MECHANICAL TRUCKS

• Product and Competition

• Break
• Product Support
• Operating Costs
• Break
• Truck Production Analysis
• Test
• Summary
• Komatsu engine 330M
• Handrails
• Hi-visibility non-
Rops cab (optional
Rops canopy)
• Handrails
• Rock deflector
over cab
• air conditioner is
standard
 • 78 cy horizontal
330M bolster body
• hydraulic tank
• fenders &
mudflaps
• Komatsu 7-spd
auto transmission
• Long wheelbase
for stability and
ride
• Komatsu rear axle
330M
(built in Peoria)
• air-over-oil
suspensions
• body is wider than
tires
• lighting and horns
• rock ejectors
 • Frame with
330M castings at high
stress areas
• Fuel tank and
ladder
• Air system
• Batteries
• Exhaust heated
body
 330M
• RH visibility
• Headlights, turn
signals, front
clearance lights
• Muffler (non-heated
body) option
• Engine prelube is
standard
330M

• LH &RH ladders
• Engine air
cleaners are
center deck
• Rock deflector
over cab
 330M

• Flat floor
• 200,000 psi, 400
Bn steel
• Liners optional
• Sideboards
optional
 330M Features
• Experience
• Performance &
Handling
• 100 st capacity
• Hydraulics
• Safety
• Operating cost
 330M Experience
• Built in U.S. since ‘91
• All U.S. content, except transmission, which
comes from Komatsu Japan
• Over 50 customers in N.& S. America with
good experience
• Outstanding frame & power train life
• Same as HD-785-5 sold in remainder of the
world
• 100 short ton rating because of world- wide
experience since 1988
 Performance & Handling
• 1050 BHP, Best Weight-to-Power, Komatsu
engine--equals or out performs cat!
• 7 Spd Komatsu Electronic Control, Auto.
Transmission--smooth shift,long life!
• A-frame front suspension & multi-link final
drive suspension for manuverability and
handling--improves cycle time at shovel and
dump, plus operater likes the ride!
 330M
Komatsu SA12V140Z Engine
• Extended service intervals
• Full authority electronics
– Engine control
– Monitoring
• Capable of year 2000
emissions
• Built by Cummins-Komatsu
Eng. Co., Seymour, Indiana
• Product improvements for
increased life
Komatsu 7-spd Transmission
• Power shift
• Electronic control
removes chance for
abuse
• 12,000 hr life
• Midship mount for
serviceability
• Self-contained
hydraulic system
• Multi-link distributes load better than single point connection
• Aids ride control

• A-frame allows 45º turn angle

• Longer suspension life
MENU
Pins and Bearings Are Long Life
18,000 Plus Hours!

MENU
330M Maneuverability
Turn Diameter

330M
0’ 65’ EUC CAT
78’ 80’

MENU
 330M - 100 Ton Capacity
• GVW rating for true 100 ton capacity
(367,000 lbs.) - high productivity!
• 78 c.y. rock body for mining application
--- low load height, wide target for
shovels or loaders!
• Time & job proven frame with castings
utilized at all critical high stress areas ---
long life frame with low maintenance
costs!
 330M GVW Rating
Std. Truck EVW: 152,400 lbs
Optional ROPS: 1,800
Liners & Other Options: 12,800
Field EVW: 167,000
Payload: 200,000 lbs
Max GVW: 367,000 lbs

MENU
 330M 78 yd Body 3

• 2850 lbs/yd X 78 cu yd X .9 fill factor = 100 st

(2850 lbs/yd = 1690 kg/m)
 330M Hydraulic System
• Hoist, steering & brake cooling in one
tank for efficiency & serviceability.
• Transmission and torque convertor
utilize self-contained hydraulic system
with separate cooler.
--- hydraulic hose, piping, and
connections are fewer and simpler for
low operating cost and safety!
 330M Safety
• Best down hill loaded retard capacity - high productivity
with operator comfort (1330 HP, continuous rating)!
• Oil Cooled rear brakes & caliper disk front brakes -
excellent braking, with low operating cost!
• Separate dual caliper disk park brake - high capacity
brake mounted on the input to the final drive!
• Hydraulic pumps mounted on transmission PTO housing
for serviceability & safety --- metal fire shield between
engine exhaust and hydraulic pumps!
 330M Rops Option
Rops Option
Muffler Option
Instrument Panel
New cab seat
Recessed in floor
for proper
suspension
height
Retractable seat belt
Lets look at the outstanding
330M video! Good for
customer presentation!!

