Presentazione di PowerPoint

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Welcome to the AFTER SALES MEETING 2005
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MAY 10th Service session
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Today aims
General overview on 2004 activities New
activities and tools forecasted for
2005 Technical briefing
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• Create a closer relation between Komatsu
  network and Komatsu Division in Italy
• Service support
• Production plant (Luzzara factory)
• KFL

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Technical Documentation

• 2004-2005 Activities overview
• Service Bulletins in 4 languages EN, DE, FR, IT
• Enhanced availability of EU languages for
  Operators Manuals
• AX50 and BX50 operators manuals in EN, DE, ES,
  FR, IT, HU, CZ, EL, PL
• www.komatsuforklift.net
• the newest KFL electronic documentation available
  on the site
• European production documentation
• Service page
• NOVA IPC (Illustrated Parts Catalogues)

2005 NEWS
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Technical Documentation

• Service page

DOWNLOAD AREA 109 operator manuals 39 parts
books 29 workshop manuals 358 Service Bulletins
and News
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NOVA Illustrated Spare Parts Books
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NOVA web spare parts books

• NOVA spare parts book publication on June 1st
• Main features
• Web parts books
• this tool allows the web publication of parts
  books on web, and it will be used for KOMATSU
  European production
• together with CSS-net the web publication in
  electronic format is now complete for all the
  KOMATSU range
• Interaction with ISA SAP Internet Sales
• illustrated electronic parts books are available
  for the choice of spare parts and direct transfer
  of the parts order to ISA
• No-licence

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NOVA web spare parts books
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NOVA web spare parts books
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NOVA web spare parts books
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NOVA web spare parts books
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NOVA web spare parts books
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NOVA web spare parts books
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NOVA web spare parts books

• WEB features
• Books choice and load
• The user can choose one of more books for
  navigation the choice of a single books provides
  best performances
• Books navigation
• Cover
• Pages
• Interactive graphics and list of parts
• Search
• The search functionality is within the complete
  set of books
• Save of a list of parts for future uses
• Pdf file available for print

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NOVA web spare parts books

• OFF LINE version NOVA IPC VIEWER
• The viewer is a stand-alone application that
  allows the navigation of parts books saved on
  hard disk
• NOVA IPC VIEWER installed on the DIAGNOSYS
  DATACASE
• The next update of the Diagnosys Datacase will
  include the installation on the NOVA IPC VIEWER,
  and the complete set of up-to-date parts book
• NEW and UPDATED parts books available on KD web
  site www.komatsuforklift.net

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NOVA web spare parts books
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NOVA web spare parts books

• UPDATE PROCESS
• NOVA web application will include the parts
  books up-to-date
• (Service Manuals CDs last version 2003 NOVA
  books up to year 2005)
• NEW BOOK or UPDATE BOOK
• The parts books publication process is completely
  new, so that the electronic format is the main
  and first result the printed copy is just an
  additional funtionality of the issue
• IMMEDIATE AVAILABILITY ON WEB
• IMMEDIATE AVAILABILITY ON www.komatsuforklift.net
  for download

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Trainings activity
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Academy Technical Trainings
TRAINING TARGETS

• REDUCTION OF SERVICE MAINTENANCE TIME

• IMPROVEMENT IN CUSTOMER SATISFACTION

• HUMAN RESOURCE DEVELOPEMENT

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ACADEMY 2004
66 TRAININGS
30 WH
9 IC
25 ECB
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ACADEMY 2004, KOMATSU
21 TRAININGS
16 WH
1 IC
4 ECB
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Training requirements audit (Dec. 2004)

• 2005 PLANNING ( 1st half)

