Komatsu Introduces the World's First Hydraulic Excavator: Hybrid Evolution Plan for Construction Equipment

Komatsu Ltd. (President & CEO: Kunio Noji) announced today that the Company is going to launch sales of the PC200-8 Hybrid excavator, the world's first hybrid construction equipment. (*1)
The PC200-8 Hybrid is powered by the Komatsu Hybrid System which uses a newly developed electric motor which turns the upper structure, power generation motor, capacitor and diesel engine. Compared with the standard PC200-8 hydraulic excavator, the hybrid model achieves about 25% reduction of fuel consumption. (*2)
Earlier in May 2007, Komatsu launched the world's first hybrid electric forklift trucks on the market. We are introducing this hybrid excavator as it is our flagship construction equipment.
As a leading company of the construction equipment manufacturing industry, we are determined to meet the needs of the time by practically proposing innovative equipment designed to reduce environmental impact, including CO2 reduction.

1. Fuel Economy

Compared to the standard PC200-8, we have achieved an average of 25% reduction in fuel consumption. (*3) Furthermore, in the operation tests by customers, we have confirmed the maximum reduction of 41% at a jobsite where the machine's upper structure turns more frequently.

* Notes
1. Based on our research on seven major products (crawler-type hydraulic excavator, wheel-type hydraulic excavator, wheel loader, bulldozer, rigid-type dump truck, articulated dump truck and motor grader as of May 13, 2008.
2. This figure varies depending on the nature of work.
3. Computed according to our internal-use standard concerning average ways of using construction equipment.

2. Outline of the Komatsu Hybrid System

Our proprietary Komatsu Hybrid System converts energy generated when the upper structure reduces its speed while turning, stores the energy in the capacitor, and uses it to assist the power of the engine via the power generation motor when the engine accelerates.

All components of the Komatsu Hybrid System are made in-house , ensuring high reliability and durability.(*4)

* Note 4.Excluding capacitor cells.

3. Major Characteristics of the PC200-8 Hybrid when Compared to Standard Construction Equipment and Hybrid Cars

1) Comparison with Standard Construction Equipment
While standard equipment normally uses a hydraulic motor to turn the upper structure, for this movement, Komatsu has newly developed an electric motor for the Hybrid. By using this electric motor which collects energy generated when the upper structure's turns slow down, we have achieved a hybrid excavator.
While standard construction equipment uses only diesel engines for power, our new hybrid excavator utilizes regenerated energy to assist the engine when it is accelerating, enabling the use of the engine in a low revolution zone with high-efficiency combustion. In addition, while the engine runs idle, our hybrid excavator keeps the revolution at a super low level, achieving impressive reductions in fuel consumption.

2) Comparison with Hybrid Cars
Hybrid cars require a large amount of electric energy when they start moving and accelerating, then they can run with relatively stable engine revolution. By comparison, construction equipment has to accommodate dynamic and frequent fluctuations of the engine revolution, for example, for excavation work. To assist the engine for such fluctuations, the PC200-8 Hybrid is mounted with a capacitor.
Automotive batteries work on the principle of chemical reactions, thus it takes time for them to discharge electricity, lacking sufficient support when applied to construction equipment. Meanwhile, capacitors can instantaneously and efficiently collect, store and discharge electricity.

[PC200-8 Hybrid Excavator]

 

[Energy motor enables the operator to see the flows of electric energy, such as storing and regenerating.]

 

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Hitachi Zaxis 180LC-5 excavator

ZX180LC-5 excavator from Hitachi has a boom/arm configuration that provides greater lift capacity than its smaller sibling, the ZX160LC-5, and it has a wider undercarriage for more stability. The ZX180LC-5 has a Tier 4-Interim Isuzu AI-4JJ1 diesel that generates 121 horsepower. Hitachi says the DPF will go 4,500 hours before dealer replacement. Three work modes are available: High Productivity (HP) delivers more power and faster hydraulic response; Power (P) delivers a balance of power, speed, and fuel economy for normal operation; and Economy (E) maximizes fuel efficiency while delivering an enhanced level of productivity. Three years ZXLink Ultimate is standard, enabling 24/7 online access to machine location, health, utilization, fuel consumption, and other machine information.

