5.9-3 00.5.

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Table of Contents

3 Environment-friendly Products and Services 14

3.1 Solutions for Environmental Activity 15
3.1.1 Conserving the Environment through Technology 15
3.1.2 Environmental Cleanup Technology 21
3.2 Products and Services: Reducing the Environmental Impact 22
3.2.1 Improvement of Fuel Economy 23
3.2.2 Reduction of Exhaust Emissions 24
3.2.3 Reduction of Noise and Vibration 25
3.2.4 Reduction of Environmentally Burdensome Substances 26
3.2.5 Improvements in Recyclability 27
3.2.6 Development of Biodegradable Hydraulic Oil 28
3.2.7 Recycling of Rubber Crawler Shoes 28
3.2.8 Reman 30

5.9-3 00.5.10 5:08 PM 14

3 Environment-friendly Products
and Services

As part of our efforts to conserve the environment, Komatsu

actively develops and promotes the use of recycling equipment to support customers recycle construction waste, and at
the same time, also reduce their costs by doing so. With all
our environmental policies, we work to utilize technological
innovations to control costs. This concept of ecology and
economy in balance guides all of Komatsus technical development related to environmental conservation.

The Promise of Komatsu Technology:

Ecology and Economy in Balance
Technology for
environmental
conservation

Ecology

&
Cost

Importance of Facilitating Rapid

Implementation
Komatsu is striving to develop environment-friendly measures at a reasonable cost that will help to facilitate their
rapid implementation.
Environment-friendly products thus represent a viable
solution to the evolutionary state of environmental issues.
However, if such environment-friendly products were to
increase the customers operating costs, such products would
not proliferate and would ultimately fail to contribute to the
conservation of our earth environment.
For example, in the case of reducing CO2 emissions, environmental policies are directly connected with customer fuel
costs. If appropriate fuel-conserving devices are developed
which will be quickly adopted. In the case of NOx emissions,
however, with conventional technologies, there may be no
cost reduction for the customer or there may even be a cost
increase. Because economic considerations form a barrier to
acceptance in such a case, only taking on the challenge of
technological innovation makes it possible to reduce both
environmental impact and customer costs. Using technological innovation to develop environment-friendly products,
which are also economically beneficial to the customers,
enables us to help improve the environment on a global
scale. This is the meaning of Komatsus ecology and economy in balance policy.

Environmental Forum Incubates Ideas for Ecology and

Economy
The control of manufacturing costs is a constant concern in the
development of products that are respectful of the
environment. No matter how good the product is, the customer
will not be able to employ the product if it is prohibitively
expensive. Therefore, to implement environmental conservation on a continuing basis, we need to devise a new technology
that helps protect the environment while enhancing the manufacturers competitiveness.
The creation of such a technology demands that we see
things from a different perspectivethat we discern the true
nature of the issue and use that as an inspiration for our
research and development. It is not enough simply to extend

14

Economy

Promoting Solutions through Unique

Technologies
Komatsus environment-friendly construction machinery is
a notable example of ecology and economy in balance.
Given our involvement in the construction industry, we
know the disposal of construction waste and excess soil is a
major subject of concern. Of course, waste disposal is not just
a matter of environmental responsibility; it is also a matter
of cost.
We at Komatsu therefore advocate that waste materials be
crushed and recycled on-site to the greatest extent possible.
In fact, the simplest solution is to dispose on-site by crushing,
refining, and recycling the felled trees, boulders, and soil
excavated during preparation and construction. We believe
that this system is about to change the relationship involving
building materials, construction processes, and the environment.
Komatsu offers other unique solutions for customer
engagement in environmental activities, including the processing of contaminated soil and waste recycling at quarry
sites.

our traditional way of thinking. This is the reason that

Komatsu has placed its Environmental Forum on our in-house
computer network database. Through it, we can gather, combine, and develop the views and ideas of our own experts,
whose knowledge encompasses many fields.
Anyone with an idea on how to be more environmentfriendly can casually post a message in the Environmental
Forum. It serves as a means to gather expertise from different
fields, and also provides the means to discover a technology
with which we can contribute to the environment at a higher
level. We are proud to say that Komatsus ecological, economical solutions are the result of brainstorming by experts in various fields. The Environmental Forum has been their network
and the crystallization of their knowledge.

