September 01, 2017 -- Earlier this year Anglo American’s New Vaal Colliery took delivery of a Komatsu PC4000 super shovel, the only one of its kind in the business’s opencast mining fleet.

The machine was built at our manufacturing facility in Germany, before being shipped to South Africa in modules. A combined team made up of New Vaal and Komatsu personnel, with support from companies including Cummins and Jormid Electrical, assembled the 400-tonne unit on site.

New Vaal is situated just south of Vereeniging in the Free State province and supplies an annual 16 million tonnes of coal to Eskom’s Lethabo Power Station.

End of an era

The arrival of the shovel represents the end of an era for New Vaal, as the operation’s first Demag H285 excavator has been  retired. This reliable old workhorse first started mining in 1988, and three of its peers are still in service at the mine today. Demag was, of course, acquired by Komatsu and the design of the PC4000 is very closely related to the product it replaces.

Section Engineer Le Clus Taute describes these units as ‘bullet proof’ and ‘exceptional’ and says that it was this factor, along with cost, Anglo American’s strong historical relationship with Komatsu and the proven track record of its products that influenced the mine’s purchasing decision.

“As the new unit bears a strong resemblance to its great-grandfather, we also benefit from a maintenance and operational perspective as our team is instantly familiar with it,” he says.

Advancements

The PC4000, does, of course, boast an extensive array of advancements, including impressive digging forces, greater ease of bucket filling and an on-board machine health monitoring system designed not only to increase output but to aid maintenance personnel with on-board fault-finding sensors. It also features a Komatsu low noise cab on multiple viscous mounts for reduced noise and vibration.

“We selected a backhoe diesel power configuration, an ideal combination for mining middle and bottom seam coal as it offers us the flexibility we need to mine under often wet and complex conditions,” says Taute. [POSSIBLE PULL OUT QUOTE]

While the substantial presence of the original Demag H285 will no longer be visible, it will continue to serve the operation it has called home for more than 29 years. Taute says that many of its parts are still fit for purpose. “Several key components, including its electric motor, will be used to support the remaining three Demag shovels.” 

Features

Komatsu technology and expertise

• Machines innovatively developed for high production, safety and environmental factors
• Quality management ISO 9001 certified
• Environmental management ISO 14001 certified
• High, consistent quality through continuous investment in personnel, design and manufacturing systems and processes

Easy maintenance

• Simple, common-sense design provides quick, easy access to all major components
• Generous walk-through gangways throughout the platform and around the power train
• Enclosed, internally lit, engine and pump house
• Automatic central lubrication
• Swing-out hydraulic oil coolers enable complete and regular service
• Ground-level access to hydraulically-powered swing-down service arm with Wiggins connections

Vehicle health monitoring system

• Provides real-time and stored information about the operating status of the machine
• Touch-controlled colour monitor screen with continuous display
• Service messages in data, snap-shot and trend analysis format with battery back-up security Automatic engine shut-down for critical malfunctions
• Data download capable, either to a laptop computer or by wireless link

Large comfortable cab

• Low internal noise level
• New generation viscous cab mounts
  
• Comprehensive climate control with pressurized, filtered air ventilation and air conditioning .High specification multi-adjustable air suspension seat for full shift comfort