12 TRAINING REQUIRED
8 TRAININGS ON CALENDAR 6 FULLY PARTECIPATED
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ACADEMY 2005, KOMATSU YTD
7 TRAININGS
4 WH
0 IC
2 ECB
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• Training requirements 2005

to be returned within June 15th
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DIAGNOSTIC CASE
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DIAGNOSTIC DATA CASE
GLOBAL SOLUTION
ALL TRUCKS SOFTWARES
ALL BOOKS
ALL CABLES
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NEW UPDATE
NEW PARADIG SOFTWARE, CAN-BUS CONNECTION, INSIDE
NAVIGATOR SOFTWARE
NEW PC SOFTWARE FOR OLD PMOS NOVA VIEWER ACCESS
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Total TSI
N of TSI received
from all european Komatsu Distributors
Period April 2004 April 2005
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Reason
Low number of TSI means

• No technical problem on Trucks

• Locally solved small technical problems

• Not reported small technical problems

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TSI Distribution
European distribution of TSI (Apr.2004 Apr.2005)
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Feedback
T.S.I. (Technical Service Information)
Advantages of sending feedback by T.S.I

• Check Trucks performance and reliability on Field

• Improve Quality from production line

• Definitive solution from Factory of big and small
  problem, locally solved by Distributor

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Product Quality Reliability problems
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Product Quality Reliability problems
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Field campaign STATUS
Fixed trucks
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Field campaign STATUS
Completed In progress Overdue less than 6
month Overdue more than 6 month
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Field campaign STATUS
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Field campaign
You are reminded that the European Directive
201/95/CE, regarding general product safety, laid
down the distributor to collaborate with the
manufacturer in order to encourage controlling
safety of the products placed on the market.
Failure and/or delay in forwarding the requested
information or in carried out the requested job
is a violation of the provisions Directive and
responsibility will be at Dealer charge.
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Technical briefing Quality and reliability
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Problems discussed INDEX

• AM/E-2R truck
• Vibrations of the steer
• ALARM 65, hours misalignment
• Encoder failure
• Field campaign R05-01

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Problems discussed INDEX

• Warehouse equipment
• Cable failure on electromagnetic brake
• Slackening of bolt on the wheel
• Oil leakage from lift cylinder
• Adjustment of lift-stop sensor
• Oil seal damage

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Problems discussed INDEX

• Warehouse equipment
• Elastomer on pivoting wheel
• Push on the tiller head
• Tiller card failure

• MWQ 20 2R
• Control panel failure

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Problems discussed INDEX

• IC TRUCKS
• AX/BX 20 power sterring cylinder
• CX Clutch drum failure
• DX, inspection of rear hub
• DX, drive gear replacement

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AM/AE-2R Truck
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AM/AE-2R
Steerring Vibrations
Description
On traction at low speed, the truck have
vibrations on steering column. This condition is
caused, specially with triplex mast and very
smooth floor, by superelastic tyres from
Solideal. This problem appears after 200 / 400
working hours.
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AM/AE-2R
Steerring Vibrations
Solution in the Field
New tyre with different design (see image) Is
under testing by 3 Customers. After about 200
working hours the consumption is normal and the
vibrations absent.
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AM/AE-2R
Steerring Vibrations
Solution for Production
The supplier Solideal has increased the hardness
of the intermediate part of the tyre from 58 ShA
to 63 ShA, starting from SN 04 182 xxx (marked on
the tyre), that is from June 30th 2004. This
improvement reduces the vibrations on the truck
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AM/AE-2R
ALARM 65, hours misalignement
Description
Starting from November 2003 production, the truck
has 2 separated hour counters into the Power and
Display modules. At key on, if the two hour
counter have a difference over than 10 hours, the
Alarm 65 appears (Truck not blocked).
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AM/AE-2R
ALARM 65, hours disalignment
Solution on the Field

• See Technical Bulletin W05-03 to solve its
  necessary to install
• On standard trucks
• Eprom FI 0.35 on the power control
• Eprom FI 0.27 on the display
• On Joystick Trucks
• Eprom EJ FI 1.18 on the power control
• Eprom FI 1.40 B on the display
• connect 48V to pin B14
• To ask Eprom, please send request form to KD
  Field Engineers