5.9-3 00.5.10 5:08 PM 15

3.1 Solutions for Environmental Activity

3 Environment-friendly Products
and Services

the soil that is excavated by hydraulic excavators is too weak

and unstable to be reused as is, and each year, it becomes
more difficult to secure locations for its disposal. Moreover,
the establishment of new landfills is difficult. Therefore, the
creation of a new recycling method that is not hindered by
conventional methods is being sought. This has prompted
the Ministry of Construction to promote early-stage recycling by mandating recycling to those who order construction.

Komatsu has developed the Mobile Crusher as a means of

achieving on-site recycling of construction waste. Through
this system, materials generated at the construction site can
be recycled without the need to transport them elsewhere for
processing. Mobile Crusher has helped minimize the environmental impact of construction while reducing overall
construction costs.

3.1.1

Conserving the Environment through

Technology

Trends in the Construction Industry

Japans economic recession has placed great pressure on the
construction industry to reduce construction expenses.
Under such circumstances, the increased cost of waste disposal due to the lack of landfill space poses a threat to company profit margins, resulting in the need to employ an efficient, low-cost waste-disposal method.

Trends in Waste Management

Waste is generated through various construction activities
such as building demolition and road construction, which
are designed to improve the public infrastructure. Concrete
debris, wood scrap, and other materials generated in construction are commonly referred to as construction waste or
construction byproducts. This constitutes a major portion of
industrial waste and is hard to handle. Additionally, most of

Amount of Industrial
Waste Generated (FY 1994)

Amount of Construction Waste

Generated by Category (FY 1995)
Other industries
36,657 (9.0%)

Beverage, feed, and tobacco

manufacturers 7,377 (1.8%)
Food manufacturers
11, 856 (2.9%)

Constructiongenerated wood
6 (6%)

Other (waste plastic, waste

paper, metal debris)
1 (1%)

Construction
industry
Mixed construction
76,931 (19.0%) waste 10 (10%)

Chemical industry 17,928 (4.4%)

Nationwide
Total 405,455 Agricultural
thousand tons industry
74,878 (18.5%)

Ceramics and stone-and-clay

product manufacturers
19,425 (4.8%)
Pulp, paper and processed
paper product manufacturers
24,917 (6.1%)

Amount of Soil Generated

by Construction (FY 1995)

Asphalt/concrete
debris 36 (36%)

Nationwide
total 99
million tons

Private civil engineering

18 (4%)

Nationwide
total 446
million m3

Construction
43 (10%)

Steel industry
30,081 (7.4%)

Electricity, gas, heat supply

and water industry
74,610 (18.4%)

Mining Industries 30,793 (7.6%)

(Source: Comprehensive measures against construction byproducts)

Construction sludge
10 (10%)

Public civil engineering

384 (86%)

Concrete blocks
36 (37%)

(Source: Survey on the state of construction byproducts,

Ministry of Construction)

Number of Remaining Years for Landfills

(Source: Survey on the state of construction

byproducts, Ministry of Construction)

Changes in the Value Structure model of Construction

3.5
3.0

3.1

2.5

Decreased unit cost of construction

2.7

2.6
2.3

Gross
profits

2.0

2.0

1.6
1.5

Value

Remaining years

3.0

Disposal
expenses

Increased
cost

1.0

Direct
construction
expenses

0.5
0

1993

1994

1995

1996

1997

1998

1999
Fiscal year

(Source: Nikkei Construction, January 2000)

1990

1999

Fiscal year

15

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Employing an On-site Recycling Construction Method

(toward Zero emission construction)
New road construction generates vast amounts of roots and
felled trees, boulders, and soil through excavation and the
removal of trees. Traditionally, such construction waste and
soil has been transported off-site for disposal. At Komatsu,
though, we hit upon the idea of employing an on-site recycling method in which materials could be recycled and
reused on the premises. Ultimately, the development of an
on-site recycling machine designed for the on-site crushing
and recycling of waste materials became the basis for an onsite recycling construction method.
The presence of a recycling machine at the construction
site will make the crushing of materials more efficient.
Specifically, roots and felled trees can be turned into chips
for mulching or spraying materials; boulders can be turned
into grading materials; and bad soil can be improved for use
as a roadbed material. The result is not only a reduction in
the amount of waste generated but also produces savings in
the use of new materials (resources) and energy for transportation, thereby contributing to environmental conservation. Since the costs associated with waste-disposal, new
materials, and transportation can be kept to a minimum, the
total cost of construction can be drastically reduced.

