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KOMATSU INDIA PRIVATE LIMITED

A project report

By

M.YESHWANTH RA1611002020107

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

SRM UNIVERSITY

2016-2020

Manager Senior AGM. Deputy Manger


(MANUFACTURING (MANUFACTURING AND (HUMAN RESOURCE)

ENGINEERING) PLANT ENGINEERING)


AKNOWLEDGEMENT

I would like to thank Mr.S.Srikrishna- director, Sr. VP HRD for offering


me this wonderful opportunity. I would thank Mr.G.Prakash –human
resource department, Mrs.Shahira-human resource department, Mr.
G.Prabhakaran – manufacturing engineer for supporting me throughout
the training period and Mr.karthik, engineer for guiding me. I would like
to extend my hearty thanks to all stage heads and quality assurance team
for providing me with valuable knowledge. I would like to thank all the
technical employees of KOMATSU India private limited for sharing
their experience, knowledge and helping throughout my training period.
CHAPTER NO. TITLE

1. INTRODUCTION
1.1 HISTORY
1.2 HISTORY OF KIPL

2. DUMP TRUCK
2.1 KOMATSU HD 465
2.2 KOMATSU HD 785
2.3 FABRICATION PROCESS
2.4 ASSEMBLING PROCESS

3. EXCAVATOR
3.1 PC 71
3.2 PC 130
3.3 PC 210
3.4 PC 300
3.5 PC 350
3.6 PC 450
3.7 FABRICATION PROCESS
3.8 ASSEMBLING PROCESS
1. INRODUCTION

Komatsu Ltd. (株式会社小松製作所 Kabushiki-gaisha Komatsu Seisakusho) or Komatsu is a


Japanese multinational corporationn that manufactures construction, mining,
and military equipment, as well as industrial equipment like press machines, lasers
and thermoelectric generators.[2] Its headquarters are in Minato, Tokyo, Japan. The corporation
was named after the city of Komatsu, Ishikawa, where the company was founded in 1921.
Worldwide, the Komatsu Group consists of Komatsu Ltd. and 182 other companies (146
consolidated subsidiaries and 35 companies accounted for by the equity method).
Komatsu is the world's second largest manufacturer of construction equipment and mining
equipment after Caterpillar. However, in some areas (Japan, China), Komatsu has a larger share
than Caterpillar. It has manufacturing operations in Japan, Asia, Americas and Europe.

1.1 HISTORY

Komatsu Iron Works was started by Takeuchi Mining Industry as a subsidiary to make
industrial tools for the parent company. Komatsu eventually became large enough to sell to the
public, and was spun off on May 13, 1921 as Komatsu Ltd.
Komatsu produced its first agricultural tractor prototype in 1931. Through the 1930s, Komatsu
also produced tractors for the Japanese military, as well as bulldozers, tanks and howitzers.
After World War II, under its new president Yoshinari Kawai, Komatsu added non-military
bulldozers and forklifts to its line of equipment. In 1949 it began production of its first diesel
engine. Its growth as a company was aided by the strong demand for its bulldozers during
Japan's post-war reconstruction in the 1950s. In August 1951 the corporate headquarters were
moved to Tokyo. By 1957 the company had advanced technologically to the point that all its
models were using Komatsu engines.

Komatsu 61PX dozer


Expansion overseas was a major focus in the 1970s, with Komatsu America Corporation being
established in February 1970 in the United States. A year later, in January 1971, Komatsu
Singapore Pte. Ltd. was established in Singapore. September 1974 saw the founding of Dina
Komatsu Nacional S.A. de C.V., a joint venture with truck maker DINA S.A. in Mexico. April
1975 was the founding Komatsu do Brasil Ltda. in Brazil. This company produced
the Komatsu D50A bulldozer, marking Komatsu's first offshore production of construction
equipment. Komatsu Australia Pty., Ltd. in Australia was established in Feb. 1979.
Komatsu and Dresser Industries established Komatsu Dresser to make mining tractors and
related equipment in 1988. This 50-50 ownership lasted from September 1988 to August 1994,
when Komatsu bought out Dresser's share. Komatsu's mining products were consolidated under
the name Komatsu Mining Systems in 1997. To prevent brand-name confusion during these
corporate changes, the name "Haulpak" was used for the product line Komatsu began with
Dresser. The name "Haulpak" dates back to 1957 when LeTourneau-Westinghouse introduced a
range of rear dump trucks known as "Haulpaks". LeTourneau-Westinghouse equipment later
became known simply as WABCO equipment in 1967. The name Haulpak was an industry term
that eventually became applied to any type of rear dump truck. A detailed history of the
development of the Haulpak can be found in Wabco Australia.
In 1989, Komatsu bought a share of Hanomag AG and since 2002 Komatsu Hanomag GmbH has
been a 100% subsidiary of the global company.
During the 1990s Komatsu had a joint venture in Europe with Moxy were Komatsu designed
Articulated Dump Truck were built under license for the European market by Moxy. (In 2008
Moxy was taken over by Doosan of Korea.).
In 1993, two joint ventures were formed with Cummins; Komatsu Cummins Engine
Corporation (KCEC) to manufacture Cummins engines in Japan, and the Cummins Komatsu
Engine Corporation (CKEC) to manufacture Komatsu engines in the United States. Another
joint venture was set up in 1997 to manufacture industrial engines in Japan.

