Technical and field services

Training descriptions of our operator, electrical, and mechanical training are available.

Blasthole drill training descriptions

• Blasthole drill technical training catalog
• Catálogo de formación técnica de perforadoras de barrenos

Continuous miner training descriptions

• Continuous Miner Electrical Hydraulic and Mechanical Systems Training
• Continuous Miner Electrical Systems Troubleshooting Training

Electric drive wheel loader training descriptions

• Electric drive wheel loader training descriptions

Electrical rope shovel training descriptions

• Electric rope shovel technical training catalog
• Catálogo de formación técnica de pala eléctrica

Feeder breaker training descriptions

• Feeder Breaker Electrical Hydraulic and Mechanical Systems Training
• Feeder Breaker Electrical Systems Troubleshooting Training

Shearer training descriptions

• Shearer Electrical Hydraulic and Mechanical Systems Training
• Shearer Electrical Systems Troubleshooting Training

Underground training descriptions

• Underground machine online training

eLearning catalogs

• Basic Technical Training eLearning catalog
• Wheel loader maintenance eLearning catalog
• TowHaul operator eLearning catalog
• Continuous miner eLearning catalog
• Longwall eLearning catalog
• Shuttle car eLearning catalog

For more information, contact your local Komatsu Mining representative.

Employee training isn’t one-size-fits-all. When developing your employee training program, rely on flexible delivery methods that can meet your specific training needs. With e-learning and instructor-led training options available, we provide competency-based learning designed to provide your staff with the knowledge, skills and understanding required for demonstrating competence against industry standards.

Fundamental training

Fundamentals include the essential knowledge and skills required to perform one’s job description. Examples of fundamental training topics are:

• Basic electronic/electrical theory
• Basic hydraulic/pneumatic theory
• Basic mechanical systems theory

We provide a variety of basic training online. Refer to our training descriptions for more on the basic lessons offered.

Note that we highly recommend individuals have a strong fundamental knowledge prior to participating in any of our product-specific training initiatives.

E-learning

E-learning is ideal for your helping your employees master product-specific knowledge-based training. This approach allows them to review content as often as necessary to truly understand the material. Content includes engaging 2D/3D artwork, photos and animations to enhance the learning experience.

Examples of our product-specific knowledge-based training include:

• System descriptions
• Theory of operations
• System diagnostics
• System inspection/maintenance practices

You and your employees can access our training online in multiple languages at any time, from anywhere. With virtual learning, your training costs are reduced, while your staff benefits from the ability to learn at their own pace and in their own environment. In addition, this format allows you to offer consistent training to all your staff around the world.

Instructor-led training

Instructor-led training (ILT) is ideal for mastering product-specific skills-based training. We offer our ILT training in our Milwaukee, Wisconsin and Longview, Texas, locations, as well as in the field at your location.

ILT in Milwaukee and Longview gives your staff the opportunity to work hands-on with the latest equipment system components. Students are introduced to skills-based topics in a classroom environment and then move to our training lab for practice on successfully troubleshooting and maintaining specific equipment.

Field-based training is held at your preferred location, using your equipment. This approach allows your staff to work directly with their own equipment with instructors that tailor the training for your particular models. Our regional trainers are able to deliver customized training that is backed by the world-class training principles used in Milwaukee and Longview.

Virtual instructor-led training

For additional flexibility in scheduling, we offer virtual instructor-led training, with the same level of quality training as with the in-person training. Our instructors use a variety of delivery tools, like Webex and Microsoft Teams, to reach your technicians and operators – without the travel expenses.

This virtual training uses existing course outline topics that can be scheduled in two to four-hour sessions. They can be customized to small group sessions for maintenance training. Operator training uses the same platform as the maintenance training, except we suggest using a local agent to assist in directing the training. We can also provide a “coaching” type session to discuss topics like operator best practices.

Our training model is designed to incrementally develop the knowledge and skills required to successfully operate and maintain our equipment. Based on the industrial training model widely used in the manufacturing and service industries, our training categorizes knowledge and skills into three levels.