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AM/AE-2R
ALARM 65, hours disalignment
Solution for Production
The new software with the same modification is
inserted from the Control panel SN F14016S00147
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AM/AE-2R
Encoder failure
Description
Several replacement for encoder fitted on
traction motor
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AM/AE-2R
Encoder failure
Note

• Analisys of the encoder returned under warranty
• A lot of encoder perfectly working its
  necessary to verify that the gap between the
  sensor and the metallic rotor is exactly 0,6 mm
• Some failed encoders has a break on the wire
  near the connector its caused by stress of the
  cable, for example if an object, raised from the
  wheel, crashed on the cable

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AM/AE-2R
Field campaign R05-01KD
Description
An anomalous activation of the traction when the
operator leaves the truck (opening the contact of
seat switch), without pulling the hand brake and
switching off the key in very few cases occurred.
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AM/AE-2R
Field campaign R05-01KD
How the problem was managed

• Communication to inform Distributors
• Communication to final Customers information
  about correct use of the truck
• Field Campaign R05-01KD

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AM/AE-2R
Field campaign R05-01KD
Technical modification
Field Campaign R05-01KD is in progress. A Timer
Card (code 40163607000) must be installed near
the Power Module. It opens the two Line
Contactors 2 seconds after the Operator leaves
the Truck, and it disables the speed control on
descent ramp
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AM/AE-2R
Field campaign R05-01KD
Technical modification

• When the card is installed
• If the Driver is not seated, it appears alarm
  45, until he seats back.
• If the Driver leaves the seat while the
  traction, or any hydraulic function (eg.
  hydraulic steer) are active, a blocking alarm
  will be displayed (ex. Alarm 19, 2, 3, 43)
• To avoid previous alarms its necessary to leave
  Truck with all functions disabled, or to reduce
  the parameter HYDRO TIME

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AM/AE-2R
Field campaign R05-01KD
Mass Production
Starting from SN F14016S00453 the Timer Card is
integrated into the Power Module. In this case
Alarm 45 wont be displayed when the operator
leaves the Truck). Its however necessary pull
the Hand Brake and switch off the key on leaving
the Truck.
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AM/AE-2R
Field campaign R05-01KD
VERY IMPORTANT

• To avoid this or other problem its necessary to
  follow indications inserted into Use
  Maintenance Book, and in particular
• Pull safely the Hand Brake before leaving the
  truck
• Switch off the key before leaving the truck

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Warehouse equipement
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Warehouse
Cable failure on electromagnetic brake
Description

• The supply cable for the elctro-magnetic brake
  fails near the brake body.
• It is caused by
• Too small radius of curve
• Spin of the brake body

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Warehouse
Cable failure on electromagnetic brake
Solution for the Field

• New Connector had been inserted.
• New robotic, super flexible cable fitted (see
  Service Bulletin W05-05)
• New codes
• 45204305701support screw cable
• 45205000600 brake ø 100
• 45265000600 brake ø 120

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Warehouse
Cable failure on electromagnetic brake
Solution for Production

• Same solution as for the Field.
• The solution starting from s.n
• MWS xx FA-1R F14535S00035
• MWS xxW - 1R F14527S00015
• MWS xx -1R F14525S00234
• For other Trucks, modification will be
  introduced within next months

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Warehouse
Slackening of bolt on the wheel
Description

• In case of wheel replacement, in some cases, is
  possible a slackening of bolt that fix the wheel.
• The causes are
• Narrow space to screw the bolt with dynamometric
  key
• Little thickness of bolts head

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Warehouse
Slackening of bolt on the wheel
Solution for the Field and Production

• new hole in the frame to insert the key
• increases bolts head thickness

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Warehouse
Oil leakage from lift cylinder
Description

• On the transpallet, the lift cylinder (code
  452012001) has oil leakage from
• Bottom of cylinder
• Oil seal on the rod of cylinder

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Warehouse
Oil leakage from lift cylinder
Production

• Introduction of new Cylinder (code 45204407700)
  which includes some modifications
• new o-ring in the bottom (90 Sh)
• Loctite in the bottom cap screw
• Improved Quality tests from Supplier
• The modification had been introduced since July
  2004 (GH7 mark on cylinder)

