This document provides an overview of Komatsu Mining Germany GmbH, including:
- Their history dating back to 1907 and locations in Dusseldorf, Germany.
- Their product range including hydraulic mining shovels from 15m3 to 42m3 capacity.
- Details on their manufacturing facility, quality management, training programs, and worldwide sales and service network.
- Specifications and performance estimates for their hydraulic mining shovel models.
- Case studies on the experience and reliability of over 600 large hydraulic mining shovels produced since 1980.
DLW is an integrated plant and its manufacturing facilities are flexible in nature. These can be utilized for manufacture of different design of locomotives of various gauges suiting customer requirements and other products.
DLW is an integrated plant and its manufacturing facilities are flexible in nature. These can be utilized for manufacture of different design of locomotives of various gauges suiting customer requirements and other products.
In this pdf one can get the different types of equipment used in surface mines which is very important from the examination point of view. important regulations are also included in this .
The Northern Railways is one of the 16 zones and the northernmost zone of the Indian Railways. Its headquarter is New Delhi Railway Station.
Northern Railways is one of nine old zones of Indian Railways and also the biggest in terms of network having 6807 kilometre route.[1] It covers the states of Jammu and Kashmir, Punjab, Haryana, Himachal Pradesh, Uttarakhand and Uttar Pradesh and the Union territories of Delhi and Chandigarh.
HELLO FRINDS THIS REPORT IS OF INDUSTRIAL TRAINING ON DIESEL LOCOMOTIVE TECHNOLOGY.
IT IS VERY HELP FULL FOR YOU .
SO GO THROUGH IT .
**********************Best Of Luck ************************
INTRODUCTION OF INDIAN RAILWAY
DIESEL LOCOMOTIVE WORKSHOP .CHARBAGH
DIESEL ELECTRIC LOCOMOTIVE
WORKING MECHANISIM
IMPORTANT COMPONENTS OF LOCOMOTIVES
a) POWER PACK
b) FUEL SECTION
c) LUBE OIL CONTROL SECTION
i. FUEL INJECTION PUMP (FIP)
ii. INJECTORS
d) TURBO SUPER CHARGING (TSC)
e) BRAKES
f) COMPRESSOR / EXPRESSOR
g) GOVERNORS
h) TRACTION MOTER
i) BOGIE
j) GENERATOR
k) RADIATOR
l) ENGINE SECTION
m) CROSS HEAD
i. INLET AND EXHAUST VALVE
FAILURE ANALYSIS
a) MAGNAFLUX LAB
b) ULTRASONIC TEST
c) ZYGLO TEST
d) RDP TEST
An E.O.T. crane stands for Electric Overhead Traveling crane. this is used for handling & moving a maximum specified weight of the components called capacity of the crane within a specified area. In this slide you can learn how to use eot cranes.
Summer Training Report,DIESEL LOCOMOTIVE WORKS,VARANASI(DLW)Vivek Yadav
Summer Training Report,
Locomotive Manufacturing Workshops(EES,LTS,LFS,HMS)
DIESEL LOCOMOTIVE WORKS, VARANASI(DLW),
MECHANICAL ENGINEERING,
Diesel locomotive works (DLW) is production unit under the ministry of railways. This was set up in collaboration with American Locomotive Company (ALCO) USA in 1961 and the first locomotive was rolled out in 1964. This unit produces diesel electronic locomotives and DG sets for Indian railways and other customers in India and abroad.
In this pdf one can get the different types of equipment used in surface mines which is very important from the examination point of view. important regulations are also included in this .
The Northern Railways is one of the 16 zones and the northernmost zone of the Indian Railways. Its headquarter is New Delhi Railway Station.
Northern Railways is one of nine old zones of Indian Railways and also the biggest in terms of network having 6807 kilometre route.[1] It covers the states of Jammu and Kashmir, Punjab, Haryana, Himachal Pradesh, Uttarakhand and Uttar Pradesh and the Union territories of Delhi and Chandigarh.
HELLO FRINDS THIS REPORT IS OF INDUSTRIAL TRAINING ON DIESEL LOCOMOTIVE TECHNOLOGY.
IT IS VERY HELP FULL FOR YOU .
SO GO THROUGH IT .