TEV 429---$10.00
PAL version---$25.00
(9 minutes)
 • Cum KTA50 engine
530M • Rock deflectors
over cab
• Dual air cleaners in
front
• Handrails
• 4-post integral
Rops cab (same as
730E, 830E, 930E)
• std air conditioning
• Powertrain
530M
Mangmt. Control
(PMC) is standard
• Deflector over cab
• mudflaps
• PLM II is standard
• Payload Meter
lights
 • Horizontal
530M Bolster body with
flat floor
• Hydraulic tank--
ALL HYDRAULIC,
NO AIR!!
• Komatsu 7-spd
auto
transmission
 • Komatsu rear
530M axle (built in
Peoria)
• air-over-oil
suspensions
• body wider than
dimension over
duals
• lighting & back-
up horn
• Frame with
45% castings 530M
(by weight)
• fuel tank
• std body
heating
• optional
muffler (non-
heated body)
• batteries on
deck
 •
530M Dual ladders
• Payload lights
• Headlights, turn
signals, front
clearance lights
• L & M radiator and
brake oil cooler (5
yr/25000hr
warranty)
 530M
• Tow- hooks
• Brake system
cabinet
• good visibility
530M • Flat floor, wide
body
• 200,000 psi, 400Bn
steel
• Liners, sideboards,
rail cap, tail
extensions are
available
 530M
• Experience
• Performance &
Handling
• All-Hydraulic
brake system
• Serviceability
• Operating cost
 530M DEVELOPMENT

• 96-HD 1200’s built (120mton truck)

• 530M Komatsu-Haulpak Engineering
joint venture--started in 1992
• Prototype built and put into
extensive test program Jan ‘96.
 530M DEVELOPMENT

• Unit #2 (Minexpo) put at Cortez

Pipeline on 1500 hr evaluation.
– 95% availability
– operators praised handling, braking,
performance , cab
 530M DEVELOPMENT

• 2 units to Japan --sold to Fujisaka

Quarry
• 4 units--sold to NA Coal-Sabine Mining,
Texas. 2000-3000 hrs, 95% avail., good
place to take customers!
• 1 unit to Japan--sold to Nippon Cement
 530M DEVELOPMENT

• 4 units sold to Golding Contractors

(coal mine), Queensland, Australia.
Doing well, 95% availability!
Performance
• 1450 BHP for Speed
and Gradeability
• Komatsu 7 Speed
Electronic Controlled
Transmission
• Heavy Duty Final
Drive Designed for
Long Life
Cummins KTA 50 Engine
• V-16, 4 cycle
turbocharged &
aftercooled
• 3067 in3, 50.3 L
displacement
• 1450 rated horsepower
@ 1900 rpm
• CENTRY electronic
control
 7-Speed Automatic Transmission
Electronic Transmission Control

Hydraulic Output
Pump Shaft
Drive

Oil
Reservoir

Torque Converter
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:
1. Longer clutch life
2. Improved transmission
efficiency
 Remote-mounted Transmission
The transmission,
torque converter,
and the hydraulic
pumps are one
module mounted
in between engine
and final drive
for excellent
serviceability.
4-Wheel oil cooled brakes

Long Downhill
Retard Capability
All-Hydraulic System

• No Air in the Truck

• Fewer Components
effected by moisture
• Faster Response with
All-Hydraulic Brakes
Suspension
Hydraulic Tank
• Split tank, with common
fluid for steering, hoist
and cooling.
• Divider plate with strainer
(at bottom of tank) which
allows flow between the
steer section and hoist
brake cooling section
Frame Castings
Castings are 45% of frame weight
and are used in high-stress-areas.