BR60, the first model of the series marketed in fiscal 1992

16

On-site Recycling Machine: Mobile Crusher

When considering a construction method for on-site recycling, the machinery must be mobile so that it can be set up
in the immediate presence of waste generation. It should also
be compact yet fully capable of handling large amounts of
waste. If the waste could be crushed and processed at the
source, we would be able to minimize our impact on the
environmental, as well as to cut back on construction costs.
To that end, based on customer requests, we established the
following basic structure for our family of mobile recycling
equipment products:
(1) A crawler-type mobile device
(2) A crushing device
(3) A device to feed materials to the crusher
(hopper/feeder)
(4) A device for the discharge of crushed materials (belt
conveyer)
(5) A power unit (engine)
In fiscal 1992, responding to the need to crush debris from a
demolished house so that it could be reused as a banking
material on-site, we put together the Mobile Crusher BR60, a
product equipped with an impact crusher. Since then we
developed a variety of mobile recycling equipment and in
fiscal 1999 we marketed the Mobile Tub Grinder BR200T.
These products have won acclaim in a society that now
avidly promotes recycling.

The BR200T was introduced to the market in fiscal 1999

5.9-3 00.5.10 5:08 PM 17

On-site Recycling Construction Method

Tree-planting
on slopes

Logging

Excavating
Felled trees
Banking

Boulders

Bad soil

Traditional Construction Method

Paving

Recycling

Felled trees

Mobile tub grinder

Mulching materials

Boulders

Mobile crusher

Grading materials

Bad soil

Mobile soil recycler

Roadbed materials

Logging
Tree-planting
on slopes
Excavating
Felled
trees

Transporting to outside
the construction site for
disposal
Transporting

Boulders

Banking

Bad soil

Paving

Disposal

Outside collection
and transport to the construction site

Transporting

Collecting new materials

17

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Our mobile recycling equipment becomes a series

Amid the growing demand for on-site recycling construction
methods, we expanded our range of products. Currently, we
offer a lineup of sixteen models. As a single unit, or as a
small-plant system in conjunction with peripheral units, our
machines continue to serve in site-optimized configurations.

Komatsu has sold roughly 1,400 units of this series products in Japan and 150 overseas, as of fiscal 1999. As a key
component in on-site recycling construction, these units
have contributed to environmental conservation in Japan
and other countries. Moreover, the series has drawn attention for its potential application in other areas, such as junkyards for the disposal of tires and household appliances.

Komatsus Mobile Recycling Equipment Products

Natural rock

Concrete
debris/asphalt
concrete debris

Oversized
garbage
mixtures

Excavated
soil (excess soil)

Wood-based

Mobile crusher
BR200T

Mobile crusher

BZ200, and others

Mobile crusher
Mobile tub grinder

BR300S, and others

BR210JG, and others
Mobile soil recycler

BR1600JG
(made to order)
BR500JG, and others

BR250RG, and others

Supporting the entire product family units on-site

BM2014C mobile belt conveyer

18

BM3618S mobile screen

5.9-3 00.5.10 5:08 PM 19

Application of Mobile Crusher (1): Concrete Debris,

Asphalt Concrete Debris, and Natural Rock

Application of Mobile Tub Grinder (2): Wood-based

waste

Generally, concrete and asphalt concrete debris is made of

most of rock. Therefore, when we remove foreign objects
such as reinforcing steel bars and wood chips from the debris
and crush and sort the remainder, we can recycle that material as base materials used for road grading and construction
backfill. Additionally, we recently began crushing and sorting debris down to midsize blocks ranging between 150 and
250 millimeters for reuse in riverside breakwater work.

Traditionally, trees felled for the purpose of construction

have for the most part been burned on-site. However, the
proper disposal of felled trees has become an issue of concern in recent years, in light of new regulations banning
field burning and the rise of the dioxin problem.
Komatsu proposes a solution in which felled trees can be
processed into wood chips. This material can then be used as
mulch spread over, as well as for fuel. They can also be used
as fertilizer and in the manufacture of board.

Fuji Sand-Control Office, Ministry of Construction: Construction to remove rock

from the Osawa avalanche site at Mt. Fuji, Shizuoka Prefecture, where a downslide
of lava, sand, and stone occurred.

Processing Felled Trees at a Land-reclamation Site in Oita Prefecture

The lava, sand, and rock removed is crushed and sifted through a screen. Fine
pieces of 50 mm or less are utilized in roadbeds and as material to raise the ground
level of houses, while the coarser pieces of 50 to 150 mm are used to build up and
prevent the erosion of beaches.