Fundamental training

Fundamentals are the essential knowledge and skills required to perform one’s job description. These are typically acquired by successfully completing a formal apprenticeship, career college, or military technical program. Fundamental training includes:

Knowledge

• Basic electronic/electrical theory
• Basic hydraulic/pneumatic theory
• Basic mechanical systems theory

Skills

• Basic hand tool skills, including multi-meter and callipers
• Pressure gauge reading
• Oscilloscope operation

We do not provide this type of training. We highly recommend that individuals have a strong fundamental knowledge prior to participating in any of our product-specific training initiatives.

Product-specific knowledge-based training

This level of knowledge is usually reached after on-the-job experience, combined with training provided by us. For this level of training, we provide eLearning and limited instructor led training. Product-specific knowledge based training includes:

Knowledge

• System descriptions
• Theory of operations
• System diagnostics
• System inspection/maintenance practices

Product-specific skills-based training

This level of knowledge and skills is usually reached after mastering product-specific knowledge and on-the-job experience, combined with training provided by us. For this level of training, we provide instructor-led training, in the field or in our training lab. Job-specific training includes:

Knowledge

• Review of product-specific skills-based topics

Skills

• Perform system adjustments
• Install and configure product-specific application software
• Removal and replacement of system components
• Operate P&H equipment

Our training needs analysis evaluates your staff on product-specific maintenance and operation knowledge and gives you a clear, objective analysis at both the individual employee and collective group level.

This analysis allows us to work with you to create customized training plans, at the individual or group level, to address any knowledge gaps. The approach means we can target just the specific areas that need improvement, saving you both time and money.

Our assessments, available in multiple languages, cover electrical, mechanical, and hydraulic/pneumatic competencies related to products. These assessments are web-based and can be accessed at any time. 

We now offer our product manuals through our convenient ProManual application. For a small annual subscription fee, you can access the most up-to-date product documentation for every piece of our surface mining equipment at your site. Key features include:

• Secure online and offline availability: once a manual is downloaded, it is made available within the ProManual app for online/offline access and printing
• Version management: our ProManual app updates the latest product manuals; users receive updates to downloaded manuals when they are logged in and connected to the Internet
• Streamlined communication process: our ProManual app allows users to submit detailed feedback for any product manual instantly
• Multi-language support: our ProManual application and documentation are available in multiple languages
• Supported operating systems: Apple iOS 9 or higher, and Windows 10.0 or higher 

Apple and the Apple logo are trademarks of Apple Inc., registered in the US and other countries. App Store is a service mark of Apple Inc. 

Windows and the Windows logo are trademarks of Microsoft Corporation, registered in the US and other countries. Windows Store is a service mark of Microsoft Corporation.

All commissioned equipment includes a standard mechanical, electrical, and operator manual package.  This package includes:

• Three printed operator suites (colour)
• One printed mechanical suite (colour)
• One printed electrical suite (colour)
• Three CDs of the operator/mechanical/electrical suites (PDF files)

If you require replacement suites, please contact your local Services office.

You expect your dragline to operate for decades. However, as your machine ages and new technologies become available, it becomes critical that certain upgrades and improvements take place to provide optimal productivity for the duration of your dragline’s life cycle.

Our machine audit process uses our centre-of-excellence dragline service organization to provide you with a comprehensive picture of the health of your dragline. Our audits include:

• Static inspection testing, such as:
  • Non-destructive tests, including eddy current, radiographic, and ultrasound
  • Visual inspection of key components, including gears and gear cases
  • Electrical inspections
  • Oil analysis to identify levels of particulates
• Dynamic operational testing, such as:
  • Thermography for locating mechanical and electrical hotspots
  • Digital signal processing and analysis to confirm acceleration, velocity, and displacement
  • Vibration analysis
    • Baseline analysis performed at commissioning establishes the benchmark
    • Subsequent readings help identify trends

Our audit experts can be deployed worldwide, which means you have access to our full audit staff and our full range of test options, regardless of your location. Our experts can also evaluate the electrical drives, control system, and motors on your dragline.

Audits reveal which components should be addressed in the short term, as well as provide a component life model for forecasting purposes. Subsequent inspections can be tailored to regularly assess components that are nearing replacement status. This helps minimize production delays, since replacement parts can be ordered well in advance and delivered in time for a planned exchange. 