1.2 HISTORY OF KIPL

(1958)-Komatsu Initiated Business in India


(1965)-Established First Office at Kolkata
(1966)-Komatsu Initiated Manufacturing in India
(1997)-Appointed Distributor in India
(1998)-Established Manufacturing Facility in Bangalore
(2006)-Komatsu expanded its Business
(2007)-Established Komatsu India Pvt. Ltd.
(2008)-Established Industrial Machinery Division
(2009)-Established Parts Distribution Center
Expanding its presence throughout India
2. DUMP TRUCK

DUMP TRUCK AND ITS SPECIFICATIONS

A dump truck (known in the UK as a dumper/tipper truck) is a truck used for transporting
loose material (such as sand, gravel, or demolition waste) for construction. A typical dump truck
is equipped with an open-box bed, which is hinged at the rear and equipped with hydraulic
rams to lift the front, allowing the material in the bed to be deposited ("dumped") on the ground
behind the truck at the site of delivery. In the UK, Australia and India the term applies to off-
road construction plant only, and the road vehicle is known as a tipper, tipper lorry (UK, India)
or tip truck (AU).

There are two types of dump trucks assembled in the plant . one is model 465 and the other is
785. The parts for the dump truck are imported from different countries and only the assembling
of dump truck is done in this plant 1.

DUMP TRUCK HD465 DUMP TRUCK HD785


2.1 DUMP TRUCK HD465

Komatsu HD465
Standard Body

Type Rigid

Max. Gross Vehicle Weight 99,680 kg

Net Power 715 HP

Engine speed 2000 rpm

Max Payload 55 tonnes

Heaped Capacity 34.2 cu. m.

Max Travel Speed 70 kmph

Limestone Body
Type Rigid

Max. Gross Vehicle 110,180 Kg


Weight

Net Power 715 HP @ 2000


rpm

Max. Payload 55 Tonne

Heaped Capacity 40 cu. M

Max. Travel Speed 70 Mph


2.2 DUMP TRUCK HD785

Komatsu HD785

Type: Rigid
Max. Gross Vehicle Weight: 166000 kg

Engine
Power: Net 1178 HP
Engine speed: 1900 rpm
Max Payload: 91 tonnes
Heaped Capacity: 60 cu. m.
Max Travel Speed: 65 kmph
2.3 ASSEMBLING PLANT FOR DUMP TRUCK (PLANT 1)

The assembling plant is split into three lanes. The center lane has welding for main frame then
paint booth for painting the main frame, then the 5 stations for assembling the truck together
.Then the modification area. On the left side we have two sub stations , one is pressure
accumulator sub and the other is platform sub.

The right lane of the plant consists QA sub , hydraulic , radiator , cabin , transmission , engine ,
assembly rear axle, rear axle motoring sub.

1. WELDING AREA
The fabrication of the main frame is done in the welding area . the locally imported frame
is fabricated by tact and saw welding, then sent for the painting.

2. PAINT BOOTH
The fabricated main frame is painted here and is sent for assembling

3. MAIN LANE
The stations are split up into 5 . Each station assembles a part to the dump truck. The
radiator ,engine, wheels and the cabin of the dump trucks are assembled in this 5 stations.

4. QA
Parts of the main frame are checked here by the inspection crew.

5. HYDRAULIC AND FUEL FILLING SUB


The hydraulic oil and the fuel is filled in the dump truck. the hydraulic oil helps in
suspension and lifting the weights.