Conventionally, the foliage, stumps, and roots of trees felled for land reclamation
were burned. Now they can be crushed into chips on-site and recycled for use as
ground cover in reforestation areas or as woodchips or mulch.

Chips after
processing
Lava, sand, and rock accumulated at the Osawa Delta.

Crushed rock from 50 to 150 mm

is utilized in beach construction
projects.

Used as mulch
spread

19

20 00.5.11 3:23 PM 20

Application of Mobile Soil Recycler (3): Excavated Soil

Therefore, Komatsu has developed an on-site, recycling

soil-stabilization method that improves soil quality by combining it with fortifying materials on-site. This is another
product that we have commercialized as part of the series. It
enables excavated soil to be recycled on-site and put to
immediate use as a banking material in the construction
process.

The soil excavated from construction sites has high watercontent, thus necessitating its transport to processing plants
where it is reconstituted. However, with the current small
number of stationary processing plants available, the necessary transport distances tend to be excessive, negatively
affecting the environment and increasing total construction
costs.

Chugoku Highway, Chugoku Bureau of Japan Highway Public Corporation

Completed roadbed improvement work

Improving the roadbed of the Chugoku Highway (Shimane Prefecture)

The dirt excavated at the site has excessively high moisture content and cannot be
used as is. The excavated dirt is therefore improved by mixing it on-site with a
hardening agent. The improved dirt is then used to raise the roadbed. Compared
with conventional methods, this process both improves the quality of the mixture
and increases work efficiency.

Awards won by the Mobile Recycling Equipment Series

The series is widely recognized as construction machinery that contributes to environmental conservation. As such, it has won
the following awards.
Product

Award

Prize

Name

Sponsor

Mobile
crusher

FY 1995 Award for Recycling

Development Project et al

The Minister of
International Trade
and Industry Award

Development project for

mobile crushers

Clean Japan Center

Mobile
crusher

21st Award for Outstanding

Environmental Machinery

Chairmans Award
from the Japan
Society of Industrial
Machinery
Manufacturers

Mobile recycling
debris crusher

The Japan Society of

Industrial Machinery
Manufacturers

Mobile soil FY 1998 Award for Recycling

recycler
Development Project et al

MITI Environmental
Development of mobile
Protection and
Industrial Location
soil recycler
Bureau Directors Award

Mobile soil FY 1999 Chairmans Award

from Japan Construction
recycler
Mechanization Association

Encouragement prize

Clean Japan Center

Development of the BZ200

mobile soil recycler

Japan Construction
Mechanization Association

Mobile soil FY 1999 Outstanding Energy- Chairmans Award

from the Japan
recycler
saving Machinery
Machinery Foundation

BZ200 mobile soil recycler

The Japan Machinery

Federation

FY 2000 Technical Award

Mobile soil
(through joint application
recycler
with Tokyo Gas Co., Ltd.)

Recycling excavated soil

through use of a mobile
soil-recycling plant

The Japan Gas Association

20

JGA technical award

5.9-3 00.5.10 5:08 PM 21

3.1.2

Environmental Cleanup Technology

Apatite Treatment: A Cleanup Technology for Soil
Contaminated with Heavy Metals
Komatsu General Atomics Engineering Corporation* in 1998
introduced a technology developed in the U.S. designed to
clean soil contaminated with heavy metals, and since then
has successfully expanded its activities in the cleanup business.
This metal-contaminated soil-treatment technology turns
toxic heavy metals, which are present in the soil, into a
water-insoluble, nontoxic mineral as an apatite. In this way,
they are prevented from leaching into and contaminating
external media. One of the typical apatite minerals is apatite
hydroxide Ca5(PO4)3OH. Metals with positive ions, such as
lead (Pb), can infiltrate the apatite hydroxide structure
replacing calcium (Ca), thus turning the apatite into Ca5-n
Pbn(PO4)3OH (where n is 5 or less).
The resultant isomorphous apatite naturally exhibits the
fundamental characteristics of apatite minerals. Unlike the
conventional, chemically insoluble treatment, however, the
material turns into a very hard mineral crystal with great