**********************Best Of Luck ************************
INTRODUCTION OF INDIAN RAILWAY
DIESEL LOCOMOTIVE WORKSHOP .CHARBAGH
DIESEL ELECTRIC LOCOMOTIVE
WORKING MECHANISIM
IMPORTANT COMPONENTS OF LOCOMOTIVES
a) POWER PACK
b) FUEL SECTION
c) LUBE OIL CONTROL SECTION
i. FUEL INJECTION PUMP (FIP)
ii. INJECTORS
d) TURBO SUPER CHARGING (TSC)
e) BRAKES
f) COMPRESSOR / EXPRESSOR
g) GOVERNORS
h) TRACTION MOTER
i) BOGIE
j) GENERATOR
k) RADIATOR
l) ENGINE SECTION
m) CROSS HEAD
i. INLET AND EXHAUST VALVE
FAILURE ANALYSIS
a) MAGNAFLUX LAB
b) ULTRASONIC TEST
c) ZYGLO TEST
d) RDP TEST
An E.O.T. crane stands for Electric Overhead Traveling crane. this is used for handling & moving a maximum specified weight of the components called capacity of the crane within a specified area. In this slide you can learn how to use eot cranes.
Summer Training Report,DIESEL LOCOMOTIVE WORKS,VARANASI(DLW)Vivek Yadav
Summer Training Report,
Locomotive Manufacturing Workshops(EES,LTS,LFS,HMS)
DIESEL LOCOMOTIVE WORKS, VARANASI(DLW),
MECHANICAL ENGINEERING,
Diesel locomotive works (DLW) is production unit under the ministry of railways. This was set up in collaboration with American Locomotive Company (ALCO) USA in 1961 and the first locomotive was rolled out in 1964. This unit produces diesel electronic locomotives and DG sets for Indian railways and other customers in India and abroad.
Every Media Works [www.everymediaworks.com] is a Creative Design Agency, that Creates State of the Art Business Presentation and other Multimedia Creative Content for its Clients. Here is one of the Business Presentation that we have Created for SandFits Foundries Pvt. Ltd. Disclaimer : This is for Demonstrative Purposes and not to be used for Commercial Purposes. The Content is Copyrighted to SandFits Foundries Pvt. Ltd. and the usage of Contents can solely be done with discretion of the Content Owner and SandFits Foundries Pvt. Ltd..
VEMC is now an APOEM (Authorised Pump Original Equipment Manufacturer) of Kirloskar Brothers Ltd. In today’s time, we provide complete fluid and energy management solutions for a wide array of projects in Water Supply, Power Plants, Irrigation, Oil & Gas etc.
Every Media Works [www.everymediaworks.com] is a Creative Design Agency, that Creates State of the Art Business Presentation and other Multimedia Creative Content for its Clients. Here is one of the Business Presentation that we have Created for SandFits Foundries Pvt. Ltd. Disclaimer : This is for Demonstrative Purposes and not to be used for Commercial Purposes. The Content is Copyrighted to SandFits Foundries Pvt. Ltd. and the usage of Contents can solely be done with discretion of the Content Owner and SandFits Foundries Pvt. Ltd..
SDS Surface Drive System is made by FRANCE HELICES.This system can equip pleasure or defense boat. For more information about our products : www.surfacedrivesystem.com
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Symptoms like intermittent starting and key recognition errors signal potential problems with your Mercedes’ EIS. Use diagnostic steps like error code checks and spare key tests. Professional diagnosis and solutions like EIS replacement ensure safe driving. Consult a qualified technician for accurate diagnosis and repair.
"Trans Failsafe Prog" on your BMW X5 indicates potential transmission issues requiring immediate action. This safety feature activates in response to abnormalities like low fluid levels, leaks, faulty sensors, electrical or mechanical failures, and overheating.
What Exactly Is The Common Rail Direct Injection System & How Does It WorkMotor Cars International
Learn about Common Rail Direct Injection (CRDi) - the revolutionary technology that has made diesel engines more efficient. Explore its workings, advantages like enhanced fuel efficiency and increased power output, along with drawbacks such as complexity and higher initial cost. Compare CRDi with traditional diesel engines and discover why it's the preferred choice for modern engines.
Why Is Your BMW X3 Hood Not Responding To Release CommandsDart Auto
Experiencing difficulty opening your BMW X3's hood? This guide explores potential issues like mechanical obstruction, hood release mechanism failure, electrical problems, and emergency release malfunctions. Troubleshooting tips include basic checks, clearing obstructions, applying pressure, and using the emergency release.