Benefits:
• Allow use of variable
thickness when needed
• Castings can use large
radii at transition points
(to dissipate stresses)
• Allow weld joints to be
used in low stress areas
330M vs 777D
 330M vs CAT 777D
Performance
330M 777D
Power to Weight: 350 lbs/hp 354 lbs/hp
Fuel (Max) 50.7 gal/hr 51.4 gal/hr
Min. Turn Diameter: 65’ 80’

The 330M will haul the same tonnage at faster

speeds using the same or less fuel!!
 Suspension Comparison
Caterpillar
Caterpillar

Komatsu 330M
Retarding Comparison (loaded,
continuous)
T.G.R. 330M 777D
-2% 42.0mph 39.0mph
-4% 31.0 “ 29.0 “
-6% 24.0 “ 16.5 “
-8% 17.5 “ 16.5 “
-10% 17.5 “ 12.0 “
-12% 13.5 “ 8.5 ”
Retard Hp-continuous 1330 1200
 330M vs CAT 777D
Simplified Hydraulic System
• 777D has the transmission mounted on the rear axle,
torque converter mounted on engine, transmission
fluid tank mounted on the outside of frame

• 330M torque converter, transmission, & reservoir are

one unit

• 330M is a lower operating cost truck because of the

simplified hydraulic system!!
Hydraulic System Comparison
330M 777D
1 tank for hydraulic 1 steer tank on deck,
system 1 hyd. system tank
(hoist, brake cool,
(transmission/t.c. and t.c.)
has self-contained hyd. 1 trans. Tank
system)

330M has a low op. cost hydraulic system!

330M vs CAT 777D
Serviceability
 330M vs CAT 777D
Serviceability
Lube interval
330M 777D
Steering & Final
Drive Linkage 250HR 50HR
Engine Oil 500HR 250HR

330M P.M. costs are lower!!

 PREV. MAINT. COSTS
330M 777d
QTY PARTS LABOR QTY PARTS LABOR

4 $ 546.00 $ 60.00 --ENG. OIL CHANGES-- 8 $ 924.00 $ 120.00

1 $ 397.60 $ 15.00 --HYD. OIL " -- 2 $ 560.00 $ 30.00
1 $ 231.00 $ 15.00 --F.D. OIL " -- 2 $ 602.00 $ 30.00
2 $ 193.90 $ 30.00 --TRANS . OIL " -- 2 $ 154.00 $ 30.00

400 $ 16.00 $ 200.00 --GREASE FITTINGS-- 632 $ 25.28 $ 316.00

50 $ 1,281.38 $ 125.00 --FILTERS-- 50 $ 840.00 $ 125.00

$ 2,665.88 $ 445.00 $ 3,105.28 $ 651.00

$ 3,110.88 --TOTAL P &L-- $ 3,756.28

$ 1.56 --HOURLY P.M. COST -- $ 1.88

330M vs Euc R90C
330M vs Terex
33100B
 Komatsu 530M vs Cat 785C

Competitive Comparison
 530M vs Cat 785C

• Performance
• Engine & Transmission
• 4-Wheel Oil Cooled Brakes
• All-Hydraulic System
• Powertrain Management Control (PMC)
• Service and Reliability
 Performance
• 1450 BHP for Speed
and Gradeability
• Komatsu 7 Speed
Electronic Controlled
Transmission
• Heavy Duty Final
Drive Designed for
Long Life
 Competition
530M Strengths vs Cat 785C
Performance
• The 530M will generally operate at faster speeds
downhill (same weight, 7 speed transmission,
higher retard capablility).
• Maneuverability and handling will be better.
530M has longer wheelbase & 45 degree steering
angle, L & R.
 Performance Comparison
Komatsu 530M vs Cat 785B

160 530M
Cat 785
140

120 The 785C is probably very comparable

Rimpull in Pounds
(Thousands)

100 to the 530M up to about 25 mph.