Recycling of Quarry Waste

The inorganic sludge generated in quarry operations has
long been disposed of as industrial waste. However, Komatsu
has discovered that a simple modification to the inorganic
sludge can result in outstanding clay properties and watersolubility. Taking advantage of the properties of this recycled
clay, we have commercialized a soil admixture for use with

leaching resistance over a wide pH range. Furthermore, compared to the cement-fixation method, this treatment barely
affects the condition of a medium like soil.
In 1998, we undertook a consigned research study on
behalf of the Environmental Agency to establish a soil-contamination cleanup technology and verify its feasibility. The
results of that study proved the advantages of apatite cleanup
over chemically insoluble treatments, which heretofore had
been the conventional cleanup method for soils contaminated with heavy metals. In fiscal 1999, the technology was

Cleanup of hexavalent chromium-contaminated Soil Using a Mobile Soil recycler

underground excavators, thanks to a joint project with

Komatsu IM Engineering.* Compared to the conventional
alkaline admixtures, this environment-friendly, pH-neutral
admixture is safe to groundwater.
In fiscal 1999, this admixture was marketed as the excavation
additive Gravel Coat, and proved to dramatically improve
impermeability to water and soil discharge in damp areas.

Admixture Injection Cycle

Clean dumper
Multi planter
Water hose or
slurry hose

Plug zone

3. Agitation and creation of plugs

1. Agitate the water

and admixture,
then pump the
mixture.
4. Adjust the
injection of the
admixture.

2. Injection
Preparing the Admixture
Komatsu General Atomics Engineering Corporation processes hazardous materials, toxic waste, and contaminated soil and develops, manufactures, and sells
related processing technologies and equipment.
Komatsu IM Engineering provides consultation on the operation of pipe-laying
machinery and manufactures and sells excavation additives.

21

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3. Environment-friendly Products
and Services

3.2 Products and Services: Reducing the

Environmental Impact

Construction equipmentKomatsus mainstay productis

employed in the fields of resource development, civil engineering, agriculture, and elsewhere, all of which is intended
to make our lives more comfortable. Yet, at Komatsu, we are
taking the concept a step further. We are working to develop
machines that not only benefit people but also have less of
an impact on the earths environment. It is no exaggeration
to state that the degree of impact a product will have on the
environment is largely determined during the design stage.
Accordingly, Komatsu uses life-cycle assessment (LCA) as a
means of studying the design of its construction equipment.
Today we are striving to achieve the four Midterm
Development Targets for Environmental Technology, which
we have established in accordance with our findings in LCA
research.

Midterm Development Targets for Environmental

Technology (set forth in fiscal 1999)
Objectives
(1) CO2 Emissions
(2) Recyclability
Result of 1998 PC200-681%
fiscal year
WA100-392%
(3) Environmentally
burdensome substances
(4) Life-cycle cost

Fiscal 2005
5 Comparison
to FY 1998 result

Fiscal 2010
10 Comparison
to FY 1998 result

97 or greater

99.5 or greater

50 Comparison 75 Comparison
to FY 1998 result
to FY 1998 result
20 Comparison
to FY 1998 result

Total CO2 Emissions per Lifecycle of 0.7-m3

Hydraulic Excavator
Material

Manufacturing

100

200

Use (10,000h)

300

400

Results calculated according to the Komatsu Engineering Standard.

Introducing the LCA Concept

Komatsu organized a task force in fiscal 1998 in order to do
the groundwork for our implementation of LCA. Studying
the published applications of LCA in various fields, we established a set of standardized, simple calculation methods for
which the common objective was to identify an effective yet
unique approach. In fiscal 1999 with these calculation methods, we then conducted inventory analysis on our major
products with regard to CO2 emissions. The results enabled
us to achieve a better understanding of the burdens these
products would have on the environment. Accordingly, we
established the four Midterm Development Targets for
Environmental Technology as guidelines for the reduction of
our environmental impact.
Concerned by the findings of our LCA activitieindicating that an overwhelming proportion of total CO2 emissions
is generated during the use of machinerywe turned our
efforts toward research and development, based on a comprehensive approach to emissions reduction that would address
not only the engine but also the body components as well. As
we continue under the slogan of ecology and economy in
balance, Komatsu will implement environmental measures
that lead to greater customer satisfactionmeasures that
safeguard the environment and effectively reduce the lifecycle costs associated with our products.

Midterm Development Targets for

Environmental Technology
Reducing CO2 Emission
Our goal regarding CO2 emissions is to reduce the base level
by 10 percentbeyond the national targetby fiscal 2010. In
fact, many of the products we are now developing are
designed to achieve the 2005 emission target, which calls for
a minimum reduction of 5 percent.

