730E

Electric Drive Truck

Safety

Komatsu America
Corporation
Cartersville Georgia USA
Copyright © 2007 All rights reserved.

KT00105 Technical Training Slide 1

 730E
Electric Drive Truck
Pre-operation Inspection
and
Operation
Komatsu America
Corporation
Cartersville Georgia USA
Copyright © 2007 All rights reserved.

KT00105 Technical Training Slide 2

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Introduction

● Specifications
● Features
● Pre-operation inspection
● Operation
● Safety Hazards & Aspects

KT00105 Technical Training Slide 3

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Electric Truck Assembly Line

● Komatsu Mining Systems, Inc.

● Peoria Operations

KT00105 Technical Training Slide 4

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Specifications

● Max. GVW 715,000 lb. / 324 318 kg

● Max. Payload 195-205 U.S. ton / 177-186 m ton
● Max. Speed 34.6 mph / 55.7 km/h

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Specifications 730E DC

● Make and model Komatsu SSA16V159

● Number of cylinders 16

● Operating cycle 4 Cycle

● Rated brake power 2000 hp (1491 kW) @ 1900 rpm

● Flywheel power 1860 hp (1388 kW) @ 1900 rpm

● Weight (wet) 11,670 lb (5294 kg)

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730E Projected MTBO

Rebuild R&R
Component MTBO Man Hours Man Hours

Engine 15,000 300 16

Wheel motor 20,000 275 28
Alternator Engine Life 48 32
or Greater
Steering accumulator 14,000 8 6
Steering cylinder 10,000 11 5
Hoist cylinder 18,000 24 10
Front suspension 16,000 25 30
Rear suspension 17,000 18 12
Front spindle assembly 16,000 20 22
Steering pump 10,000 10 10
Hydraulic pump 10,000 6 16
Front brake assembly 17,000 2 16
Front brake pads 8,500 -- 12
10,000 3 16
Rear brake assembly
5,000 -- 3
Rear brake pads

KT00105 Technical Training Slide 7

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Drive System

Superior Electric Drive Performance

KT00105 Technical Training Slide 8
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New 730E Airless Control Cabinet

Airless Reverser G.E. Diagnostic

Contactor Panel

Hinged 24V
Relays &
Control
Circuits
Panel

High Voltage Wheel Motors & Main Main Control

Airless Contactors Alt Field Control Cabinet Cards

KT00105 Technical Training Slide 9

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Alternator

● G.E. GTA-22 alternator

● Dual Impeller in line blower 9000 cfm (255 m3/min)
● Max Amp. 3000
● Max volt 2000

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AC/DC Current

● Alternator G.E. GTA-22

● Control Statex III Fuelsaver
● Motorized wheels G.E 788

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Statex III Two-Digit Display

● Tracks up to 99 display codes

● Records and stores 200 problems
● Earlier/later scrolling
● Maintenance reset
● Output connector to obtain fault details
FIRST

EVENT 88 SEARCH RESET

LAST

Most problems can be solved using this display and

the troubleshooting guide
KT00105 Technical Training Slide 12
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Wheel Motor

● G.E. 788 1800-2100 rpm at full load

● Six different gear ratios, mine specific 26.825:1

KT00105 Technical Training Slide 13

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Electric Dynamic Retarder

● Electric retarding is primary means of controlling speed and

deceleration
● Continuous rated grids
● 18-element grids
● 3700 hp (2759 kW)
maximum
● Two-speed overspeed
retarding loaded or
empty

● Caution: Grids can

develop heat up to
600 Degrees

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Wheel Motor

KT00105 Technical Training Slide 15

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Electric Dynamic Retarder

Retarder braking should be used to control speed and

slow the truck during normal operating conditions
KT00105 Technical Training Slide 16
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Braking System

KT00105 Technical Training Slide 17

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Braking System

● All-hydraulic, dry-disc mechanical service brakes are

designed to stop the truck anywhere within its performance
envelope.
● Service brakes primary means of stopping truck.
● Service brakes should be used for stopping during direction
changes from
forward and reverse,
loading, dumping
areas and for
emergency situations.

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Safe and Reliable Service Brakes

● Exceeds SAE J1473 brake performance standard

● SAE J1473 test summary:
 Truck tested at max. GVW
 Tested on 8-10% grade
 5 consecutive stops from 30 mph (48 km/h)
 Maximum 20 minutes between stops

KT00105 Technical Training Slide 19

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Safe and Reliable Service Brakes

SAE = 331 ft Actual = 217 ft

65%
Actual

SAE J1473

KT00105 Technical Training Slide 20

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Service Brakes

When should they be used?