The 530M should still have a top
80
speed advantage.
60

40

20

0
0 5 10 15 20 25 30 35 40 45
Speed in mph
 Retarding Performance Comparison
Komatsu 530M vs Cat 785C
180
530M
160
Continuous Retarding Cat 785
140
Rimpull in Pounds

120
(Thousands)

100
80
60
40

20
0
0 5 10 15 20 25 30 35 40
45 Speed in mph
Suspension
Suspension Comparison
Caterpillar

Komatsu
Maneuverability

80’ Turning Circle

SAE (24.38 m)

Cat 785 circle is 90’

 530M Strengths vs Cat 785C
Engine & Transmission
• 530M will experience longer engine life. The KTA50
engine shares the same block and crankshaft with a
higher horsepower engine, the K2000 (2000 hp),while
the 3512 is at its max 1380 hp rating.
• Cummins Centry electronics will control fuel to
average 25 gal/hr, similar to Cat.
• Cummins Cense electronics monitor is linked to
P.M.C
 530M Strengths vs Cat 785C
Engine & Transmission (cont’d)
• L&M radiator (5yr/25,000 hr warranty) is standard, Cat
does not offer the L & M which is preferred in the
mining industry. Cat uses its own folded core
radiator, which has a poor reputation.
• 530M transmission is 7 speed vs Cat 6 speed, and
has electronic modulated control of lock-up clutch
for smoother shift. The Cat lock-up clutch is straight
on-off, no modulation.
 Remote Mounted Transmission
The transmission,
torque converter,
and the hydraulic
pumps are one
module mounted
in between engine
and final drive
for excellent
serviceability.
Cat Transmission & Final Drive
 530M Strengths vs Cat 785C
Four Wheel Oil Cooled Brakes
• Excellent downhill loaded speed capability, better
than Cat 785B.
• Simple accumulator pressure oil-apply, brake cooling
flow oil release brakes with low operating cost.
• Safely stops the truck in 150 ft on -9% grade with full
load from 30 MPH .
Brake Design
• Simplicity & low
rebuild cost
• Hydraulic apply
• Oil cooling flow
back pressure
releases brake
• Retarding horsepower:
Continuous = 2150 hp
Intermittent = 5080 hp
 530M Strengths vs Cat 785C

Four Wheel Oil Cooled Brakes (cont’d)

• 3 separate brakes (front, rear, park brake) for
emergency operation.
• Retarder is electronic control with modulation. The
Cat retarder control on the steering column is an air
control valve, which has poor modulation and is slow
to respond.
 530M Strengths vs Cat 785C

All Hydraulic System

• Total elimination of air system for lower operating
costs. Cat is still air-over-hydraulic.
• Brakes & steering are powered by accumulators for
fast response and safe emergency control
• All truck hydraulic pumps are mounted on a bank in
front of the torque converter. A complete fire shield
separates the engine and hydraulic pumps
530M Engine Fireshield
All-Hydraulic System
• No Air in the Truck
• Fewer Components
effected by moisture
• Faster Response with
All-Hydraulic Brakes
530M Strengths vs Cat 785C

P.M.C. (Powertrain Management Control)

• Standard on the 530M and comparable (and

competitive) to the Cat VIMS.
Powertrain Management Control
 530M
POWERTRAIN MANAGEMENT
CONTROLLER
(PMC)
A complete truck electronic monitor and data
management system. All critical functions (engine,
transmission, brakes, cab instrumentation, payload
meter system, and options) are electronically linked
to a central controller.
 530M Strengths vs Cat 785C

Serviceability & Reliability

• 530M engine access gives better serviceability.
• Transmission is remote mounted. Cat transmission
is mounted on final drive.
• 530M rear wheel hub bearings are “staked” to
eliminate a short spindle life problem that exists on
Cat 785.
• 530M final drive has a 6 point, 3 trailing link
suspension design vs. the single, center pivot on a
Cat truck.
Komatsu 530M vs Cat 785C

Competitive comparison
Operating Cost
Fuel
Preventative Maint.
Repair
Tires
Operator