What Does the PARKTRONIC Inoperative, See Owner's Manual Message Mean for You...Autohaus Service and Sales
Learn what "PARKTRONIC Inoperative, See Owner's Manual" means for your Mercedes-Benz. This message indicates a malfunction in the parking assistance system, potentially due to sensor issues or electrical faults. Prompt attention is crucial to ensure safety and functionality. Follow steps outlined for diagnosis and repair in the owner's manual.
Comprehensive program for Agricultural Finance, the Automotive Sector, and Empowerment . We will define the full scope and provide a detailed two-week plan for identifying strategic partners in each area within Limpopo, including target areas.:
1. Agricultural : Supporting Primary and Secondary Agriculture
• Scope: Provide support solutions to enhance agricultural productivity and sustainability.
• Target Areas: Polokwane, Tzaneen, Thohoyandou, Makhado, and Giyani.
2. Automotive Sector: Partnerships with Mechanics and Panel Beater Shops
• Scope: Develop collaborations with automotive service providers to improve service quality and business operations.
• Target Areas: Polokwane, Lephalale, Mokopane, Phalaborwa, and Bela-Bela.
3. Empowerment : Focusing on Women Empowerment
• Scope: Provide business support support and training to women-owned businesses, promoting economic inclusion.
• Target Areas: Polokwane, Thohoyandou, Musina, Burgersfort, and Louis Trichardt.
We will also prioritize Industrial Economic Zone areas and their priorities.
Sign up on https://profilesmes.online/welcome/
To be eligible:
1. You must have a registered business and operate in Limpopo
2. Generate revenue
3. Sectors : Agriculture ( primary and secondary) and Automative
Women and Youth are encouraged to apply even if you don't fall in those sectors.
In this presentation, we have discussed a very important feature of BMW X5 cars… the Comfort Access. Things that can significantly limit its functionality. And things that you can try to restore the functionality of such a convenient feature of your vehicle.
Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
Core technology of Hyundai Motor Group's EV platform 'E-GMP'Hyundai Motor Group
What’s the force behind Hyundai Motor Group's EV performance and quality?
Maximized driving performance and quick charging time through high-density battery pack and fast charging technology and applicable to various vehicle types!
Discover more about Hyundai Motor Group’s EV platform ‘E-GMP’!
Things to remember while upgrading the brakes of your carjennifermiller8137
Upgrading the brakes of your car? Keep these things in mind before doing so. Additionally, start using an OBD 2 GPS tracker so that you never miss a vehicle maintenance appointment. On top of this, a car GPS tracker will also let you master good driving habits that will let you increase the operational life of your car’s brakes.
Things to remember while upgrading the brakes of your car
01 general 59889
1. GENERAL.PPT/ 07.07 / 8112
Slide
Quality you can rely onQuality you can rely on
01
2. GENERAL.PPT/ 07.07 / 8112
Slide
Basic Management Policies
02
• Constantly provide environment-friendly, safe and
innovative products/services and systems from
the viewpoint of our customers.
• Constantly promote self-initiated innovations in
technology and management.
• Promote consolidated management from a global
perspective.
• Work for the community as a good corporate
citizen.
The Cornerstone of Komatsu's Management:
Commitment to "Quality and Reliability"
5. GENERAL.PPT/ 07.07 / 8112
Slide
Branches Distributors
Liaison and Regional Offices
Komatsu
Chile
Komatsu
America Corp.
Komatsu
Southern Africa
Komatsu
Australia
Komatsu Ltd.
Komatsu Global Manufacturing Bases Mining Equipment
and Sales & Service Network
Komatsu
Mining Germany GmbH
05
Modular Mining
Systems, Inc.