A key factor affecting your dragline productivity is the expertise of your operation and maintenance personnel. We offer extensive dragline training to improve the skills of your dragline operators and maintenance technicians.

Operator training

New operator training covers the basic functional controls of the machine, as well as the core operational tasks: walking, setup to dig, digging cycle, and digging sequence. In addition, we provide training for all types of modes, including highwall cutting, overhand digging, and efficient spoiling. Finally, we can provide refresher training for veteran operators to hone skills and develop best practices.

Maintenance training

We also offer P&H equipment maintenance training for both mechanical and electrical maintenance technicians.

• For electricians:
  • Our dragline overview class reviews the basic electrical system, the drive system (AC or DC), and the dragline control system
  • Our digital drive system class focuses on variable speed motor control, closed loop systems, and failure analysis
  • Our dragline control system class focuses on process control and failure analysis
• For mechanics:
  • Our basic dragline mechanical maintenance class reviews the components and theory of operation of the major mechanical systems
  • Our dragline mechanical system class reviews the operation and maintenance of various dragline mechanical systems

From start to finish, we act as your primary contractor to seamlessly handle the teardown, packing, shipping, re-erection, and commissioning of your dragline. In the last 20 years, we have handled over 20 dragline relocations – across countries and across the globe - including both P&H draglines, as well as draglines from every major dragline manufacturer. 

These services can be combined with a machine audit and upgrade of appropriate parts to ensure that relocated dragline will start up with the highest possible availability and productivity.

For example, upgrades to past relocations have included:

• New radial tubs, including new rails, rollers, and racks
• Frame enhancements, such as revolving frame extensions, deck extensions, monorail systems, and supply crane platforms
• Swing machinery enhancements, such as swing case rebuilds (including timing and assembly) and new swing case platforms
• Boom enhancements, such as boom chord/lacing upgrades, boom crossover platforms, boom and mast repairs and replacements, and suspension rope change-out platforms
• House enhancements, such as cam enclosures, noise abatement, intake fan silencers, and fan house false floor and height extensions
• Electrical enhancements, such as electrical control upgrades, exhaust/intake/bleeder fans, new electrical cable and wire, and new lighting fixtures
• Additional enhancements, such as gear ratio changes, propel girder extensions, lifting hook re-locations, roller circle support diaphragm improvements and rear A-leg hub forged hubs

We can also evaluate your dragline to determine if rated suspended load (RSL) improvements are possible, by examining the following:

• Hoist and drag motor heating
• Line speed balance
• Running rope size
• Suspension pendants
• Propel and swing stability

The entire management of the project and the associated logistics is handled by seasoned professionals who have moved many draglines of all sizes and brands across the globe.

We have earned worldwide recognition as the leading supplier of OEM-quality replacement parts to the surface mining industry. We provide a comprehensive line of P&H brand parts for P&H draglines, as well as for draglines from every other major manufacturer.

We use the industry’s most advanced design and engineering tools to ensure that every dragline part meets or exceeds OEM specifications. We continually improve the performance of each part in the field by incorporating design and manufacturing enhancements where appropriate.

When you use P&H dragline replacement parts — regardless of your equipment’s manufacturer — you are assured of parts that have been meticulously developed and rigorously inspected and tested to deliver the long-term performance you expect from an OEM.

In addition, we offer customized engineered solutions for your specific needs. Past solutions have included:

• Boom design and replacements, including tubular booms and masts
• P&H gradial-design dragline tub, customized for non-P&H draglines
• Improved forged cam and cam shafts
• Reduced-size planetary swing and propel
• Improved boom point swivels
• Control system upgrades
• AC system upgrades

Our engineered solutions apply our world-class technology to your equipment without exceeding the OEM specifications for that machine. 

