01 general 59889

GENERAL.PPT/ 07.07 / 8112Slide

Quality you can rely onQuality you can rely on

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Basic Management Policies

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• 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"


Major Businesses

ConstructionEquipment

MiningEquipment

RecyclingEquipment

ForestMachines

UtilityEquipment

03

Others(Tunneling machines,Engines, Components,Casting Products, etc.)

Manufacturing Bases of Mining Equipment

Komatsu Mining Germany GmbH


Wheel loaderHydraulic mining shovelsBulldozer

Dump trucks Mine fleet management system

Main Products Mining Equipment

04


Branches DistributorsLiaison and Regional Offices

KomatsuChile

KomatsuAmerica Corp.

KomatsuSouthern Africa

KomatsuAustralia

Komatsu Ltd.

Komatsu Global Manufacturing Bases Mining Equipmentand Sales & Service Network

KomatsuMining Germany GmbH

05

Modular MiningSystems, Inc.


History of Komatsu Mining Germany

1907

1996

Joint VentureKomatsu

MannesmannDemag

1999

100 %Komatsu

Komatsu

Mining Germany

2004

PC 800042 cu.mbucket

2005

PC 3000-6Introduction

1921

Establishment of Komatsu Ltd.,

Tokyo

1968

Start of excavator manufacturing

1954

Manufacturing of the first fully

hydraulic excavator

Carlshütte buildsfirst electric driven

rope shovel

2006

PC 550028 cu.mbucket1925

Demag gains full control of Carlshütte

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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

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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)

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1972 Demag‘s first 100 t hydraulic shovel – H 101


Komatsu Mining Shovel Experts in the Heart of Europe

● HarboursHamburg 400 kmBremerhaven 300 kmRotterdam 200 kmAntwerp 220 kmDüsseldorf 10 km

AirportsDüsseldorf 30 kmCologne 50 kmFrankfurt 200 kmAmsterdam 240 km

Close to International Connections

Komatsu Düsseldorf PlantFactory & Worldwide Parts Centre

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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

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Factory Layout

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EntranceParkingPlaceGuests

Small Machining

ManagerMachining

Cylinder Assembly

Mill

ing

Mac

hine Large Machining

Assembly Undercarriages

and Attachments

Cylinder Assembly

Electrical Facilities

Cylinder Production

Induction Hardening

Storage Area

Small Machining

Adm

inis

trativ

eO

ffice

sE

lect

rical

Cen

tre

Parts Warehouse

Parts WarehouseParts

Welding Shop

Welding Shop

QS

PC 3000 Components

Shipping

Robot Welding

Metal Cutting and Shaping

ShotBlasting

Welding Shop Painting Shipping

Manager Welding

ManagerMach.&Ass.

Pre-Assembly

Final Assembly

Warehouse

Warehouse

Parts Office

Rec

eivi

ng

Inspection Area

Sto

rage

Are

aS

tora

ge A

rea

Testing / Research

Offi

ce

Social Building

Offi

ce

Small Machining

Office


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

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• 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


Experience

Mining Germany GmbH

Introduction / Experience Years

PC 400022 cu.m

PC 300015 cu.m

PC 800042 cu.m

PC 550028 cu.m

Mannesmann Demag Komatsu Demag

100

700

300

500

Serv

.-Wei

ght

[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 m³H 485 SP / 35 m³

H 655 S

2002

2004

PC 4000 / 21 m³

PC 5500 / 26 m³

H 255 S / 14 m³H 185 S / 14 m³

H 285 S / 19 m³

PC 8000 / 38 m³

H 455 S / 25 m³

PC 3000 / 15 m³

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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

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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**


Temple of Performance

High Performance Low Cost

Qua

lity

Trai

ning

App

licat

ion

Serv

ice

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

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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

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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


X Standard SupplyO 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


Special Buckets on request Longer Attachmentson 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 SupplyO Option Depending on Application and Material Abrasiveness


Prod

uctio

n [t

/h]

Production figures are depending on attachment combination, site conditions and dump trucks used

PC 300015 cu.m

PC 400022 cu.m

PC 550028 cu.m

PC 800042 cu.m

Digging Condition

Shovel Type

Estimated Production of Komatsu Mining Shovels(in well shot material and with skilled operator)

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Truck MatchKomatsu Mining Shovels with Komatsu Trucks

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HD 785100 sh t

HD 1500165 sh t

630E190 sh t

730E205 sh t

830E255 sh t

930E320 sh t

PC 300015 cu.m 3/4 passes 6 passes

PC 400022 cu.m 3 passes 4 passes 5 passes 5 passes


PC 800042 cu.m 3 passes 4 passes


Truck MatchKomatsu Mining Shovels with Mining Trucks

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100 - 115 sh tons

150 - 165sh tons

190 - 215sh tons

240 - 255sh tons

300 - 330 sh tons

360 - 400 sh tons

PC 300015 cu.m 3/4 passes

PC 400022 cu.m 3 passes 4 passes 5 passes


PC 800042 cu.m 3 passes 4 passes 5 passes


Front Shovel Capacity 15 cu.m

Max. Digging Force 1100 kN

Backhoe Bucket Capacity 15 cu.m


Komatsu Super Shovel PC 3000

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24







25




Backhoe Bucket Capacity 42 cu.mBucket capacity for material density of 1,7 t/cu.m