Hitachi ZX180LC-5 Specifications

• Operating weight: 40,419 pounds
• Net power: 121 horsepower
• Bucket capacity: 0.52-1.43 cubid yards
• Lifting capacity over front, ground level: 11,656 pounds

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Komatsu PC4000 Hydraulic Shovel Offers Reliability and Durability

Komatsu’s PC4000 hydraulic shovel, with an operating weight between 855,500–879,800 lbs. (388-399 M. tons) and a bucket capacity of 29 yd3 (22 m³), is designed with the goal of helping mining customers move more material in less time for reduced costs per ton and increased profits. A powerful Komatsu SDA16V160E-2 diesel engine and four circuit advanced “Hydropilot” hydraulics are two of the major improvements to this model. Blending innovative technology and engineering, Komatsu’s PC4000 stands up to the rugged-use of today’s mining applications.
The Komatsu SDA16V160E-2 diesel engine has a rated power of 1875 HP (1400 kW). The shovel’s low engine emission levels meet EPA regulations TIER II and the time saving oil management system is fitted as standard on all machines. Electric drive 4,16 kV – 7,2 kV, 50 or 60 Hz, is also available.
• Productivity Moves More Tons Per Hour
With backhoe break-out force of 250,000 lbs. (1155kN) and loading shovel crowd force of 300,000 lbs. (1330 kN), the Komatsu shovel is designed with the highest digging forces in its class to increases mine productivity. All cylinders are mounted in the shadow of the attachment’s steel structure for component protection. A wide-range of wear packages and buckets are available to suit various densities and applications. Different track shoes can be selected to meet various ground conditions. Komatsu’s PC4000 is recommended for use with trucks ranging from 150 to 240 US tons.
• Large Cab for Operator Comfort
The PC4000 features an insulated cab on multiple viscous mounts for reduced noise and vibration. The cab has a deep wide front window with the operator positioned and seated on a multi-adjustable air suspension seat for improved operator comfort and visibility. The cab has A/C climate control with pressurized filtered air ventilation. An optional back up A/C or heater is available.
• Advanced Hydraulics
The four circuit advanced “Hydropilot” hydraulics on the PC4000 deliver precision control and extended reliability. The single engine is connected to a gearbox driving four identical Komatsu main pumps that draw hydraulic oil from an unpressurized hydraulic tank. The open circuit hydraulic system is fitted with swing out oil coolers and monitored filtration which contributes to enhancement of machine efficiency and operating life over previous versions of the PC4000.
• Easy Maintenance
The PC4000’s maintenance-friendly design provides quick access to major components for easier maintenance. Access to all major service points are at the machinery’s house level and there is also ground-level access to the hydraulically-powered swing-down service arm with WIGGINS® connections.
The PC4000 is equipped with KOMTRAX Plus® (former VHMS) technology, which sends machine operating information to a secure website utilizing wireless technology. Without any additional IT expense, data such as operating hours, component trends, machine utilization (including idle time and fuel consumption) and production information are relayed to the web application and made available on-line for analysis. In real time, the KOMTRAX Plus® fleet monitoring system monitors machine availability, allows for remote diagnosis of machine issues, and provides a wealth of other information to drive business efficiency. In addition to KOMTRAX Plus, an interface for the connection of the Modular Mining System is incorporated.
Komatsu America Corp. is a U.S. subsidiary of Komatsu Ltd., the world’s second largest manufacturer and supplier of construction and mining equipment. Komatsu America also manufacturers and supplies specialized equipment for the forestry, materials handling and numerous other industries. Through its distributor network, Komatsu offers a state-of-the-art parts and service program to support its equipment. Komatsu has been providing high-quality reliable products for nearly a century. Visit us at http://www.komatsuamerica.com/ for more information.

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Komatsu America Corp. Launches New WA470-7 Wheel Loader