6. RADIATOR SUB
The assembling of radiator into a fully finished part is done here.

7. CABIN SUB
The cabin for the dump truck is assembled and finished . the lining for the cabin is also
done here.

8. ENGINE SUB
The engine of the dump truck is checked here
9. REAR AXLE SUB
The rear axle is assembled in this sub

10. MODIFICATION AREA


The finished dump truck is checked by the specialists and then made to run . after the
checking the dump truck is brought back to the modified area and is separated for the
dispatch for shipment.
3. EXCAVATOR

EXCAVATOR AND ITS SPECIFICATINOS


Excavators are heavy construction equipment consisting of a boom, dipper (or stick), bucket and
cab on a rotating platform known as the "house". The house sits atop an undercarriage
with tracks or wheels. They are a natural progression from the steam shovels and often
mistakenly called power shovels. All movement and functions of a hydraulic excavator are
accomplished through the use of hydraulic fluid, with hydraulic cylinders and hydraulic
motors. Due to the linear actuation of hydraulic cylinders, their mode of operation is
fundamentally different from cable-operated excavators which use winches and steel ropes to
accomplish the movements.

Usage
Excavators are used in many ways:

 Digging of trenches, holes, foundations


 Material handling
 Brush cutting with hydraulic saw and mower attachments
 Forestry work
 Forestry mulching
 Construction
 General grading/landscaping
 Mining, especially, but not only open-pit mining
 River dredging
 Driving piles, in conjunction with a pile driver
 Drilling shafts for footings and rock blasting, by use of an auger or hydraulic drill attachment
 Snow removal with snowplow and snow blower attachment

There are 5 types of excavators which are been facbricated and assembled in the komatsu plant
. the plant is spilt up into two . one is for the fabrication of excavators and the other for
assembling.
3.1 PC 71

Operating Weight 7050 kg


Standard Attachments
Backhoe Boom - 3.71 m
Stick - 1.65 m
Bucket - 0.3 cu. m.
Dozer Blade - 2.26 m
Optional Bucket 0.09 cu. m. - Trenching
0.35 cu. m. – GP
0.3 cu. m. – HD (Granite)
Engine
Make KOEL
Power (SAE J 1349) 60 HP
Engine Speed 1900 rpm
Hydraulic System HydrauMind
Swing Speed 12 rpm

Options Lifting Arrangement for Machine


Rock Breaker, Cold Start Kit, Air Prefilter, Front Cab Mesh,
Tunnel Attachments, Long Arm (2.25m)
3.2 PC 130

Operating Weight 12600 kg


Standard Attachments
Backhoe Boom - 4.6 m
Stick - 2.1 m
Bucket - 0.64 cu. m.
Monitor Self-Diagnostic, Facilitating Trouble Shooting
Options Rock Bucket - 0.53 cu. m.
GP Bucket - 0.70 cu. m.
HD Bucket- 0.64 cu. m.(Granite)
Rockbreaker Adaption Kit
Air Conditioned Cabin
Service Valve Kit
Long Arm (2.5m)
Cab Mesh Guard
Return Line Filter
Engine
Make KOMATSU
Power (SAE J 1349) 89 HP
Engine Speed 2200 rpm
Hydraulic System HydrauMind
Swing Speed 0~11 rpm
3.3 PC 210

Type Crawler Mounted


Horsepower 147 HP @ 2000 rpm
Operating Weight 21.6 T
Standard Attachments
Backhoe Boom - 5.7 m
Arm – 2.4 m
Bucket - 0.85 – 1.7 cu. m.
Swing Speed - 12.4 m
Standard Equipment Komtrax
AC Cabin
Self – Diagnostic TFT Monitor with EMMS
6 Working Modes
Seven Spool for RB Adaptation
Optional Equipment 500 mm Track
2.9 m Arm
RB Adaptation Kit
HD Spec / Non- AC Cabin
3.4 PC 300

Operating Weight 33300 kg


Standard Attachments
Backhoe Boom - 6.47 m
Stick - 2.22 m / 3.2 m
Bucket - 1.4 cu. m. – 2.1 cu. m.
Monitor Self-Diagnostic, Facilitating Trouble Shooting
Engine
Make Komatsu
Power (SAE J 1349) 242 HP
Engine Speed 1900 rpm
Hydraulic System Hydraumind
Swing Speed 9.5 rpm
Optional Equipment Rock breaker Adaptation Kit
AC Cabin
3.5 PC 350

Operating Weight 33300 kg


Standard Attachments
Backhoe Boom - 6.47 m
Stick - 2.22 m / 3.2 m
Bucket - 1.4 cu. m. – 2.1 cu. m.
Monitor Self-Diagnostic, Facilitating Trouble Shooting
Engine
Make Komatsu
Power (SAE J 1349) 242 HP
Engine Speed 1900 rpm
Hydraulic System Hydraumind
Swing Speed 9.5 rpm
Optional Equipment Rock breaker Adaptation Kit
AC Cabin
3.6 PC 450