6. GENERAL.PPT/ 07.07 / 8112
Slide
History of Komatsu Mining Germany
1907
1996
Joint Venture
Komatsu
Mannesmann
Demag
1999
100 %
Komatsu
Komatsu
Mining Germany
2004
PC 8000
42 cu.m
bucket
2005
PC 3000-6
Introduction
1921
Establishment of
Komatsu Ltd.,
Tokyo
1968
Start of excavator
manufacturing
1954
Manufacturing of
the first fully
hydraulic excavator
Carlshütte builds
first electric driven
rope shovel
2006
PC 5500
28 cu.m
bucket
1925
Demag gains full
control of Carlshütte
06
7. GENERAL.PPT/ 07.07 / 8112
Slide
History of Komatsu Mining Germany
1907 Carlshütte builds first electric driven rope shovel
1925 Demag finally gains full control of Carlshütte
1954 First fully hydraulic excavator B 504
1978 First hydraulic mining shovel H 241
1986 Worldwide largest hydraulic mining shovel H 485
1996 Joint Venture “Demag Komatsu GmbH”
1999 100 % Komatsu Komatsu Mining Germany
07
8. GENERAL.PPT/ 07.07 / 8112
Slide
History of Komatsu Mining Germany
1907 Carlshütte builds first
electric driven rope shovel in
Duisburg and Demag finally gains
full control of Carlshütte in 1925
1954 Manufactures first
fully hydraulic excavator –
B 504
1978 Introduction of the 270 t
hydraulic mining shovel – H 241
1986 Worldwide largest hydraulic
mining shovel (500 t) – H 485
2004 PC 8000 with 42 cum
front shovel (720 t)
08
1972 Demag‘s first 100 t hydraulic
shovel – H 101
9. GENERAL.PPT/ 07.07 / 8112
Slide
Komatsu Mining Shovel Experts in the Heart of Europe
● Harbours
Hamburg 400 km
Bremerhaven 300 km
Rotterdam 200 km
Antwerp 220 km
Düsseldorf 10 km
Airports
Düsseldorf 30 km
Cologne 50 km
Frankfurt 200 km
Amsterdam 240 km
Close to International Connections
Komatsu Düsseldorf Plant
Factory & Worldwide Parts Centre
09
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Slide
Continuous improvement in design and
manufacturing tools to ensure high product
quality.
The quality management system is
certificated in confirmation with DIN EN ISO
9001 : 2000 and the environmental
management system in confirmation with
DIN EN ISO 14001 : 2005.
Ground Area 110,000 m² (27.2 acres)
Factory Area 33,000 m² ( 8.15 acres)
Hydraulic Mining Shovel Plant
10
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Slide
Factory Layout
11
Entrance
Parking
Place
Guests
Small Machining
Manager
Machining
Cylinder Assembly
Milling
Machine
Large Machining
Assembly
Undercarriages
and
Attachments
Cylinder Assembly
Electrical Facilities
Cylinder Production
Induction Hardening
Storage Area
Small Machining
Administrative
Offices
Electrical
Centre
Parts Warehouse
Parts Warehouse
Parts
Welding Shop
Welding Shop
QS
PC 3000 Components
Shipping
Robot Welding
Metal Cutting and Shaping
Shot
Blasting
Welding Shop Painting Shipping
Manager Welding
Manager
Mach.&Ass.
Pre-Assembly
Final Assembly
Warehouse
Warehouse
Parts Office
Receiving
Inspection Area
StorageAreaStorageArea
Testing / Research
Office
Social Building
Office
Small Machining
Office
12. GENERAL.PPT/ 07.07 / 8112
Slide
Intensive training is held to ensure
that customers are getting the highest
performance of their Komatsu Mining
shovel.
Training program covers
- General mining shovel technology
- Hydraulic systems
- Electric and electronic systems
- Mining shovel service
- Mining shovel maintenance
At the Düsseldorf location,
participants can make themselves at
home in the company’s own guest
house with 10 rooms in our training
center.
Training Centre, Düsseldorf-Benrath