Komatsu America Corp. introduces the WA470-7 wheel loader. With a net horsepower of 272 hp (203 kW), the WA470-7 is powered by a Komatsu SAA6D125E-6 engine and is EPA Tier 4 Interim and EU Stage 3B emission certified. Built upon a proven Tier 3 engine platform, Komatsu has leveraged its leadership in technology and innovation to design a more environmentally-friendly engine that increases power while decreasing fuel consumption by approximately 8 percent, compared to the WA470-6.
Weighing in at 52,007 pounds (23,590 kg), the WA470-7 features improved efficiency, lower fuel consumption, improved operator comfort, and enhanced serviceability to maximize productivity while lowering operating costs.
The WA470-7 is equipped with the latest KOMTRAX® technology, which is fully integrated with Komatsu’s Tier 4 technology. Machine operating information such as operating hours, fuel consumption, location, cautions and maintenance alerts are wirelessly relayed to a secure website for analysis.  The KOMTRAX fleet monitoring system results in increased machine availability and, reduced risk of machine theft when compared to machines not equipped with KOMTRAX. The technology also allows for remote diagnosis by the distributor and provides a wealth of other information to drive business efficiency and productivity.
New features of the WA470-7 include:
• EPA Tier 4 Interim and EU Stage 3B Emission Certified Engine
Built upon proven Tier 3 technology, the SAA6D125E-6 engine provides lower emissions while also lowering fuel consumption. The Komatsu Tier 4 Interim engine uses an advanced electronic control system to manage air flow rate, fuel injection, combustion parameters and aftertreatment functions to optimize performance, reduce emissions, reduce fuel consumption and provide advanced diagnostic capability.
As a leader in hydraulic technology, Komatsu has also developed a hydraulically actuated Komatsu Variable Geometry Turbocharger (KVGT) and an Exhaust Gas Recirculation (EGR) valve, resulting in better precision and air management as well as longer component life. The Komatsu Diesel Particulate Filter (KDPF) has an integrated design that will not interfere with daily operation but will keep the operator aware of its status.
The WA470-7 also features Komatsu Smart Loader Logic (KSLL), which provides optimal engine torque for the job required. KSLL allows for fuel reduction by decreasing engine torque when the loader isn’t working hard, such as when it is driving with an empty bucket. KSLL functions automatically with machine operation and results in saving fuel without decreasing production.
• Large Capacity Torque Converter with Lock-Up
The WA470-7 has a newly designed Komatsu Large Capacity Torque Converter with Lock-Up as a standard feature. This provides improved acceleration, faster hill climb ability, a higher top speed and lower fuel consumption. The Lock-Up function activates in 2nd, 3rd and 4th gears giving the machine a maximum ground speed of 23.8 mph (38.3 kph).
The wheel loader has greater productivity in V-cycle applications because of the increased tractive effort. The faster hill climbing ability allows the WA470-7 to up-shift gears faster because of improved acceleration. The wheel loader can also achieve higher gear ranges and maintain higher ground speeds when working in load-and-carry applications. In most applications, production is increased and fuel consumption reduced, resulting in improved fuel efficiency.
• Enhanced Operator Environment
The new cab provides a more comfortable and quieter work environment so the operator can maximize productivity. The front glass has been lowered and the dashboard has been redesigned to improve visibility. Electronic Pilot Control (EPC) levers and an F-N-R switch are part of a redesigned seat-mounted right hand console. An auxiliary input has also been added to connect an MP3 player or other device along with two 12-volt ports that have been incorporated into the cab.
A new high resolution 7” LCD monitor features enhanced capabilities and displays information in 25 languages for global support. Using the monitor, the operator can easily modify settings for items such as the Auto Idle Shutdown or the auto-reversing fan. The operator can also check operational records, such as working hours or fuel consumption; monitor the KDPF soot load; or check how much time is required before the next maintenance interval. In addition, the monitor offers the operator the option of using the ECO Guidance (economy) function, which will provide operational tips to reduce fuel consumption. A separate high-resolution back-up camera is standard with every machine and is mounted on the right hand side of the console for operator convenience.
• Customer peace of mind is standard because of Komatsu CARE®
Komatsu remains focused on lowering the customer’s ownership costs by engineering machines with increased fuel efficiency and productivity. Komatsu CARE® complimentary scheduled maintenance is standard on all WA470-7 wheel loaders for three years or 2000 hours (whichever occurs first). Services are performed by factory certified technicians using only Komatsu genuine parts and fluids. Also included are two complimentary KDPF exchanges at 4,500 hours and 9,000 hours within the first five years.
• Convenient Maintenance and Serviceability
The WA470-7 provides easy service access in order to reduce downtime. The new model has increased cooling capacity, wider cooling fin spacing and a standard auto-reversing fan to help keep the radiator clean. The machine is equipped with the exclusive Komatsu Equipment Management Monitoring System (EMMS), which provides enhanced diagnostic features that give the operator and technicians greater monitoring and troubleshooting capabilities. EMMS continuously monitors all critical systems, as well as the planned preventative maintenance schedule, and provides troubleshooting assistance to minimize diagnosis and repair time.
Note: All comparisons and claims of improved performance made herein are made with respect to the prior model, WA470-6, unless otherwise stated.
Komatsu America Corp. is a U.S. subsidiary of Komatsu Ltd., the world’s second largest manufacturer and supplier of construction, mining and compact construction equipment. Komatsu America also serves forklift and forestry markets. Through its distributor network, Komatsu offers a state-of-the-art parts and service program to support the equipment. Komatsu has proudly been providing high-quality reliable products for nearly a century. Visit the website at www.komatsuamerica.com/ for more information.