In the last 20 years, we have supported almost 50 major dragline shutdowns around the world, handling major overhauls on virtually all types of draglines:

• All sizes, from the smallest to the largest draglines in the world
• All vendors and all makes
• All capacities

Past shutdown upgrades have included a wide range of services, such as:

• Gradial-design tub installations
• Rails, rollers, and racks service
• Propel system rebuilds
• Cam bearing installation
• Front-end rebuilds
• Tri-structure feet and back leg installation
• Deck pad installation and concentric conversion
• Front girder upgrades
• Swing rack installation

Our shutdown process includes full project management from our team of dragline experts. We act as your primary contractor for the entire process, handling everything from shutting down the equipment, completing the overhaul, and re-commissioning the equipment. Our project management processes have been proven to minimize shutdown times to the lowest in the industry.

We use P&H brand parts – regardless of your equipment’s manufacturer – assuring you of parts that have been meticulously developed and rigorously inspected and tested to deliver the long-term performance you expect from an OEM.

Understanding draglines inside and out

We developed a true center of excellence with our dragline service organization. Our staff comprises more than 800 years of combined experience in draglines, meaning we are the OEM with more institutional dragline mining knowledge than anyone else in the industry.

Comprehensive dragline upgrade programs

The experience is most evident in our dragline upgrade programs. Only we provide a comprehensive line of P&H upgrade components for P&H draglines, as well as for draglines from every other major manufacturer. When we exchange your current high-maintenance OEM components with reliable, proven P&H components, you will see increased machine reliability and availability, which in turn translates to higher production.

We have planetary swing transmission, dragline boom designs, ventilation modules, and other upgrades available to make your dragline more dependable and productive. All our upgrade components are designed for severe dragline operations and have a proven track record in numerous mining applications around the world.

Rated suspended load improvements

We can also evaluate your dragline to determine if rated suspended load (RSL) improvements are possible, by examining the following:

• Hoist and drag motor heating
• Line speed balance
• Running rope size
• Suspension pendants
• Propel and swing stability

Electrical system upgrades

In addition, our electrical system upgrade capabilities include:

• Centurion operating system
• PLC operator interface controls
• Static analog drives
• Digital AC and DC drives
• ABB, Avtron, Siemens, and GE DC2000 motors
• Variable frequency drives

Our electrical system upgrades apply our world-class technology to your equipment without exceeding the OEM specifications for that machine. 

Our service centre repairs offer expedient repair turnaround times as well as high-quality repairs that are based on our OEM specifications and procedures. Our centres feature parts, shop services, skilled maintenance staff, project management, and a range of technical support services such as engineered solutions.

Each of our service centres is staffed with experienced and well-trained technicians committed to delivering quality and reliability. Our centres are located either on-site or close to mine locations to optimize service response times.

Experienced staff

Our service centre staff is thoroughly trained on how to repair our equipment to OEM specifications. Everyone from welders to project managers has been certified on approved procedures, using approved parts and materials. When applicable, our staff recommends productivity and reliability upgrades as part of the repair process, based on their extensive knowledge of current technologies.

Genuine OEM parts and materials

Our service centres only use genuine OEM parts and materials during the repair process.

Our parts deliver unsurpassed reliability and maximize equipment performance, productivity, and availability. Our OEM parts give you the confidence to run equipment at peak efficiency and at maximum design capacities. Genuine parts deliver substantial noise reduction, increased strength, and higher mean-time-to-failure, maximizing operator safety. Lower wear and reduced operating temperatures extend the life of core components, minimizing operating costs.

OEM inspection standards

Our service centres adhere to the same inspection and quality control standards that we use during our OEM manufacturing. Repairs follow the same processes and detailed work instructions as used in the original assembly. Sign-off inspections are conducted at each step of the repair process, ensuring that returned components are ready to function without interruption for a full equipment lifecycle. 

Frequently, only actual parts costs are considered when it is time to make a parts purchase. And on occasion, OEM parts can have a slightly higher price tag than generic parts. However, true total cost of ownership calculations must compare a part’s purchase price in relation to the inherent risks associated with the installation, performance, and impact that a non-OEM part can have on the entire system.

Consider some of the following factors when you are deciding on generic vs. genuine OEM parts.

Assurance that you are receiving the correct part

When you order a replacement or consumable part, you will receive exactly the right part for your equipment model. In addition, if your equipment had any upgrades or rebuilds, our equipment service records will allow us to confirm that new replacement or consumable parts are compatible with the upgraded or rebuilt components.