12
13. GENERAL.PPT/ 07.07 / 8112
Slide
• Documentation
- Assembly procedure - Lubrication and maintenance manuals
- Operation manuals - Service bulletins
- Service manuals - Tools and accessories
• Customer/Dealer Training
- Basic training
- Component training
- Machine systems training
- Machine training
• Special Training (Joint training with suppliers)
- Valves Rexroth
- Pumps and Motors Hydromatic
- Diesel Komatsu/Cummins
- Electric Siemens/ABB
• Operator Training (at Job Site)
- Theoretical and practical training
Service Information / Training
13
14. GENERAL.PPT/ 07.07 / 8112
Slide
Experience
Mining Germany GmbH
Introduction / Experience Years
PC 4000
22 cu.m
PC 3000
15 cu.m
PC 8000
42 cu.m
PC 5500
28 cu.m
Mannesmann Demag Komatsu
Demag
100
700
300
500
Serv.-Weight[t]
1988
1986
1984
1990
1996
1998
2000
1992
1994
H 185 / 12 m³
H 241 / 14 m³
H 485 / 23 m³/26 m³
H 485 S / 33 m³
H 485 SP / 35 m³
H 655 S
2002
2004
PC 4000 / 21 m³
PC 5500 / 26 m³
H 255 S / 14 m³
H 185 S / 14 m³
H 285 S / 19 m³
PC 8000 / 38 m³
H 455 S / 25 m³
PC 3000 / 15 m³
14
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Slide
Backhoe AttachmentShovel Attachment
* Bucket capacity for material density of 1,8 t/cu.m
** Bucket capacity for material density of 1,7 t/cu.m
Product Range
15
Type Bucket volume *
[cu.m]
Weight
[t]
Truck Size
[short tons]
PC 3000 15,0 252 90 - 165
PC 4000 22,0 391 120 - 205
PC 5500 28,0 534 165 - 255
PC 8000 42,0 722 240 - 400
Type Bucket volume *
[cu.m]
Weight
[t]
Truck Size
[short tons]
PC 3000 15,0 256 90 - 165
PC 4000 22,0 398 120 - 205
PC 5500 28,0 540 165 - 255
PC 8000 42,0 728 240 - 400**
16. GENERAL.PPT/ 07.07 / 8112
Slide
Temple of Performance
High Performance Low Cost
Quality
Training
Application
Service
Hydr. Shovel Truck Match
Site Preparation Blasting Energy Supply
Quality
Engineering
Manufacturing
Assembling
Adjustment
Training
Service
Maintenance
Operation
Safety
Service
Spare Parts Supply
Qualified Service Personal
Required Tools
Service Organisation
Application
Machines
Set up of Operation
Truck Fleet
Material Condition
16
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Komatsu Hydraulic Mining Shovels – General Product Applications
Bench Height
Swing
Production
Efficiency
( Estimated Rates – Without Commitment )
Bench height and swing angle depending on machine size and site conditions
17
up to 16 m
60° - 90°
100%
approx. 5 m
30° - 60°
approx. 3% more
approx. 5 m
90° - 180°
approx. 17% less
approx. 16 m
30° - 180°
approx. 8% less
18. GENERAL.PPT/ 07.07 / 8112
Slide
X Standard Supply
O Option Depending on Application and Material Abrasiveness
Special Buckets on request
light density
(non/light abrasive)
standard
(medium abrasive)
heavy duty
(ores/very abrasive)
X O
O
O
O
Wear Package Suggestion Buckets Attachment Basic Machine
Combinations of Front Shovel Attachment
/ SKZALLG_47A18
O
O
19. GENERAL.PPT/ 07.07 / 8112
Slide
Special Buckets on request Longer Attachments
on request
WP-3 WP-2 WP-1
X O
O
O
O
light density
(non/light abrasive)
standard
(medium abrasive)
heavy duty
(ores/very abrasive)
/ SKZALLG_47B19
Wear Package Suggestion Buckets Attachment Basic Machine
Combinations of Backhoe Attachment
O
O
X Standard Supply
O Option Depending on Application and Material Abrasiveness
20. GENERAL.PPT/ 07.07 / 8112
Slide
Production[t/h]
Production figures are depending on attachment combination, site conditions and dump trucks used
PC 3000