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Komatsu Introduces its Parallel Link Undercarriage System on Mid-Size Dozers

Rolling Meadows, IL, May 19, 2009 — Komatsu America Corp. introduced the new Parallel Link Undercarriage System (PLUS) on its D51EX/PX-22, D61EX/PX-15 and D65EX/PX/WX-15 crawler dozers. Komatsu’s revolutionary PLUS undercarriage can significantly increase wear life, reduce machine downtime and lower repair and maintenance costs.
With PLUS, undercarriage wear is more balanced across all components. Bushings will no longer wear faster than the rails. The system is designed to wear evenly so that the machine provides close to 100% usage of undercarriage components, lowering undercarriage maintenance costs by up to 40%.
Other advantages of PLUS include no maintenance between track changes other than track tension adjustments and no more bushing turns. The PLUS undercarriage is suitable for all applications including high impact applications and applications where the AR (abrasion resistant bushing) track assembly was previously required. Should service be required, the master links allows quick access to undercarriage components. PLUS also reduces noise heard by the operator, improving operator comfort.

PLUS’s strutted link provides a solid base for the box section type track and a taller, hardened link height provides longer wear. Because individual links can be replaced in the field, down time is minimized. Segmented sprockets are designed to shed material which minimizes packing. Carrier rollers have a larger diameter to increase their wear life, while track rollers with larger flanges and track roller guards that contact the link instead of the pins help maintain track alignment.
Building on Komatsu’s already robust track frame design, PLUS can be interchanged with a conventional undercarriage which makes retrofitting an existing machine simple and fast. Machines equipped with PLUS have undercarriage replacement options which include using the conventional undercarriage or using PLUS.
Komatsu America Corp. is a U.S. subsidiary of Komatsu Ltd. which is the world’s second largest manufacturer and supplier of construction, mining and compact construction equipment. Komatsu America also serves forklift and forestry markets. Through its distributor network, Komatsu offers a state-of-the-art parts and service program to support the equipment. Komatsu has proudly been providing high-quality reliable products for nearly a century. Visit the website at www.komatsuamerica.com for more information.

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Komatsu PC400-7, PC400LC-7, PC450-7, PC450LC-7 Shop Manual

This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for The Komatsu PC400-7, PC400LC-7, PC450-7, PC450LC-7 Hydraulic Excavator.

This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

APPLICABLE MODELS :
Komatsu PC400-7 Hydraulic Excavator SN: 50001 and up
Komatsu PC400LC-7 Hydraulic Excavator SN: 50001 and up
Komatsu PC450-7 Hydraulic Excavator SN: 20001 and up
Komatsu PC450LC-7 Hydraulic Excavator SN: 20001 and up

Komatsu PC400, 400LC, PC450, 450LC-7 mount the SAA6D125E-3 engine.
For details of the engine, see the 125-3 Series Engine Shop Manual.

TABLE OF CONTENTS :
GENERAL
STRUCTURE, FUNCTION
MAINTENANCE STANDARD
TESTING AND ADJUSTING
DISASSEMBLY AND ASSEMBLY
OTHERS

Downloadable : YES
File Format : PDF
Requirements : PDF Reader
Compatible : Windows & Mac
Language : English
Total pages : 782

This manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.

STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.

MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together. 

 http://www.2shared.com/document/ItdA6ooU/Komatsu_PC400-7_PC400LC-7_PC45.html

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Tecumseh Engine Modal 3203 Owners manual

Tecumseh Engine Modal 3203 Owners manual. This vehicle is not licensable. IT IS NOT TO BE OPERATED ON ANY PUBLIC ROAD, STREET, SIDEWALK or ALLEY. To do so would be a violation of local law. This vehicle may be operated only on private property and upon areas approved by local law. 2. This vehicle should NEVER be operated indoors. The exhaust from the engine contains carbon monoxide, which is tasteless, odorless, and poisonous gas. 3. This Fun-Kart is not intended nor designed for racing. 4. The operator of this vehicle should always wear a D.O.T approved helmet and other protective equipment as recommended by state and local laws. The operator should also wear face shields or goggles, boots, gloves, and other appropriate protective clothing. 5. Unless otherwise specified in this manual, all screws, nuts, and bolts must be kept tight to ensure that the vehicle is in safe operating condition. The engine must be kept free of all dirt and other accumulations, paying particular attention to throttle linkage area. 6. Prevailing Torque type locknuts lose their locking capability with repeated use and require replacement. Ensure locknuts are functioning properly. 7. The tire pressure should be checked prior to each use. The recommended inflation pressure is the maximum tire pressure which is printed on the tire’s sidewall. Improper tire pressure may cause instability and may prevent proper braking or steering. 8. Modification of this vehicle or removal of any original equipment or safety decals may render the vehicle unsafe or illegal. Never remove any chained guard, or belt clutch guard. These covers are for the riders’ protection. 9. The vehicle should never be started without first checking to see that the throttle is in idle position. Do not start engine without verifying proper function of the throttle.
Download: Tecumseh Engine Modal 3203 Owners manual

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