Assurance of quality and functionality

Our replacement and consumable parts are manufactured using the same specifications as the original parts to ensure exact form, fit, and functionality. Similarly, our upgrade parts are designed specifically to perform with perfect compatibility with our equipment. This OEM engineering results in parts with a longer lifespan and reliable equipment performance, with predictable Mean Time Between Failure (MTBF) and repair/replacement cycles.

Assurance of the latest design enhancements

Our engineers make continuous design enhancements during a product’s lifecycle and access to these enhancements is only available through us. You simply cannot rely on another vendor to provide you with the latest version of our parts. In addition, you can count on us to manage part obsolescence and recommended replacements.

Assurance of warranties and post-sale support

Not only do our replacement, upgrade, and consumable parts come with warranties, but we promise complete post-sale support including recalls, if necessary.

Assurance of available parts

One of the key advantages of purchasing parts from us is that we have extensive order history information that allows us to know exactly what to stock in our regional warehouses and in what quantities. Since we have numerous regional warehouses, we are able to supply your needed part as quickly as possible to minimize your downtime.

Assurance of access to our experts

When you purchase our parts, you have access to our full team of parts experts who will help guide you through the entire selection, purchasing, and post-sale support processes. If your purchase requires specialized technical information, our parts team can tap into the extensive knowledge base present in our organization. In addition, our other parts-related services include operational assessments, preventive maintenance, and field services that help you avoid problems before they turn into emergency parts replacement situations. On many occasions, more is needed than just a spare part and that is when the advantage of purchasing your parts directly from us becomes clear.

We offer a wide range of condition monitoring and preventive maintenance inspection programs. Our programs include mechanical and electrical inspections, operations and maintenance analysis, and preventive maintenance plans. These programs are designed to help you:

• Reduce unplanned breakdowns
• Increase overall machine availability and MTBF (mean time between failures)
• Increase production by reducing failures stemming from incorrect assembly and poor operation and maintenance practices

We can help you maximize productivity by providing the following levels of inspection support:

• Condition reports stating the condition of monitored components, including recommendations for corrective maintenance
• Component trending reports based on oil sampling, thermography, or vibration analysis, including proactive fault finding, component replacement plans, and corrective maintenance needs
• Root cause failure analysis for reducing similar failures in the future, highlighting correct assembly, operation, and maintenance practices

Since the key to productivity is machine availability, our inspection programs help you correct current and upcoming machine issues in a planned and controlled fashion, ultimately reducing your overall downtime.

We are committed to helping you maintain your equipment. Our on-site service programs feature experienced, knowledgeable, and well-trained service teams that are available 24/7, 365 days a year, to address any issues you encounter with your equipment. Our field service teams are your trusted advisors, working with your team to fully plan and schedule maintenance support in the most efficient manner.

Field welding

Since the 1930’s, we have been perfecting our field welding capabilities for surface mining equipment as well as ore-processing systems. When you need expert, efficient, and effective welding, our field welding team delivers the results you require.

Overhauls and rebuilds

Our overhaul and rebuilds teams can handle everything from overhauls of shovels and other surface mining equipment to complete crushing plant rebuilds. Our programs restore your equipment and plant machinery to like-new performance and greatly extend useful life.

We use not only our considerable field service resources but also our regional rebuild service centres to meet your requirements. In addition, we use a partnered, collaborative approach to help get the overhaul/rebuild done quickly and in a cost-effective manner.

Maintenance services

Our service technicians are always available to perform routine equipment maintenance, including periodic recommended preventive maintenance, lube filter change-outs, equipment adjustments and tune-ups, and fluid and lubricant management.

Assembly and relocation

Whether you need to erect a new piece of equipment or re-locate already deployed equipment, our service teams have the people, tools, and experience to get the job done quickly, safely, and in a timely manner.

Our portfolio of assembly and relocation projects is extensive, including a shovel assembly completed on time in the world’s most brutally cold climate to a transcontinental dragline relocation. In addition to handling assembly and relocation of our equipment, we have handled projects for numerous other equipment as well.