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World Population

609 Komatsu Mining Shovels > 150 t

since 1980

103

32

95

93

76

62

79

45

24

27 / 29.10.2007


References Large Hydraulic Shovels

Former H 185 S / H 255 SMODELEUROPE / CIS 53 34 21 1CANADA / USA 29 16 57 8

LATIN AMERICA 15 6 28 10AFRICA 15 16 21 2

ASIA 30 43 8 12AUSTRALIA 4 20 26 8T 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

9376

60964 62

TOTAL

119141

103

H 241 / H 285 SPC 4000PC 3000

H 455 SPC 5500

519

1614

10

H 485 S / H 655 SPC 8000

512

289

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


Application of Komatsu HydraulicMining Shovels > 150 t

29 / 29.10.2007


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


State-of-the-Art Manufacturing

Stre

ss L

evel

N/m

m²

0

Who

le L

ifeS

peci

fied

Life

Una

ccep

tabl

e

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 postmanufacturing stresses in steelstructures

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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

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Modern Welding Techniques – Welding robots

– Non destructive testing

• Ultrasonic

• Magnaflux methods

– Certified welding procedure and personal

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Automated Flexible Tool Centers and CNC-Machine Tools

– High precision and consistency

– Automatic measurement appraisal

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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

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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

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Assembly– Module assembly and testing

– Computer supported sub-assembly and hydraulic pipe bending

– Final assembly with test run and pressure setting

– Detailed parts check

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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

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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 Evacuation1 Engine Oil X X2 Engine Coolant X X3 Centinel Make up Tank X4 Open Gear Lubrication X5 Central Lubrication X6 Water for wash-hand basin X7 Hydraulic Oil X X8 Fuel X

Swing and travel is blocked when service arm is not in the locked up position

Wiggins Swing Down Service Arm

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Komatsu Mining Shovel Features

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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 DurabilityDesigned 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.

ProductivityDesigned 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 TrainPowerful 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

SafetyDesign 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


Parts Centre Düsseldorf

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Spare Parts Support

Distributor Spare Parts

KMG Spare Parts Centre

Consignment Parts

R & M contract

Consignment re-supply

Parts NewsSMAP Info

Customer

Parts from Düsseldorf works or strategic stocks

On-

line

acce

ss

E-Mail, Fax, Phone

World-wide Strategic Parts

Indonesia Parts

N America PartsSpare Parts Supply and Co-ordination

Technical SupportRecommended Parts ListTechnical Literature (hard copy/digital)(on-line 2007)

Service Exchange (Reman) ProgrammeR & M Administration

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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

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Spare Parts and Core Handling

Componentfails

Local Stock

Parts Centre Düsseldorf

Replacementunit

Order

Delivery

1

2

3

4

Corestorage Return to

Germany

OEMOverhaul

Restocking inParts Centre7

6

5

8 Core Credit

OEM = Original Equipment Manufacturer

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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 ProgramOEM = Original Equipment Manufacturer

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Type of Component Price Availability Remark

New 100 100Service Exchange Partwithout core-return(OEM remanufactured)

90 100 Same estimated lifespan as a new part

Service Exchange Partwith core-return(OEM remanufactured)

Approx. 68 100


Komatsu Mining Germany

Service

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KMG Service Technicians Worldwide

KMG own Service Techn. KMG Permanent Contr (C)Dealer Organization

RussiaKMG

KMG (C)

GermanyEurope

KMGKMG-GB

Service Org.

Great Britain

KMG

PeruMitsui KCH

KMG

ChileKCC / KCH

KMG

BrazilDealer

KMG (C)

KMG (C)

ColombiaKMG

KMG (C)

CanadaDealer

KMG (C)

USAKAC

KMG (C)

TunisiaKMG

KSA

South AfricaBotswana

KMG

AustraliaKAL

KMG (C)N. Zealand

IndonesiaDealer

KMG (C)KMG

KMG (C)Botswana

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Customer

Distributor Service

KMG Service Department

Komatsu Factory Representative

E-Mail, SMAP, Fax, Phone

Investigation & Evaluation

QualityAssurance

Meeting

Counter-measures

Service NewsField Actions

SMAP Info

Service Review Engineering Assessment Manufacturing Appraisal Quality AppraisalSupplier co-operation

Degree of Counter-measures Priority of Response Range of Response

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Field Issues Service Process


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 7109-377Fax: +49 (0)211 718816

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3 sets with machine on request

through SMAP,E-mail distribution or

as Hardcopyon request

Shop Manual

Operation- & Maintenance

Manual

Parts & Service News

Repair Manual

Service Manual

KMG Service Literature

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01 general 59889

Automotive