SMS Equipment uses Expander pins in new Komatsu haul truck ...

Just north of Fort McMurray lies one of SMS Equipment’s largest branches—strategically located to support the heart of Canada’s oil sands and mining operations. As a world-class provider of heavy equipment solutions and one of the largest independent Komatsu dealers globally with over 40 branches, SMS Equipment supplies the equipment, parts, and services needed to keep these critical operations running efficiently. The branch employs approximately 600 people and plays a key role in maintaining machine fleets and performing on-site assembly of large mining machinery, such as haul trucks, for industry-leading mining companies.

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For one of their projects, SMS Equipment outfitted an alternative pin solution for a Komatsu 980E with the Expander® System. Let’s look at why and how. 

The complexities of traditional pin installation and removal

Anyone who has stood next to a haul truck used in mining knows their massive size. For those who have not, and to put it simply – these are huge machines, working at horsepower with over 1 million pounds operating capacity (total operating weight) and 400 standard ton capacity. Considering the tough working conditions and weight of materials transported from the pits, such sizes, allowing for high operating capacities, are highly necessary. 

However, due to their size, installation, repairs, and maintenance can be time-consuming and require proactive safety measures to protect operators and technicians.

Traditional installation, maintenance, and removal of pins typically involve large torque wrenches, sledgehammers and techniques such as line boring. But with these tools being rather clunky to maneuver, requiring strenuous work through pulling or beating, and the use of high temperatures, the risk of accidents and injuries is always imminent. 

SMS Equipment continually explores solutions and technologies that enhance safety and reduces downtime, and for the last decade, they have turned to Expander.

Expander has provided us with a very unique product in the pin world. It’s a great solution when it comes to field installations, safety, life-cycle support, reducing our customers downtime, maintenance, and physical labor to rebuild certain components.

Alex Kitsinelis, Operations Manager, Fort McMurray, SMS Equipment

Link to ME Mining

A safer, more effective alternative

Based on their positive experiences with Expander, SMS Equipment decided to use Expander pins as original components when piecing together a Komatsu 980E haul truck. This meant that the Expander System was installed on all pivot pin positions of the truck.  

Expander was brought in as a partner to provide additional options for haul truck pins to allow for easier installation. When we were working on the haul truck, the time savings were incredible, and the pins went in so quickly and easily.

Brenda Wolski, Mining Product Support Representative, SMS Equipment

Previously, SMS Equipment used Expander pins primarily as a spare parts solution for aftermarket repairs and maintenance. Therefore, the project with the Komatsu 980E was unique since it marked the first time Expander pins were installed in a brand-new Komatsu.  

The project used our new mining standard, which is a multi-bolt design that has a lot of new features. It allows technicians to use standard hand tools for installation and removal with lower torque values.

Nicholas Addington, Global Mining Segment Manager, Nord-Lock Group

Easier operations for a range of benefits

Whether for safety, time or cost saving reasons, SMS Equipment leverages the Expander System for its ability to support technicians in performing safer and more efficient installation, removal, and maintenance on haul trucks.  The use of multiple smaller bolts simplifies installation, while the Expander technology eliminates the need for traditional removal methods such as lancing or forcefully driving pins out of the bores. SMS Equipment also utilized the Expander System’s slide hammer, which, once inserted, enables both pushing and pulling of the pins for easier removal.

Watch the video to see SMS Equipment fitting Expander pins on the Komatsu 980E, including the multi-bolt pivot pin and slide hammer in action, and hear them elaborate on more benefits of the Expander System. 

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The HD785-8 off-highway haul truck from Komatsu America Corp. has been built to ensure optimal comfort, productivity, and safety for heavy equipment operators.

The Tier 4 Final compliant rigid frame haul truck has a rated payload of 101.6 US tons for high production mining, quarrying, and aggregate applications. The truck’s oil cooled, multiple-disc brakes on all four wheels provide excellent retarding capability for downhill travel while the Komatsu SAA12V140E-7 engine outputs 1,140 net horsepower for high productivity on grade. 

Komatsu Traction Control (KTCS) comes standard on the HD785-8 and provides optimum traction in various ground conditions. 

The HD785-8 has the best-in-class tight turning radius at 10.1 m (33 ft. 2 in.) thanks to its McPherson strut type front suspension for excellent maneuverability when spotting or positioning to dump. The McPherson strut type front suspension has a special A-arm between each wheel and the main frame. The wider space created between the front wheels and the main frame increases the turning angle of the wheels. The larger turning angle provides a smaller turning radius for the truck.

Maintenance benefits

In addition to offering reliability and durability, the HD785-8 offers operators and maintenance staff the advantage of not requiring diesel exhaust fluid (DEF) or selective catalytic reduction (SCR) technologies.

“We achieve Tier 4 final regulatory compliance with two DPF canisters on the machine,” Witkowski says.

“There are lots of inherent issues with DEF, and the fact that it freezes up in cold climates and then needing heating systems inside the machines,” Heddle adds. “When people think of Tier 4, they think of DEF, but it’s not on the HD785-8. It’s a very mature truck. Very sophisticated and reliable.”

The haul trucks also come standard with an auto idle shutdown feature to help reduce idle times and operating costs.

“It automatically shuts down the engine if the truck is left in an idle state. The threshold can be anywhere from five to 60 minutes,” Witkowski says.

Additional maintenance-friendly features include an advanced monitoring system with onboard diagnostics with no laptop required; anchored tie of points (ISO ) around the machine for providing technicians locations to attach service lanyards; fast fuel fill coupler; ground level battery isolator; starter isolator and machine immobilization switch with lockout/tagout capabilities; a jump start receptacle; a modular radiator core system; and KOMTRAX Plus for remote access to maintenance and performance information. “There are lots of service points in it. The HD785-8 is laid out very service friendly. There’s lots of room around the engine to access things – centralized grease points, ground-level servicing. Komatsu puts a lot of effort into this,” Heddle says. “This truck has very good wiring systems and hydraulic systems all well laid out for the operator to be able to access.”