Operating Weight 45000 kg


Standard Attachments
Backhoe Boom – 7.06 m
Stick - 2.6 m
Bucket – 3.1 cu. m. (Optional Bucket – 1.9 cu. m/2.6 cu.m/ 2.85 cu. m)
Monitor Self-Diagnostic, Facilitating Trouble Shooting
Optional Equipment Automated Centralized Lubrication System
RB Adaptation KIT
Engine
Make KOMATSU
Power (SAE J 1349) 330 HP
Engine Speed 1850 rpm
Hydraulic System HydrauMind
Swing Speed 9 rpm
3.7 FABRICATION PLANT FOR EXCAVATOR (PLANT 2)

The fabrications of revo frame and the track frame are done here. The plant is split up into three
column . One for track frame, the other for revo frame and the last one is for the boom and arm.

The fabrication is done by using different welding process .Each welding process is described
below. The products are also checked before and after the fabrications.

1. QA

This crew checks if the product has any minor defects or change in structure after the
fabrication is done.

2. FIXTURE AREA

The parts are fixed with in a fixture and are made to combine with a tack welding for a
support.

3. RAW

Raw is known as robotic arm welding , the welding is done by a robot. This welding is
done after the tact welding for a strong support. The robot welds the joints of the two
parts above the tact welding.

4. SAW

This is known as semi atomatic welding. The parts after the raw welding is made to
undergo semi atomatic welding for the left out edges which doesn’t get welded by raw.

5. SHORT BLASTING

Shot Blasting is also used for removing burrs, scale and rust that may interfere with
the part's integrity, appearance or definition. Shot blasting can also prepare the surface of a part
for coating by removing surface contaminants and provide a surface profile for increased
coating adhesion.
Shot Blasting is different than Shot Peening which is used to induce compressive
stresses on a part's surface for increased fatigue life, increasing the part strength or preventing
fretting.
6. PAINT BOOTH

Painting booth is used to paint the finished products . The finished material is made to go
inside a booth where the robot paints all the parts seperatly.
3.8 ASSEMBLY PLANT FOR EXCAVATOR (PLANT 3)

The fabricated boom ,arm ,track frame, revo frame are shifted to plant 3 which is
assembling plant. The assembly plant assembles all the parts together. The assembly
plant is divided into three columns. The first column assembles the track frame ,track
shoes and fills the grease and the places the engine .There are even small subs left side of
the plant. The small sub assembles the cabin , radiator and arm and the bucket. After the
fixture of these parts , the track frame is moved to the second column where the marriage
assembly takes place. This column fills the hydraulic oil and fuel . before that the swing
machine and the main valve is connected to the excavator.
The boom is then connected to the half finished excavator use using a crane to move the
boom from column 1 to 2. After fixing the boom the bucket is fixed .
Then the finished excavator is shifted to the third lane for flushing. After flushing the
vehicle an inspection is completed for any defects. Then the machine is sent for the repair
and painting . after the painting , once again the vehicle is going through an inspection.
After checking everything , the excavator gets ready for the shipment.

1. TRACK ROLLER SUB

The rollers are fixed to the track frame . then the track frame is sent to track lane.
2. TRACK SHOE SUB

The track shoe is fixed in this area by placing the track frame above the stretched
track shoe.
3. GREASE FILLING SUB

The grease is filled for a smooth movement and for reducing the friction
4. CABIN SUB

The cabin interior connections are connected in this sub.


5. RADIATOR SUB

The radiator is fixed in the machine


6. MAIN VALVE AND ENGINE SUB

The main valve for the excavator is fixed into the track frame and then the engine is
also placed in between the track frame for the rotation.
7. FLUID FILLING SUB

The hydraulic fluid is filled into the excavator. The fuel is also filled into the
excavator for the engine.
8. COUNTER WEIGHT ASSY

The counter weight for the excavator is fixed here. The counter weight helps the
excavator balance the weight correctly.
9. BOOM, ARM AND BUCKET ASSY

The three parts are assembled step by step in the excavator. The parts are lifted using a
crane and moved from one lane to another for fixing.
10. FLUSHING AREA

The finished excavator is water washed and sent for an inspection for checking any
defects. The excavator is operated and made to move into all the directions for
checking. The excavator is made to undergo several levels for testing.
11. REPAIR, PAINTING AND DECAL

The checked excavator is dent for painting. The painting for the excavator is fully
man powered. Once the painting is finished, The layer of the paints after checked for
a perfect paint coating using a lazer device.
12. SHIPMENT

After a long process of fabrication and assembling the excavator is ready for the
shipment at the shipment area.