15 cu.m
PC 4000
22 cu.m
PC 5500
28 cu.m
PC 8000
42 cu.m
Digging Condition
Shovel Type
Estimated Production of Komatsu Mining Shovels
(in well shot material and with skilled operator)
20
21. GENERAL.PPT/ 07.07 / 8112
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Truck Match
Komatsu Mining Shovels with Komatsu Trucks
21
HD 785
100 sh t
HD 1500
165 sh t
630E
190 sh t
730E
205 sh t
830E
255 sh t
930E
320 sh t
PC 3000
15 cu.m
3/4 passes 6 passes
PC 4000
22 cu.m
3 passes 4 passes 5 passes 5 passes
PC 5500
28 cu.m
3 passes 4 passes 5 passes 6 passes
PC 8000
42 cu.m
3 passes 4 passes
22. GENERAL.PPT/ 07.07 / 8112
Slide
Truck Match
Komatsu Mining Shovels with Mining Trucks
22
100 - 115
sh tons
150 - 165
sh tons
190 - 215
sh tons
240 - 255
sh tons
300 - 330
sh tons
360 - 400
sh tons
PC 3000
15 cu.m
3/4 passes
PC 4000
22 cu.m
3 passes 4 passes 5 passes
PC 5500
28 cu.m
3 passes 4 passes 5 passes 6 passes
PC 8000
42 cu.m
3 passes 4 passes 5 passes
23. GENERAL.PPT/ 07.07 / 8112
Slide
Front Shovel Capacity 15 cu.m
Max. Digging Force 1100 kN
Backhoe Bucket Capacity 15 cu.m
Max. Digging Force 800 kN
Komatsu Super Shovel PC 3000
23
24. GENERAL.PPT/ 07.07 / 8112
Slide
Front Shovel Capacity 22 cu.m
Max. Digging Force 1330 kN
Backhoe Bucket Capacity 22 cu.m
Max. Digging Force 1050 kN
Komatsu Super Shovel PC 4000
24
25. GENERAL.PPT/ 07.07 / 8112
Slide
Front Shovel Capacity 28 cu.m
Max. Digging Force 1870 kN
Backhoe Bucket Capacity 28 cu.m
Max. Digging Force 1270 kN
Komatsu Super Shovel PC 5500
25
26. GENERAL.PPT/ 07.07 / 8112
Slide
Front Shovel Capacity 42 cu.m
Max. Digging Force 2320 kN
Backhoe Bucket Capacity 42 cu.m
Bucket capacity for material density of 1,7 t/cu.m
Max. Digging Force 1800 kN
Komatsu Super Shovel PC 8000
26
27. GENERAL.PPT/ 07.07 / 8112
Slide
World Population
609 Komatsu Mining Shovels > 150 t
since 1980
103
32
95
93
76
62
79
45
24
27 / 29.10.2007
28. GENERAL.PPT/ 07.07 / 8112
Slide
References Large Hydraulic Shovels
Former H 185 S / H 255 S
MODEL
EUROPE / CIS 53 34 21 1
CANADA / USA 29 16 57 8
LATIN AMERICA 15 6 28 10
AFRICA 15 16 21 2
ASIA 30 43 8 12
AUSTRALIA 4 20 26 8
T O T A L 146 135 161 41
Including with Electric Motor 32 11% 27 13% 16 25% 42 68% 117 19%
Attachment
Front Shovel 138 49% 158 78% 46 72% 58 94% 400 66%
Backhoe 142 51% 48 24% 18 28% 4 6% 212 35%
77
93
76
60964 62
TOTAL
119
141
103
H 241 / H 285 S
PC 4000PC 3000
H 455 S
PC 5500
5
19
16
14
10
H 485 S / H 655 S
PC 8000
5
12
28
9
8
Repeat Customers: 49 customer 2 units 5 customer 6 units 1 customer 10 - 14 units
37 3 units 5 " 7 units 3 customer 15 - 19 units
5 " 4 units 4 " 8 units 2 customer > 20 units
8 " 5 units 1 " 9 units
28 / 29.10.2007
29. GENERAL.PPT/ 07.07 / 8112
Slide
Application of Komatsu Hydraulic
Mining Shovels > 150 t
29 / 29.10.2007
30. GENERAL.PPT/ 07.07 / 8112
Slide
Hydraulic Mining Shovel Experience
• More than 600 Mining Shovels over 150 t operating weight have accumulated
over 14 mill. operating hours since 1980
• Top Hours:
- H 185 S/H 255 S /
PC 3000 over 80,000 hours
- H 241 “ 100,000 hours
- H 285 S /
PC 4000 “ 91,000 hours
- H 455 S /
PC 5500 “ 79,500 hours
- H 485 S/H 655 S /
PC 8000 “ 76,500 hours
30 / 29.10.2007
31. GENERAL.PPT/ 07.07 / 8112
Slide
State-of-the-Art Manufacturing
StressLevelN/mm²
0
WholeLifeSpecifiedLifeUnacceptable
Innovative In-House Design
– Engineering supported by Finite Element Analysis
– Telemetry appraisal (strain gauge tests etc.)