● Emergency situations
● Speeds below 8 Mph
● Direction changes
● Loading & dumping locations
● Parking

KT00105 Technical Training Slide 21

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Front Service Brakes

● Front inboard-mounted 46.0” (1168 mm) diameter wheel

speed disc brakes with a 3-caliper design on each brake

KT00105 Technical Training Slide 22

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Rear Service Brakes

● Rear armature speed brakes feature dual 25” (635 mm)

diameter disc with a single caliper per disc

KT00105 Technical Training Slide 23

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Emergency Brakes

● Front, rear, and parking - apply automatically when

hydraulic system pressure drops below the level necessary
to meet secondary stopping requirements.
● Brake accumulators
will store enough
pressure for 26
applications of the
service brakes, for
an emergency.

KT00105 Technical Training Slide 24

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Brake Lock

● Hydraulically-applied and Spring released

● Use at shovel and dump.
● Use when exiting the cab,
in conjunction with the
parking brake, for added
safety

DO NOT use alone for parking.

System will bleed down and
release brakes.
KT00105 Technical Training Slide 25
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Parking Brake

● Spring-applied and Hydraulically released

● Will release if movement is sensed
● Will not apply if travel speed is .3 mph or more

KT00105 Technical Training Slide 26

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Steering

● Accumulator-assisted twin cylinders provide constant rate

steering. Emergency power steering automatically applied
by accumulators

KT00105 Technical Training Slide 27

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Hydraulic System

KT00105 Technical Training Slide 28

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Hydraulic System Features

● Common tank for steering, hoist and brake systems

● Common fluid for all systems
● Fewer components, less hydraulic hose and tubing
● Reduced maintenance, simple servicing
● Externally mounted filter keeps system clean, easy to
service
● Brake control valves limit oil flow, save horsepower and fuel
(when brakes are not in use)
● Vane-type pump for steering and braking - saves fuel,
increases component life
● Gear-type pump for hoist

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Service Capabilities

● Cooling system 108 U.S. gal (409 L)

● Crankcase * 59 U.S. gal (233 L)
● Hydraulic system 193 U.S. gal (731 L)
● Motor gear box, (each) 10.5 U.S. gal (40 L)
● Fuel 850 U.S. gal (3217 L)
● * Includes lube oil, filters

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WHY DO WE DO A PRE-SHIFT
INSPECTION ?

KT00105 Technical Training Slide 31

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730E Electric Truck Pre-Operation Inspection

● Protects you as well as your peers

● Required by law
● Do a complete inspection
● Be aware of your surroundings
● Report safety items

KT00105 Technical Training Slide 32

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Inspection Front

● Look to see if anybody is in cab, insure that chock blocks

have been placed.
● Shut off engine by the emergency kill switch on the bumper
before looking at the engine compartment.
● Look for any damage to the front of machine ladders
handholds etc.

Inspection Front
KT00105 Technical Training Slide 33
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Inspection Front

● Look at radiator make sure there is no leaks or debris.

● Check all of your lights.
● Check fire extinguisher and fire suppression plunger if
equipped.
● Look under the machine for any major leaks.

Inspection Front
KT00105 Technical Training Slide 34
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Inspection Front

At the start of every

shift, clean the air filter
collection cones.

KT00105 Technical Training Slide 35

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Inspect Front Brakes (front / rear)

● Disc for signs of heat, bluing, checkering etc.

● Pads for excess

wear.

● Calipers.

KT00105 Technical Training Slide 36

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Inspect Front Suspension

● Look for loose bolts.

● Look for proper strut adjustments.

● Look at the inside side-wall of tires, for cuts and oil.