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Warehouse
Adjustment of lift-stop sensor
Description
The gap between the inductive end lift stop
sensor and the battery holder increases, and the
truck does not lift. It is caused by normal use
of the truck,
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Warehouse
Adjustment of lift-stop sensor
Solution for Production and Field

• New type of sensor (magnetic) which has a bigger
  intervention distance. The Service Bulletin
  W05-04 indicates the codes for replacement
• 45203582001 magnet support
• 7915496231for NPN magnetic Sensor, or
  7915496230 for PNP magnetic Sensor
• In June the new sensor magnet will be fitted in
  Production

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Warehouse
Oil seal damage
Description
the oil seal breaks due to accidental
introduction of objects on the wheel
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Warehouse
Oil seal damage
Solution for Production

• Introduction of new Protection to reduce damages
  of the oil seal.
• Introduction in Production
• MWP 18/20-1R F24520R01239
• MWS 10/12-1R F24521R00824
• MWS 14/20-1R F24525R00356
• MWS 14/20A-1R F24528R00080
• MWS 14/20FA-1R F24535R00110
• MWS 14/20F-1R F24523R00519
• MWP 22/30-1R F24526R00118
• MWP 20 FS-1R F24537R00237

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Warehouse
Elastomer on pivoting wheel
Description
On turning, MWP20FS-1R, appears instable. The
cause is not correct rigidity of the elastomer on
pivoting wheels.
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Warehouse
Elastomer on pivoting wheel
Solution for the Field and for Production
The Elastomer type had been changed. It's
possible to recognise the new Elastomer from its
blue color. Modification is fitted from s.n
F24537R00246
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Warehouse
Push-buttons on the tiller
Description
The push-buttons on the tiller, in some case has
short-circuit. On trucks the damage is shown by
INCORRECT START alarm on switching ON. Air
humidity inside the push causes oxidation.
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Warehouse
Push-buttons on the tiller
Solution
Actually new glue is under test by Design
Dept. The new glue reduces the input of humidity
into the push-button.
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Warehouse
Tiller card failure
Description
Several failures occurred on Tiller Card
(code 45203608601 and 452249551)
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Warehouse
Tiller card failure
Solution

• Increased quality of Tiller card by
• New assembling procedure for Support
• New card with automotive components for MWP
  xx-1R, MWP 20FS-1R (start of production from July
  2005).
• New assembling procedure for Support and new
  Card with automotive components, for the other
  trucks, (under test on Design Dept).

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MWQ 20-2R Truck
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MWQ20-2R
Control panel failure
Description
The failure of Control Panel appears with alarm
VFIELD NOT OK on switching on the key.It is
caused by break of Transorb in Field Circuit.
Test with university laboratory showed that the
cause are electrostatic charges accumulated on
the frame
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MWQ20-2R
Control panel failure
Solution for the Field
In case of use of the truck on resin floor or in
presence of palletising machines with belt
winders, it's indicated to mount the protection
card code 45163605100 (see Technical Bulletin
W05-02KD).
Protection card
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MWQ20-2R
Control panel failure
Solution for Production
The protection card code 45163605100 is inserted
in production from s.n F24516S00064
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IC Komatsu Trucks 2004 News
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AX/BX 20
PS Cylinder
Y2004-12 Improved PS Cylider Rod on AX/BX series.
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CX Trucks
Clutch Drum failure
Y2004-001 The clutch drum worn and broken with
the friction plates. Increased the drum wall
thickness from 3 to 4 mm to heighten the
durability. New drum recognizable by a tool mark
on the external drum surface.
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DX Trucks
Inspection of Rear Hubs for a crack
R2004-008 Replacement of both rear hubs with
reinforced hubs (3FD-24-21151SA) in case of
crack. Test those with dedicated penetration dye.
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DX Trucks
Replacement Drive Gear Damage
R2005-009 Risk of damage for final drive gear
under extreme stress. Solution replacement of
improved parts under risk of damage
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