Komatsu has released the HD1500-8 mechanical drive dump truck, a 142 metric tonne capacity hauler designed to reduce cost per tonne through such features as highest payload in its class, faster cycle times, improved fuel efficiency, longer component life and enhanced maintainability.
It replaces Komatsu’s successful
HD1500-7, introduced in 2008 and with more than 50 units operating in Australia
working in mining applications across coal, gold and nickel.
“Our new HD1500-8 truck will
further build on the success the HD1500-7 has had in Australia,” said Scott
Harrington, Komatsu Australia’s National Product Manager, Mining.
“It’s a completely new, redesigned
truck, developed using principles developed by the Earth Moving Equipment
Safety Round Table (EMESRT) to ensure high standards of safety and harm
minimisation,” he said.
“This new truck builds on the
performance and reliability characteristics of the HD1500-7, as well as
incorporating technological advances from our proven HD785-7, such as the
Komatsu Traction Control System.
“It will deliver our customers
outstanding productivity due to its high payload and high engine power,
enabling faster cycle times.
“We estimate it will provide a
further 6% cost per tonne advantage compared with the HD1500-7, through reduced
operating costs due to component life improvements, improved fuel efficiency
and better maintainability,” he said.
Power comes from a 16 cylinder Komatsu
SDA16V159-3 engine, based on the Cummins QSK50 Tier 2 diesel (also available in
fuel-optimised calibration), rated at 1175 kW gross – a 6% increase in power
over the 12-cylinder Komatsu SDA12V160 powering the HD1500-7.
“While this engine is new to the
Australian imported HD1500-8, it’s been used across other Komatsu mining
products, and is well-proven in the industry,” said Harrington.
Fuel efficiency is improved
compared with the previous model through a number of engine management and
control features, including:
- Komatsu “on demand”
energy saving technologies, such as variable displacement pumps for the
steering and hoist circuits
- Improved hydraulic
pressure management for the transmission system
- Operator feedback
systems, including ECO fuel saving guidance on the in-cab monitor to
encourage more fuel-efficient operation
- Operator selectable
operating modes, with a choice of “Power” or “Economy” mode depending on
operating conditions and haul road profiles.
A key element in the truck’s
improved fuel efficiency, higher productivity and increased safety is a
completely revamped transmission system which offers a seven speed Automatic
transmission with selectable reverse gear ratio. This is combined with
electronically controlled technologies found in the HD785-7 designed to
optimise operating efficiency.
- K-Atomics, electronic
shift control with automatic clutch modulation in all gears, optimising
clutch engagement for smoother shifting without any loss of torque
- Komatsu Traction
Control System (KTCS); this system, introduced on the HD785-7 truck,
continuously – and automatically – monitors the rear wheels’ rotating
speeds and vehicle speed to minimise wheel slip, maximising traction,
improving productivity and extending tyre life
- Komatsu Automatic
Retard Speed Control (ARSC) which allows the operator to easily set a
downhill travel speed and go down inclines at a constant speed, allowing
them to fully concentrate on steering.
“We’ve also significantly upgraded
the transmission and rear axle components to ensure improved maintainability
and durability,” said Harrington.
Reliability and durability have
been further enhanced through a redesigned high-rigidity frame, incorporating
castings in high-stress locations where loads and shocks are most concentrated.
In addition, the HD1500-8
incorporates a payload monitoring system (PLM) which assists in managing the
payload of each haul cycle, as well as analysing production volumes and working
The PLM has also allowed Komatsu
introduce a “loading policy” for the truck, providing guidelines for ensuring
correct target payloads are achieved every haul cycle – maximising
productivity, reducing operating costs, and extending the life of tyres, brakes
and other components,” said Harrington.
Improving maintainability was
another important design aim in developing the new truck. To achieve this, the
Australian-spec truck includes such features as:
- Centrally located
service centre on the bottom part of the steering/hoist tank, allowing
changing of engine oil, coolant, transmission oil, steering hoist oil, and
brake cooling oil at a common location
- Centralised filters
engine cooling fan drive belt, with tension maintained by an auto-tensioner
- Auto-greasing system which
automatically supplies grease to each point at a preset number of hours;
the reservoir’s refill port is accessible from ground level.
- Easy radiator tube
replacement with individual cooling tubes held in headers with flexible seals
for easy to removal and installation
- A battery isolation
- LED headlamps and
- Flange-type tyre rims.
Komatsu has also made use of the
latest information communications technology (ICT) developments to further
improve reliability and maintainability, increase site and operator safety, and
enhance productivity and efficiency.
- KOMVISION camera and
radar system, with six cameras and eight radar units providing full
situational awareness for the operator of nearby machines, site vehicles,
personnel and hazards
- The latest KOMTRAX
Plus machine monitoring system, to analyse the vehicle operation as well
as machine health condition
- A road condition
analysis system, using suspension cylinder pressures to map haul road
conditions, allowing the development of optimal travel speed guidelines
and schedule road maintenance – further contributing to maximising vehicle
Safety and operator comfort have
also been upgraded on the new truck, including the provision of a new ergonomically
designed automotive-style cab, an automatic climate control system, reduced
in-cab noise levels of 75 dBA, and a number of new features to reduce vibration
and movement. These include large capacity viscous cab mountings, a
hydropneumatic suspension system and independent McPherson strut type
suspension on the front wheels.
“These upgrades, combined with the
additional operator feedback, monitoring and situational awareness systems,
along with centralised maintenance locations, make this a far safer truck to
operate, maintain and work around,” said Harrington.
This, in conjunction with its
productivity, efficiency and maintainability improvements, position the
HD1500-8 as the leading truck in this class,” he said.
Brief specs of the HD1500-8 are: Payload
capacity, 142 tonnes, body capacity (SAE heaped 2:1), 78 to 94 cu m; engine,
Tier 2 or fuel-optimised Komatsu SDA16V159-3 engine rated at 1175 kW gross;
maximum travel speed, 56.5 km/h; loading height, 5070 mm for 94 cu m body or
4750 mm for 78 cu m body; hoist raise/lower times, 13.5/12.5 seconds.