Repairs and rebuilds

Equipment repairs and rebuilds can play a key role in your managed costs. We operate repair and rebuild centres near key mining areas, allowing much of the work to be done in these centers and then installed in the field. Our capabilities include:

• Component repair and return programs for motors, transmissions, drives, and generators
• Dipper and bucket rebuilds and conversions
• Drum rebuilds and laggings
• Component exchanges
• Fabrication services
• Gear re-banding
• Handle and boom rebuilds and conversions
• Tub rebuilds

Electrical re-commissioning

Our service teams are able to test your shovel’s electrical system and re-commission it to like-new standards.

Emergency services

W can send out emergency service teams 24/7, 365 days a year, if your equipment experiences a breakdown. Even if the emergency occurs on a holiday, we are able to send a response team to help your equipment return to productivity.

Motors warranty and repair services

Our rebuild and repair centres are well-equipped and staffed to handle all your motor warranty and service support needs.

Upgrades

Over time, even the best-maintained equipment can become technologically obsolete. One way to receive the highest possible production levels from your equipment is to apply performance-enhancing upgrades. Numerous proven upgrade packages are available for drills, draglines, shovels, hydraulic excavators, loaders, and trucks that can give you cost-saving productivity gains. 

Our service-for-hire teams are equipped to provide OEM-quality services and repairs at your shop or mining operation location, allowing you to extend the life of your equipment while maximizing your long-term investment.

We know the key to field service success is having skilled, trained personnel. Our service team members are experts in surface and underground mining equipment repairs as well as disassembly, relocation, and reassembly. They have the capability to perform OEM quality repairs on all our equipment as well as surface and underground mining equipment from all major manufacturers.

The team is experienced in a variety of market applications, including coal and industrial minerals, and understands the specific needs of these applications. We work directly with your staff, ensuring expedient turnaround times.

These safety-focused mechanics, welders, and electricians come to your site with completely tooled service trucks, ready to perform a full range of welding, mechanical, hydraulic, and electrical services. In addition, we have a service sled for transferring repair equipment to underground locations.

The team is certified for surface and underground work in all states, with the appropriate contractor licenses in place where required.

Use our service-for-hire team for the following services and repairs:

• Service across all product lines
  • Component replacement
  • Line-boring services
  • Proximity/camera system installation
  • Hydraulic cylinder replacement
• Continuous Miners
  • Cutter drum maintenance and/or replacement
  • Traction system repairs for wear runners, crawler chains and planetaries
  • Gathering head repairs
• Feeder-Breakers
  • Redecking
  • Sprocket replacement
• Longwall Systems
  • Shearing machines cutter drum maintenance and/or replacement
  • Welding services for armoured face conveyors
  • Powered roof support maintenance and repair
  • Support for longwall moves
• Wheel Loaders
  • Mechanical, electrical and hydraulic repair services
• Shovels/Dragline
  • Welding, mechanical and electrical repairs

The Reliability Centered Maintenance (RCM) process involves:

• Identifying critical machine functions
• Relating performance characteristics and requirements to functional failures
• Performing Failure Mode Effect Analysis (FMEA) to identify maintenance requirements
• Defining the tasks, maintenance intervals, resources and personnel requirements
• Generating transferable data from the RCM into the customer’s Computerized Maintenance Management System (CMMS)

Become more efficient by implementing Reliability Centered Maintenance (RCM):

• Perform the right tasks for planned downtime; developed from data-driven reliability analysis of global fleet
• Plan downtime at the right time; developed from data-driven component life estimates of global fleet specific to application and environment
• Optimize maintenance efficiency by having the right people, the right resources and the right equipment available during planned maintenance events

Deliverables from a partnership in maintenance excellence:

• RCM facilitators guide both customer participants and OEM field service experts to ensure final maintenance tasks account for local operating conditions
• Life Cycle Management team maintains RCM templates that, when customized to the mine’s geological conditions, create optimized, application specific maintenance plans. We provide a set of optimized plans to be used in the customer’s CMMS
• Maintenance and reliability experts will partner with the mine to provide yearly maintenance audits as well as updated reliability analyses of our global fleet in order to continuously improve the mine’s maintenance plans