Front and Rear

KT00105 Technical Training Slide 37
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Inspect Engine Compartment

● Access ladder and hand holds

● Engine oil level
● Guards and belts
● Engine air intake
tube condition and
dirt build up
● Radiator/engine
compartment for
leaks, trash and
dirt

KT00105 Technical Training Slide 38

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Check Oil Level Optional Oil Burn System

KT00105 Technical Training Slide 39

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Inspect Steering Linkage

● Loose nuts and bolts

● Pins
● Proper greasing
● Excess wear and play

KT00105 Technical Training Slide 40

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Inspect Front Wheel and Tire (front / rear)

● Oil leaks
● Lug nuts none missing all tight
● Rim hardware
● Tires for bubbles and cuts
● Hub oil level full rotated to
bottom
● Hub oil vent plug clean

KT00105 Technical Training Slide 41

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Rim Nomenclature

KT00105 Technical Training Slide 42

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Inspect Left side

● Steering accumulators for leaks

KT00105 Technical Training Slide 43

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Inspect Hydraulic Oil Level

● Engine running
● Body down
● Fluid should be in lower glass
● Never in top glass with engine running

KT00105 Technical Training Slide 44

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Inspect Mid- Machine

KT00105 Technical Training Slide 45

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Inspect Mid-Machine

● Bed hoist cylinders for leaks and grease

● Underneath Leaks
● Pumps and drive shafts
● Underneath flexible ducting from main blower to final drive
housing, is in good condition

KT00105 Technical Training Slide 46

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Inspect Rear Tires And Wheels

● Wheel motor covers and latches (report damaged or

missing covers immediately)
● Lugs loose or missing
● Leakage
● Tires cuts or bubbles
● Rock ejector

KT00105 Technical Training Slide 47

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Inspect Rear of Machine

● Rock ejectors
● Suspension height and leakage
● Drag link
● Pins for grease
● Lights
● Dump body hinge pins
getting grease
● Hoist limit switch for
damage

KT00105 Technical Training Slide 48

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Inspection Rear hatch

Open rear hatch

● Turn on work light
● Leaks wheel motor mounting
● Brake hoses
● Covers on wheel motor sumps in place
● No rags or tools left behind
● Condition of hatch gasket and report if needed

KT00105 Technical Training Slide 49

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Inspect Right Side of Truck

KT00105 Technical Training Slide 50

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Inspect Right Side of Truck

● *Rear duals - wheels, covers, lugs, tires,

● *Hoist - cylinders, pins, leaks & grease
● Fuel tank and mounts
● Fuel gauge agrees with the one in cab
● *Right front wheel – leaks, steering, brakes, suspension
grease and excessive wear

*Items the same as the left side

KT00105 Technical Training Slide 51

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Inspect Right Side of Truck

● Insure no damage or debris build up to retarder grids

(Deck Level)
● Hoist and steering filters – behind fuel tank
● Engine compartment and radiator for leaks or debris build
up

KT00105 Technical Training Slide 52

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Inspect Right Side of Truck

Hoist Filters

Pivot Pin Rear Drive

Housing
Steering/Brake
Filters

KT00105 Technical Training Slide 53

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Inspect Lube Systems

Automatic Lubrication Oil burn System

System (optional)

KT00105 Technical Training Slide 54

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Before Mounting

● Insure shutdown switch is on

● Insure ladders and hand rails are in good shape and clean
of any foreign materials, such as ice, snow, oil or mud

KT00105 Technical Training Slide 55

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Inspection Deck

● Coolant level.
● Fire Suppression.
● Hand rails.
● Mirrors clean.
● Retarder grid covers and air inlet is free of debris.
● All cabinets, good condition.

KT00105 Technical Training Slide 56

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Inspection Deck

● Do not open electrical cabinet doors, or grid covers when

the engine is running! Do not climb on or use power cables
as hand holds.
● The engine must be shut down and the system verified at
rest.

KT00105 Technical Training Slide 57

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Inspection Deck

● Open doors to Brake cabinet inspect for leaks

● Inspect fire extinguisher and (fire suppression) system if
equipped

KT00105 Technical Training Slide 58

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Inspection Cab

● Clean windows and mirrors

● Insure cab is clean of grease, oil, mud and trash

● Adjust seat, steering wheel and mirrors

KT00105 Technical Training Slide 59

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Inspection Cab

● Insure all personnel are clear

● Park brake engaged
● Transmission in neutral
● Sound horn to alert area of your intentions
● Key switch on, allow the central warning system to do a
self test all warning lights, gauges and alarm should sound
for approximately. 3 seconds.
● Do Not Start if there is a “Do Not Operate Tag” attached

KT00105 Technical Training Slide 60

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Start-Up Safety

● Use horn signals

● Always wear your seatbelt
● Properly adjust seat, joystick console or steering wheel
● Check equipment warning systems for proper operation
● Check back-up alarm
● Ensure that all controls are functioning properly
● Check brakes
● Do Not Start if there is a “Do Not Operate Tag” attached
● Always set the park brake and dump brake before exiting
the cab

KT00105 Technical Training Slide 61

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Equipment Safety checks

● Check all gauges and warning lights to insure all systems

operation properly. Pay special attention to steering and
brake circuits. Do Not operate if a brake or steering light is
on.

