01 general 59889

GENERAL.PPT/ 07.07 / 8112
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Quality you can rely onQuality you can rely on
01

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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"

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Major Businesses
Construction
Equipment
Mining
Equipment
Recycling
Equipment
Forest
Machines
Utility
Equipment
03
Others
(Tunneling machines,
Engines, Components,
Casting Products, etc.)
Manufacturing Bases of Mining Equipment
Komatsu Mining Germany GmbH

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Wheel loaderHydraulic mining shovelsBulldozer
Dump trucks Mine fleet management system
Main Products Mining Equipment
04

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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.

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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

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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
07

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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)
08
1972 Demag‘s first 100 t hydraulic
shovel – H 101

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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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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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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

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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

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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

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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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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**

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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

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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

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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

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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

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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
PC 8000
42 cu.m
3 passes 4 passes

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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
PC 8000
42 cu.m
3 passes 4 passes 5 passes

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Front Shovel Capacity 15 cu.m
Max. Digging Force 1100 kN
Backhoe Bucket Capacity 15 cu.m
Komatsu Super Shovel PC 3000
23

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24

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25

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Bucket capacity for material density of 1,7 t/cu.m
26

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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

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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

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Application of Komatsu Hydraulic
Mining Shovels > 150 t
29 / 29.10.2007

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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

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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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 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

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 Modern Welding Techniques
– Welding robots
– Non destructive testing
• Ultrasonic
• Magnaflux methods
– Certified welding procedure and personal
33

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 Automated Flexible Tool Centers and
CNC-Machine Tools
– High precision and consistency
– Automatic measurement appraisal
34

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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
35

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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
36

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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
37

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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
38

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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 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

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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

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Parts Centre Düsseldorf
41

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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

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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
43

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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

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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 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

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Komatsu Mining Germany
Service
46

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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

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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

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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

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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

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