MINE MAINTENANCE
Komatsu delivering value through full-service solutions
Komatsu’ s underground aftermarket offering is designed to deliver maximum value throughout the lifecycle of its machines, with a philosophy that spans the entire value chain – from new equipment development to proactive maintenance and optimisation.
The OEM begins with new machine development and manufacturing, ensuring every unit meets stringent safety standards and undergoes rigorous compliance testing. This commitment to quality reduces the risk of downtime and safeguards the workforce from day one, it says.
To extend equipment life and optimise investment, it offers complete and mini rebuild programs. These cost-effective solutions restore machines to near-new condition, delivering significant savings while maintaining high performance standards, according to the company.
The Komatsu component remanufacturing and service exchange programs cover all major drivetrain, fabrication / steel and hydraulic components. Each remanufactured part is tested and certified in advanced facilities, guaranteeing OEMlevel quality and reducing lead times to keep its clients’ fleets operational.
Komatsu’ s specialised on-site inspection and reliability optimisation teams provide proactive support by analysing machine performance in real-world conditions. These experts identify opportunities to improve efficiency and reduce maintenance costs, while its tailored training programs empower teams to implement best practices.“ The result is improved uptime and extended component life, translating into lower total cost of ownership,” the OEM says.
For operations requiring flexibility, the Komatsu rental services provide access to the latest equipment without the burden of capital investment. This allows clients to scale quickly and maintain productivity without compromising on quality or safety.
Finally, Komatsu offers on-site service, repair and maintenance contracts to keep machines running at their best.“ With skilled technicians available on-site, we help prevent unplanned downtime and ensure consistent performance, giving you peace of mind and predictable maintenance costs,” it explains. needs, the company says.
ME Elecmetal says it delivered a“ comprehensive fastening proposal” for SAG mill liners, fully aligned with the parameters of the SBS. The solution was structured into three stages( training and preparation, maintenance and implementation, and online monitoring) to ensure both operational excellence and long-term reliability.
To further enhance reliability, ME Elecmetal conducted a liner-specific study to determine the optimal installation tension. The solution incorporated Ridgeback – ValleyForge bolts, offering a superior fit and secure seating within the liner bores, ME Elecmetal claims.
Additionally, tension sensors were installed to continuously monitor fastening performance throughout the campaign, verifying that the recommended installation tension of 77 t was consistently achieved and maintained.
“ The benefits are primarily focused on improving and optimising key indicators of safety, reliability, availability and productivity of critical mining equipment,” ME Elecmetal says.“ This is achieved by ensuring proper operation and adopting a predictive approach to the performance of fastening systems for mill liners, campaign after campaign.”
ME Elecmetal says its SBS delivered measurable improvements in fastening performance and asset reliability.
“ By recording and monitoring installation tensions, the system enabled early detection of deviations during the installation process,” it said.“ This proactive approach allowed timely re-torque adjustments, preventing potential failures or breakages and ensuring consistent fastening integrity throughout the campaign.”
Leveraging the factory-direct model
Conveyor belts might not be quite as visually imposing as rope shovels, but the impact they have on an operation is just as – if not more – significant.
Generally, when operators install retrofitted conveyor solutions, they focus on the up-front price with little consideration for the cost of ongoing service, maintenance costs and supply chain, according to Martin Engineering. But, down the road, when critical service or parts are needed, the cost per minute difference between days and weeks of downtime, or keeping the system limping along at 25-50 % production, can amount to an entirely new equipment retrofit.
“ This is why having a close relationship with equipment manufacturers and / or their certified contractors that offer responsive‘ factory direct’ products and services is important to the cost of operation,” Martin Engineering says.“ The main factors to consider are service availability, technical expertise / safety and supply chain logistics. Reliable and timely site visits are a hallmark of a solid partnership between the operator and the factory-direct manufacturer. Service technicians and certified representatives who are available during problem-free uptime are likely to be responsive during panic-inducing unscheduled downtime, too.
During these visits, a reputable equipment manufacturer representative will examine not just their components but the entire conveyor system, offering preventative maintenance support. The goal is to find indicators of the causes of downtime and offer practical and timely solutions.“ For example, Martin’ s Walk the Belt™ program is specifically designed for predictive maintenance,” the company says.“ A Martin Service Technician or certified contractor will physically examine the entire system with an extensive checklist and then write a report, often with photos, of observations, recommendations and solutions to improve safety and efficiency.”
When it comes to technical expertise, the top equipment manufacturers consistently iterate on previous designs, seeking to improve safety and efficiency. Factory-direct technicians and certified contractors from these reputable equipment manufacturers respond quickly to calls and arrive equipped to diagnose and solve issues, minimising downtime.
Often, during the installation of retrofitted equipment, some creative engineering is required to make components fit, secure and operational. Maintenance crews can’ t have a replacement part for every bolt in their operation, especially if storage space is limited.“ This becomes acutely apparent when specialised parts are needed for repair,” the company says.“ Equipment designs should have standard, easy-tounderstand parts and procedures.”
The cost savings for a factory-direct relationship are only realised over time when that relationship is replaced by a cheaper, less reliable equipment solution from a manufacturer without the infrastructure to offer adequate service.
“ When operators realise the overall cost savings of the factory-direct model, then they understand how service, expertise and supply chain are intertwined to offer a full long-term solution,” Martin Engineering says.
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46 International Mining | JANUARY 2026