● All Safety checks on equipment should appear normal.

● Do Not operate truck if a safety item has been found

defective, until it has been repaired.

KT00105 Technical Training Slide 62

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Start-Up

● Sound horn to alert area of your intentions.

● Park brake engaged.
● Propel in neutral.
● Turn the key switch to the start position hold until the
engine starts.
● Do not crank engine for more than 30 seconds, allow
starter to cool for two minutes.
● Allow engine and hydraulics to warm before operating.

KT00105 Technical Training Slide 63

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Emergency Steering Test

The engine must be shut down with the emergency

kill switch in the cab.

NOTE: If engine dies during operation Do not turn key switch

off and try to re-start ! Steering accumulators will bleed down
and system will fail

KT00105 Technical Training Slide 64

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Emergency Steering Test

You should be able to turn the steering wheel to the

right then to the left.
(The standard is 2.5 turns stop to stop while rolling)

KT00105 Technical Training Slide 65

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Brake Checks Service Brake

Perform this test with truck parked, on dry level ground.

Always sound horn to alert area of your intentions.

● Sound horn select forward propulsion apply service brake

and release park brake.
● Increase engine rpm to approximately 1200 (particular
models may need to use the over-ride button).
● You will feel wheel motors engage and the truck will try to
move. This test should be done briefly.

KT00105 Technical Training Slide 66

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Brake Checks Retarder

● Perform on dry level ground. Sound horn before moving.

● Drive truck forward approximately 10 mph use the dynamic

brake.

● The engine will rev and truck will slow down.

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Brake Checks - Brake Lock and Park Brake

● Travel to steepest area to be used.

● Stop completely using retard and service brake.
● Set the park brake, truck should not move.
● Repeat this procedure using the brake lock switch instead
of the park brake.

KT00105 Technical Training Slide 68

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Operation

● Inspect and wear seatbelts

● Insure area is clear before moving
● Adjust mirrors
● Sound horn before moving off

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Operation Safety

● Never operate if a safety item has been found defective,

until it has been repaired.
● MSHA states all operators must be task trained on new or
modified equipment.
● Must be trained before performing a task that they have
never done before.
● Riders must be in the cab and use seatbelt provided.
● Operators need to select the proper speed and maintain
control of their machine at all times.

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Always assess your work area and develop a plan before

starting any job!

KT00105 Technical Training Slide 71

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Be Involved Mentally

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Be Involved Mentally

KT00105 Technical Training Slide 73

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Be Involved Mentally

KT00105 Technical Training Slide 74

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Operation

● Inspect & wear seatbelts

● Adjust mirrors
● Sound horn before moving off

KT00105 Technical Training Slide 75

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Operation

KT00105 Technical Training Slide 76

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Cab

KT00105 Technical Training Slide 77

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Warning Lights

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Warning Lights

KT00105 Technical Training Slide 79

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Warning Lights

KT00105 Technical Training Slide 80

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Warning Lights

KT00105 Technical Training Slide 81

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Warning Lights

KT00105 Technical Training Slide 82

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Warning Lights

KT00105 Technical Training Slide 83

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Warning Lights

KT00105 Technical Training Slide 84

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Switches

KT00105 Technical Training Slide 85

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Switches

F-N-R Selector

RSC off/on switch

Override Switch

Engine Shutdown

Retarder Speed control

Hoist Lever

Window Control Switches

KT00105 Technical Training Slide 86

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Operation

● Start on level ground whenever possible

● When starting on a hill
Fully depress service brake pedal and release park brake.
Switch to propel position and increase engine RPM. (particular models
may need to use the over-ride button.)
Once propulsion is sensed completely release brake.

KT00105 Technical Training Slide 87

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Operation Dynamic Retarder

● Forward and reverse.

● May not be effective under 3 mph.
● Will not hold truck stationary.
● Will be applied automatically if truck reaches max. speed.
(Speed should be maintained using the retarder controls
listed on the grade/speed chart to determine maximum
safe speed and to avoid an over speed condition).
● Individual Retard pedal (middle) and service brake pedal
(left)
● (Single) Retarder/Service brake pedal upper portion of
travel is retarder and lower modulates the service brakes.
● The Dynamic Retarder should be used to slow the truck as
needed.

