TURNING THE SPOTLIGHT ON KOMATSU GERMANY MINING

With a tradition that goes back more than 100 years in producing groundbreaking innovative machines, Komatsu Germany Mining headquartered in Düsseldorf, today is still leading from the front in the field of technology, as Awesome Earthmovers discovered on a recent visit to the factory.

Komatsu Germany Mining (KGM) has machines working all over the world, operating day and night under the toughest of conditions. The company’s manufacturing record to date is impressive to say the least. Since 1980, it has produced over 1200 excavators, of which around two-thirds are still in operation.

Nearly 90% of the units sold in the last 35 years have been delivered to customers. The current unit with the most working hours is a PC4000 which has worked almost 170,000 hours – that’s the equivalent of almost 20 years continuous service!

“ASSEMBLING AN EXCAVATOR REQUIRES A HIGH LEVEL OF ATTENTION AND CARE IN EVERY STEP OF THE PROCESS…”

The Komatsu brand is a worldwide synonym for top quality, achieved through continuous product development and innovation combined with reliability. KGM, a full subsidiary of Komatsu, built its first fully hydraulic excavator in 1954 and today it manufactures five types of hydraulic excavators between 250 tonnes (PC3000) and 773 tonnes (PC8000), with bucket volumes from 16m³ up to 42m³.

Customers can choose between a diesel driven engine (T2 or T4) or an electric driven version with a power up to 4020HP. Both drive types have the same performance and productivity characteristics. KGM also offers customers a variety of tailor-made solutions.

As we found out during our visit to the Düsseldorf factory, assembling an excavator requires a high level of attention and care in every step of the process. One focus is on the assembly of all hydraulic components and their sealings. Special markings on the components done by the mechanics indicate that all components are complete and have been installed correctly.

Another focus is on the connection of the engine, coupling, gearbox and pumps; all components have to be aligned to each other to ensure an error-free and flawless operation of the entire drivetrain. Careful attention is also paid to the electrical harnesses and the connections to each unit.

Ultra large hydraulic excavators consist of thousands of individual parts, from a small screw up to big bucket. It all starts with the welding process of the main components, for example, superstructure, boom or bucket, all followed by a high level quality inspection. After this pre assembly departments work parallel on several assembly groups like oil cooler, engine compartment or hydraulic oil tank, followed with the assembly of all the main components.

Hydraulic hoses and pipes are installed, the cab is set up on its base and also the counterweight is positioned and screwed on the superstructure. Bolts with a size up to M48 are used to fix all components. Parallel to the mechanical assembly the electrical harness is done over the whole excavator.

After finishing the assembly the excavator is tested -adjusting all valves, checking the electrics and checking all safety precautions. The excavator is then disassembled and painted according to customers’ requirements. The whole process can take up to three weeks.

Safety Top Priority

Safety, of course, is a top priority at Komatsu – both in the manufacturing process and during operation. In the production, there is a so-called safety dojo where employees are made aware of potential safety risks in the production, while tools such as the K-VAD valve adjustment device eliminate live work and increase workplace safety in the field. The device allows for remote operation from the excavator cab, eliminating the need for service engineers to work next to high-pressure areas.

Komatsu also trains its employees on a daily basis, for example in handling chemicals such as grease, nitrogen or cleaning agents – and there are ergonomic workstations with adequate lightning, equipped with all necessary tools and documentations on how to handle correctly large and heavy components.

PC4000-11 Hydraulic Mining Excavator

During our tour of the Düsseldorf factory, we were able to see one of the latest 400 tonne PC4000-11 excavators being assembled. More than 300 PC4000 machines have been delivered to mine sites worldwide.

It is powered by a Tier 4 Final, 1875 hp, 16 cylinder, SDA16V160E-3Komatsu engine with selective catalytic reduction (SCR) and a time-saving engine oil management system.

The PC4000-11 model comes with KomtraxPlus, Komatsu’s remote condition and health monitoring system. Data is directly transferred via the ORBCOM system, which allows for a better schedule of maintenance and operation.

In addition, the remote diagnostic functionality is easily integrated into additional tools such as Modular Mining’s MineCare system, for long-term analysis.

It also features Komatsu’s KomVision, which offers a 360° bird’s eye view for operator guidance. A monitor in the operator’s cabin shows the full view of the machine and its surroundings. The operator is additionally able to select one of the cameras for a detailed view of a required area by way of a 10-inch touch panel.

The machine’s large and comfortable cab is mounted on 18 viscous damping pads and sound insulated. The cab has automatic climate control and is pressurised. The operator’s seat is air suspended, electrically heated and has a lap seat belt and offers multiple adjustments, while low-effort joystick controls are electro-hydraulic with foot controls for front shovel clam, crawler and swing brake.

Other features include an AM/FM radio with MP3 ready CD player, a windshield two speed and intermittent wash wiper, a refrigerator, storage cabinets and heated electric mirrors which can be adjusted from inside the cab. External metal sun blinds on the cab side window and internal roller blinds on all windows are standard. The left hand window is an emergency exit.

All windows are tinted parsol green. The front window is a 19 mm thick impact resistant window. Access and maintenance are improved by the new 45° access systems. This gives operation and maintenance personnel easier and safer access to the machine. The stairways to the machinery house level, as well as the stairway from machinery house level to the cab are now simpler.

Electric Driven Machines

With over 40 years of electric-driven innovation, Komatsu Germany Mining continues to lead the way in sustainable mining solutions, delivering more than 260 machines, beyond 200 tons operating weight. These machines collectively achieved over 13.1 million operating hours, showcasing Komatsu’s leadership in advancing electric drive technology for sustainable and efficient mining solutions.

At Bauma 2025, it will present its PC7000-11E electric backhoe. Built for exceptional durability, reliability and high performance, this electrically powered hydraulic mining excavator is equipped with a class-leading 44m³ backhoe bucket for increased productivity.

Komatsu’s electric drive is designed to reduce carbon footprint by up to 95% in scope 1 emissions compared to a diesel drive. Combined with power-agnostic technology, it enables a more sustainable mining operation. Customers can save up to 50% in total ownership costs through reduced maintenance, parts, and lubrication expenses.

“WITH OVER 40 YEARS OF PIONEERING INNOVATION IN ELECTRIC-DRIVEN HYDRAULIC MINING EXCAVATORS, KOMATSU HAS SET INDUSTRY BENCHMARKS...”