– Comprehensive quality system conforms to
ISO 9001 Standards
– Innovative product team
– Heat treatment to balance the post
manufacturing stresses in steel
structures
31
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Slide
Innovative In-House Design
– Robust structural design developed from field experience
– Optimum use of castings at key points in primary structure
– Uncompromising welding procedures
– Creative engineering and manufacturing
management
– Effective field report system which confirms
product development
32
State-of-the-Art Manufacturing
33. GENERAL.PPT/ 07.07 / 8112
Slide
Modern Welding Techniques
– Welding robots
– Non destructive testing
• Ultrasonic
• Magnaflux methods
– Certified welding procedure and personal
33
State-of-the-Art Manufacturing
34. GENERAL.PPT/ 07.07 / 8112
Slide
Automated Flexible Tool Centers and
CNC-Machine Tools
– High precision and consistency
– Automatic measurement appraisal
34
State-of-the-Art Manufacturing
35. GENERAL.PPT/ 07.07 / 8112
Slide
Automatic Hardening Facilities
– Induction hardening for pins and track
system
– Flame hardening for bushings
– Constant high level of hardness quality
and depth up to 32 mm
35
State-of-the-Art Manufacturing
36. GENERAL.PPT/ 07.07 / 8112
Slide
Key Components Made
– In-House
• Main Steel Structures
• Cylinders
– By other experienced Companies
• Gearboxes by Lohmann & Stolterfoth
• Hydraulic Pumps, Motors and Control
Components by Rexroth-Hydromatik
• Engines and Hydraulic Pumps by
Komatsu
• Slew Rings by Rothe Erde
36
State-of-the-Art Manufacturing
37. GENERAL.PPT/ 07.07 / 8112
Slide
Assembly
– Module assembly and testing
– Computer supported sub-assembly and
hydraulic pipe bending
– Final assembly with test run and pressure
setting
– Detailed parts check
37
State-of-the-Art Manufacturing
38. GENERAL.PPT/ 07.07 / 8112
Slide
Convenient and safe place
for hydraulic adjustment
Wide walkways for easier service
access, example between motors
Electric controls in
cab base room
Convenient layout
for pilot controls
adjustments
Oil transfer pump
for filter pre-
maintenance
Quick release oil
filter clamps
Maintenance and Service
38
39. GENERAL.PPT/ 07.07 / 8112
Slide
1 2 3
4 5 7
1 2 3
8
Front Engine
Rear Engine
6
Benefits
One service point only
Comfortable refilling and evacuation
Reduced labour effort and time
Faster servicing
Reduce of leakages during service
Service arm down Service arm up
Service Refilling Evacuation
1 Engine Oil X X
2 Engine Coolant X X
3 Centinel Make up Tank X
4 Open Gear Lubrication X
5 Central Lubrication X
6 Water for wash-hand basin X
7 Hydraulic Oil X X
8 Fuel X
Swing and travel is blocked when service arm is not in the locked up position
Wiggins Swing Down Service Arm
39
40. GENERAL.PPT/ 07.07 / 8112
Slide
Komatsu Mining Shovel Features
40
Quality
• Quality management ISO 9001 certified.
• Environmental management ISO 14001 certified
• Consistent high quality through continuous investment in personnel,
design and manufacturing systems and processes.
Reliability and Durability
Designed for low operating costs
• Robust structural design developed from field experience and
finite element analysis
• Extended life undercarriage wear parts; big diameter rollers,
idlers and sprockets.
Large surface area and extensive precision hardening for all
running surfaces and track link pin bores.
Productivity
Designed for “HPLC”-operation (High Performance Low Cost)
• Powerful digging forces.
• Proven attachment design.
• All cylinders mounted in the shadow of the attachment for protection.
• Buckets and wear packages to suit all mining
conditions
Large Comfortable Cab
• Integrated FOPS structure according ISO 3449
• Komatsu low noise cab on multiple viscous mounts for reduced
noise and vibration according ISO 6396/2631-1/5349-1
• Comprehensive climate control with pressurised filtered air
ventilation and air condition
• High quality multi-adjustable air suspension seat
• Pressurised cab to keep dust out
• Large windows for good and safe all around visibility
Advanced Hydraulics
• Multi-circuit hydraulic system with electronic load governor
• Comprehensive monitored filtration
• High efficiency swing out oil coolers
Power Train
Powerful Komatsu Diesel Engine
• Electronic engine management
• Low engine emission levels meet EPA regulations
• Time saving oil management system fitted as standard; Centinel
Engine Oil Management, Reserve Engine Oil Supply and Eliminator
oil filter systems
Electric Drive, optional available
• Electric motor 6600 / 7200 V and 50 Hz or 60 Hz available
Easy Maintenance
• Generous access to all major service points
• Automatic central lubrication
• Electronic monitoring system providing information about the operating
status of the machine
• Ground-level access to hydraulically powered swing down service arm
with Wiggins connections
Safety
Design meets international ISO safety standards.
