730E Electric Drive Truck: Safety

730E
Electric Drive Truck

Safety
Komatsu America
Corporation
Cartersville Georgia USA
Copyright © 2007 All rights reserved.
KT00105 Technical Training Slide 1

730E
Pre-operation Inspection
and
Operation
Komatsu America
Corporation

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

Safety
Electric Truck Assembly Line
● Komatsu Mining Systems, Inc.

● Peoria Operations

Safety
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

Safety
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)

Safety
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

Safety
Drive System
Superior Electric Drive Performance

Safety
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

Safety
Alternator
● G.E. GTA-22 alternator

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

Safety
AC/DC Current
● Alternator G.E. GTA-22

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

Safety
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
Safety
Wheel Motor
● G.E. 788 1800-2100 rpm at full load

● Six different gear ratios, mine specific 26.825:1

Safety
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

Safety
Wheel Motor

Safety
Electric Dynamic Retarder
Retarder braking should be used to control speed and

slow the truck during normal operating conditions
Safety
Braking System

Safety
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.

Safety
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

Safety
Safe and Reliable Service Brakes
SAE = 331 ft Actual = 217 ft
65%
Actual
SAE J1473

Safety
Service Brakes
When should they be used?

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

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

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

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

diameter disc with a single caliper per disc

Safety
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.

Safety
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.
Safety
Parking Brake
● Spring-applied and Hydraulically released

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

Safety
Steering
● Accumulator-assisted twin cylinders provide constant rate

steering. Emergency power steering automatically applied
by accumulators

Safety
Hydraulic System

Safety
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

Safety
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

Safety
WHY DO WE DO A PRE-SHIFT
INSPECTION ?

Safety
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

Safety
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
Safety
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
Safety
Inspection Front
At the start of every

shift, clean the air filter
collection cones.

Safety
Inspect Front Brakes (front / rear)
● Disc for signs of heat, bluing, checkering etc.
● Pads for excess

wear.
● Calipers.

Safety
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

Safety
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

Safety
Check Oil Level Optional Oil Burn System

Safety
Inspect Steering Linkage
● Loose nuts and bolts

● Pins
● Proper greasing
● Excess wear and play

Safety
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

Safety
Rim Nomenclature

Safety
Inspect Left side
● Steering accumulators for leaks

Safety
Inspect Hydraulic Oil Level
● Engine running
● Body down
● Fluid should be in lower glass
● Never in top glass with engine running

Safety
Inspect Mid- Machine

Safety
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

Safety
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

Safety
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

Safety
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

Safety
Inspect Right Side of Truck

Safety
● *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

Safety
● 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

Safety
Hoist Filters
Pivot Pin Rear Drive

Housing
Steering/Brake
Filters

Safety
Inspect Lube Systems
Automatic Lubrication Oil burn System

System (optional)

Safety
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

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

Safety
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.

Safety
Inspection Deck
● Open doors to Brake cabinet inspect for leaks

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

Safety
Inspection Cab
● Clean windows and mirrors
● Insure cab is clean of grease, oil, mud and trash
● Adjust seat, steering wheel and mirrors

Safety
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

Safety
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

Safety
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.

Safety
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.

Safety
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

Safety
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)

Safety
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.

Safety
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.

Safety
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.

Safety
Operation
● Inspect and wear seatbelts

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

Safety
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.

Safety
Always assess your work area and develop a plan before

starting any job!

Safety
Be Involved Mentally

Safety

Safety

Safety
Operation
● Inspect & wear seatbelts

● Adjust mirrors
● Sound horn before moving off

Safety
Operation

Safety
Cab

Safety
Warning Lights

Safety
Warning Lights

Safety
Warning Lights

Safety
Warning Lights

Safety
Warning Lights

Safety
Warning Lights

Safety
Warning Lights

Safety
Switches

Safety
Switches
F-N-R Selector
RSC off/on switch
Override Switch
Engine Shutdown
Retarder Speed control
Hoist Lever
Window Control Switches

Safety
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.

Safety
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.

Safety
Machine Operation Travel

Safety
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.

Safety
Machine Operation Loading

Safety
Payload Meter

Safety
Payload Meter

Safety
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

Safety
Payload Meter Display light
Green – 50% or greater
Amber/Green – 90% or greater
Red/Amber/Green – 105% or greater

Safety
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

Safety
Machine Operation Dump Area

Safety
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.

Safety
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

Safety
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.

Safety
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

Safety
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

Safety
Cost – What Affects It?
● Safety
● Efficiency
● Maintenance
● Availability
● Production

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

Safety
Summary
● Injuries or equipment damage

 = Increased Cost & Lost Production
● Excessive wear and abuse

● Inefficient Operation

Safety
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!!!

Safety
Truck Side View
730E and 830E

Safety
Truck Side View
730E and 830E

730E
End of Safety
Komatsu America
Corporation

730E Electric Drive Truck: Safety

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730E

Electric Drive Truck

KT00105 Technical Training Slide 1

KT00105 Technical Training Slide 2

KT00105 Technical Training Slide 3

Electric Truck Assembly Line

● Komatsu Mining Systems, Inc.

KT00105 Technical Training Slide 4

● Max. GVW 715,000 lb. / 324 318 kg

KT00105 Technical Training Slide 5

● Make and model Komatsu SSA16V159

● 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)

KT00105 Technical Training Slide 6

730E Projected MTBO

Engine 15,000 300 16

KT00105 Technical Training Slide 7

Superior Electric Drive Performance

New 730E Airless Control Cabinet

Airless Reverser G.E. Diagnostic

High Voltage Wheel Motors & Main Main Control

KT00105 Technical Training Slide 9

● G.E. GTA-22 alternator

KT00105 Technical Training Slide 10

● Alternator G.E. GTA-22

KT00105 Technical Training Slide 11

Statex III Two-Digit Display

● Tracks up to 99 display codes

EVENT 88 SEARCH RESET

Most problems can be solved using this display and

● G.E. 788 1800-2100 rpm at full load

KT00105 Technical Training Slide 13

Electric Dynamic Retarder

● Electric retarding is primary means of controlling speed and

● Caution: Grids can

KT00105 Technical Training Slide 14

KT00105 Technical Training Slide 15

Electric Dynamic Retarder

Retarder braking should be used to control speed and

KT00105 Technical Training Slide 17

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

KT00105 Technical Training Slide 18

Safe and Reliable Service Brakes

● Exceeds SAE J1473 brake performance standard

KT00105 Technical Training Slide 19

Safe and Reliable Service Brakes

SAE = 331 ft Actual = 217 ft

KT00105 Technical Training Slide 20

When should they be used?

KT00105 Technical Training Slide 21

Front Service Brakes

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

KT00105 Technical Training Slide 22

Rear Service Brakes

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

KT00105 Technical Training Slide 23

● Front, rear, and parking - apply automatically when

KT00105 Technical Training Slide 24

● Hydraulically-applied and Spring released

DO NOT use alone for parking.

● Spring-applied and Hydraulically released