KT00105 Technical Training Slide 88

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Machine Operation Travel

KT00105 Technical Training Slide 89

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Machine Operation Travel

● Be alert and you won’t get hurt.

● Follow traffic patterns.
● Watch for other vehicles.
● General right-of-way is to yield to the left.
● Keep safe speeds for road conditions slick roads, pot holes
or other obstructions can be hazardous.
● Use retarder properly on grades.
● Call for clean-up of spill rock.

KT00105 Technical Training Slide 90

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Machine Operation Loading

KT00105 Technical Training Slide 91

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Payload Meter

KT00105 Technical Training Slide 92

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Payload Meter

KT00105 Technical Training Slide 93

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Payload Meter Operation Tips

● Use brake lock switch while loading

● Do not release brake lock while loading
● Do not activate lamp test switch while loading
● Keep loading area as level as possible
● Uneven ground, ruts, berms or carry back can affect
payload accuracy

KT00105 Technical Training Slide 94

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Payload Meter Display light

Green – 50% or greater

Amber/Green – 90% or greater

Red/Amber/Green – 105% or greater

KT00105 Technical Training Slide 95

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Machine Operation - Loading

● ALWAYS USE BRAKE LOCK, NEVER USE THE PARK

BRAKE. A SUDDEN JOLT MAY CAUSE IT TO RELEASE.
● Be aware of high bank hazards.
● Avoid bunching up.
● Stay in your truck.
● Avoid running over rock debris, wet rocks cut tires 15 to
20% quicker than dry material.
● Avoid blind turns to the right.
● Keep the action in front of you.
● Spot using short moves

KT00105 Technical Training Slide 96

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Machine Operation Dump Area

KT00105 Technical Training Slide 97

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Machine Operation Dump area

● ALWAYS USE BRAKE LOCK, NEVER USE THE PARK

BRAKE. A SUDDEN JOLT MAY CAUSE IT TO RELEASE.
● Only dump in designated areas.
● Never go behind a dozer without positive confirmation.
● Be aware of edge of berm, sloughs and cracks.
● Do not drag out berm.
● Dump, move forward to clear material, stop and lower bed
before moving off.
● Be aware of overhead hazards when ever bed is raised.
● Axle height berms to be used as guides.

KT00105 Technical Training Slide 98

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Shutdown Procedures

● Park on level surface

● Select neutral
● Set park brake and brake lock.
● Run engine for five-minute cool down.
● Check out machine for wear or leaks
● When dismounting use three, (3), points of contact
● Use wheel chocks if not in a parking ditch

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Do’s and Don’ts

DO
● Be aware of surroundings.
● Pre-op inspections.
● Observe safety rules.
● Use proper retarding techniques.
● Always lower bed before leaving dump area.
● Report damage or incidents.
● Smooth steady operation at all times.
● Wear your seat belt.

KT00105 Technical Training Slide 100

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Do’s and Don’ts

Do Not!!!
● Run over rocks or debris.
● Try to do all retarding at the bottom of the grade.
● Use the service brakes to maintain speed going down
ramps.
● Bang the berms at the dump area.
● Bounce loads off.
● Travel at excessive speeds.
● Abuse machine

KT00105 Technical Training Slide 101

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Procedures for a fire

● Do not panic
● Stop Machine Safely
● Set all brakes
● Turn off key switch
● Activate fire suppression
system
● Evacuate machine and
get a safe distance away.
● Evaluate the situation
before attempting to fight a fire with a handheld extinguisher

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Cost – What Affects It?

● Safety
● Efficiency
● Maintenance
● Availability
● Production

KT00105 Technical Training Slide 103

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Controllable Costs

● Incidents
 - Injury
 - Equipment damage
● Truck tires
 - Rock cut
● Short moves
 - Loading
 - Dumping
● Abuse of equipment

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Summary

● Injuries or equipment damage

 = Increased Cost & Lost Production

● Excessive wear and abuse

 = Increased Cost & Lost Production

● Inefficient Operation
 = Increased Cost & Lost Production

KT00105 Technical Training Slide 105

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Summary

This training summary is brief, operators need to

read and understand the operators manual.

Remember the operator is responsible for the

equipment they are operating!!!

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Truck Side View

730E and 830E

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Truck Side View

730E and 830E

KT00105 Technical Training Slide 108
 730E
Electric Drive Truck
End of Safety

Komatsu America
Corporation
Cartersville Georgia USA
Copyright © 2007 All rights reserved.

KT00105 Technical Training Slide 109