• Safe access ladder and walkways
• Controls in operator’s comfort zone
• Automatic warning and shut down where required
• Guarding on hot and rotating items according risk assessment
• Comprehensive lighting for working area
• Anti-slip surface on walkways
• Fire detection and suppression system optional available
• Fail safe braking
42. GENERAL.PPT/ 07.07 / 8112
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Spare Parts Support
Distributor Spare Parts
KMG Spare Parts Centre
Consignment
Parts
R & M contract
Consignment re-supply
Parts News
SMAP Info
Customer
Parts from Düsseldorf works
or strategic stocks
On-lineaccess
E-Mail, Fax,
Phone
World-wide
Strategic Parts
Indonesia
Parts
N America
PartsSpare Parts Supply and Co-ordination
Technical Support
Recommended Parts List
Technical Literature (hard copy/digital)
(on-line 2007)
Service Exchange (Reman) Programme
R & M Administration
42
43. GENERAL.PPT/ 07.07 / 8112
Slide
Customer Orientated Support
Worldwide parts distribution
Mine site visits to improve spare parts
supply
Parts recommendations
Maintenance program recommendations
Assistance for parts orders
Consignment stock recommendations
Remote access to KMG computer-system
Emergency call-out service
Emergency orders shipped at short
notice
Multilingual staff
(English, French, Spanish and German)
Parts availability of 95%
24 h emergency call-out service: phone +49 (0)172-680-5520
Parts Sales
43
44. GENERAL.PPT/ 07.07 / 8112
Slide
Spare Parts and Core Handling
Component
fails
Local
Stock
Parts Centre Düsseldorf
Replacement
unit
Order
Delivery
1
2
3
4
Core
storage
Return to
Germany
OEM
Overhaul
Restocking in
Parts Centre
7
6
5
8 Core Credit
OEM = Original Equipment Manufacturer
44
45. GENERAL.PPT/ 07.07 / 8112
Slide
Hydraulic cylinders, rotary joints, nitrogen accumulator
Hydraulic pumps and motors
Travel-, swing- and pump drive gear boxes
Clutches
Electronic parts
Components in REMAN Program
Comparison Table (example: hydraulic pump / motor)
REMAN = Remanufacturing Program
OEM = Original Equipment Manufacturer
45
Type of Component Price Availability Remark
New 100 100
Service Exchange Part
without core-return
(OEM remanufactured)
90 100 Same estimated lifespan
as a new part
Service Exchange Part
with core-return
(OEM remanufactured)
Approx. 68 100
47. GENERAL.PPT/ 07.07 / 8112
Slide
KMG Service Technicians Worldwide
KMG own Service Techn. KMG Permanent Contr (C)Dealer Organization
Russia
KMG
KMG (C)
Germany
Europe
KMG
KMG-GB
Service Org.
Great Britain
KMG
Peru
Mitsui KCH
KMG
Chile
KCC / KCH
KMG
Brazil
Dealer
KMG (C)
KMG (C)
Colombia
KMG
KMG (C)
Canada
Dealer
KMG (C)
USA
KAC
KMG (C)
Tunisia
KMG
KSA
South Africa
Botswana
KMG
Australia
KAL
KMG (C)
N. Zealand
Indonesia
Dealer
KMG (C)
KMG
KMG (C)
Botswana
47
48. GENERAL.PPT/ 07.07 / 8112
Slide
Customer
Distributor Service
KMG Service Department
Komatsu Factory
Representative
E-Mail, SMAP, Fax, Phone
Investigation & Evaluation
Quality
Assurance
Meeting
Counter-measures
Service News
Field Actions
SMAP Info
Service Review
Engineering Assessment
Manufacturing Appraisal
Quality Appraisal
Supplier co-operation
Degree of Counter-measures
Priority of Response
Range of Response
48
Field Issues Service Process
49. GENERAL.PPT/ 07.07 / 8112
Slide
SERVICE Around the Clock
Our service around the clock offers
you the following advantages:
● Immediate availability of parts
● Short breakdown times;
only a machine which works
makes money
If an urgent technical support
is required please call
+49 (0)172-680-8354.
Our service technician will
immediately take the
necessary measures.
SERVICE: Phone: +49 (0)211 7109-377
Fax: +49 (0)211 718816
49
50. GENERAL.PPT/ 07.07 / 8112
Slide
3 sets with machine on request
through SMAP,
E-mail distribution or
as Hardcopy
on request
Shop Manual
Operation- &
Maintenance
Manual
Parts & Service
News
Repair
Manual
Service
Manual
KMG Service Literature
50
Editor's Notes
H 285 S / 78119, Drummond / Colombia – 91.000 h (Oct ‘07)
H 455 S / 15003, Suncor / Canada – 79.500 h (Oct ‘07)
H 485 S / 12017, Jwaneng / Botswana – 76.623 h (Feb ’07)