ton unit being avail­ able with either electric or mechanical drive. The historical development of large, off highway haulage units drive systems, illustrates the reasoning behind the development of two drive systems. The mechanical drive system used on the smaller haulage units and the electric drive system used on the 120 and above classes. The development of mechanical drive haulage units was delayed, as large mechanical drive power transmissions were not available, due to limitations in gear and shaft design, clutch area limitations, and the related problems of large rotating masses that were required to power the large size hauling units. However, the obtainable conventional locomotive DC electric drive system, provided a practical solution to the problem of a power system, with an adequate capacity to drive larger hauling units. This led to the development of large electric drive hauling trucks which replaced the smaller mechanical drive trucks and tram-cars, bringing flexibility and increased efficiency into the mining operation. in the electric drive however, there are normal limitations specified for the main components such as main generators, and propulsion motors, (refer to Fig. 2). Consequently, as the vertical lift of a pit increases the travelling distance must be extended. The following five problems are encountered when the travelling distance in a pit must be extended. 1. Extension of the trip distance increases cycle time. 2. Increase in cycle time due to increase in distance and the higher speeds attained in hauling simultaneously, result in increased t.m.p.h. of tires and shorter tire service life. Downloaded from SAE International by North Carolina State Univ, Tuesday, September 18, 2018Downloaded from SAE International by North Carolina State Univ, Tuesday, September 18, 20183. The extended trip distance increases Fuel consumption, (Refer to Fig, 3) 4. Road construction costs are higher due to the longer haul roads as a result of grade limitation. 5. High speed operation in the range now allowed by tire development is unsatisfactory in terms of efficiency, particularly as tire cost, road construction cost and fuel cost amount to a lar