22

Disposal

500

600
t CO2

Recyclability
Construction equipment has traditionally enjoyed a greater
degree of recyclability by comparison with automobiles and
household appliances. We have therefore set a recyclability
target of 99.5 percent for 2010. In the meantime, to achieve
the interim 2005 target of 97 percent, we are modifying the
specifications of our existing products. For instance, with
hydraulic excavators, we must modify their concrete counterweights and rubber shoes so they can be recycled. Then, to
ultimately make our products 99.5 percent recyclable by
2010, we will develop as many as ten new recycling technologies.

Environmentally Burdensome Substances

Regarding substances that pose a burden on the
environment, we are endeavoring to halve the current volume by 2005, and to halve that result again by 2010. To do so,
we are changing our antifreezes to the non-amine-type and
phasing out the use of lead in all solder.

Life-cycle Cost
To achieve ecology and economy in balance we are offering the customer environment-friendly products while
reducing the life-cycle cost. Accordingly, we use practices of
technology development such as:
Reduced parts/equipment costs through the prolonged
service life of oil filters and other components; providing regenerated rubber crawler shoes at a reduced cost.
Providing remanufactured components for a reasonable price through our Reman operation, while striving
to extend the serviceability of components.
Further commitment to reductions in CO2 emissions, as
a result, reduction in fuel costs.

5.9-3 00.5.10 5:08 PM 23

Waste Consumables
With waste consumables, our target is to halve the current
volume by 2005 and halve that result again by 2010. For
example, for oils, filters, and antifreezes, we are finding ways
to extend their life, reduce waste, and ensure simpler methods of disposal. At the same time, we are developing recycling/regeneration technologies that will allow us to convert
waste consumables, such as used hoses and rubber shoes, into
usable resources.

3.2.1

Improvement in Fuel Economy

The volume of CO2 generated by construction equipment is
basically proportional to the volume of fuel consumed.
Reducing fuel consumption incorporates the following three
benefits, and hence, is an important goal.
(1) Protecting the earths limited resources
(2) Reducing CO2 emissions, a cause of global warming
(3) Bringing significant economic benefits to the customer
The diesel engines that drive Komatsus construction equipment provide higher thermal efficiency than gasoline
engines. As such, diesel internal combustion engines are
inherently more conducive to the reduction of CO2. On the
other hand, taking measures to reduce the emission of nitrogen oxides (NOx)one of the controlled substances present
in exhaust gasgenerally inflicts adverse effects on the
amount of fuel such an engine must consume. It has therefore become a top-priority issue for todays engine manufacturers to reduce emission gases while reducing the fuel-consumption rate.
Komatsus diesel engines have for years been among the
worlds most efficient units in terms of fuel consumption.
However, we must pursue further innovation in order to
respond to the increasingly strict requirement regarding
engines. To that end, in January 1998, Komatsu entered into
a joint-venture agreement with Cummins Engine Co., Inc., of
the U.S.the worlds leading designer and manufacturer of
diesel enginesto establish Industrial Power Alliance,
(IPA),* as its new development arm. Under the corporate
ideal of Developing engines that boast the worlds best fuel
efficiency. In fiscal 1999 IPA is moving forward in the development of various systems, including the following:

Newly Developed 6D170 Series Engines

ZF-Ecomat (automatic transmission for low-floor buses)

Development of an Ultra-high-pressure Fuel Injection

System
The Tier II emission regulations scheduled to take effect in
2001 with regard to off-road machines will impose tough new
standards. Moreover, such regulations will make it difficult
to reduce the fuel-consumption rate and still comply with
regulations on emissions controls, given the current injection pressures available with conventional fuelinjection
systems. However, one viable solution is to inject fuel at high
pressure and promoting a better fuel-air mixture, thereby
reducing the rate of fuel consumption.
Komatsus 6D170 series engines, slated for production in
2000, will be equipped with a Cummins injection system
called HPI (High-pressure Fuel Injection). HPI is capable of
an injection pressure rated at 196 MPa, a figure unmatched
in its class. The system also achieves best-in-class fuel economy of 188 g/kWh.

Engine-control Systems for the Next Generation of

Construction Equipment
Enhancing a vehicles total efficiency is another effective
means of decreasing fuel-consumption. As a member of the
Komatsu Group, IPA has the advantage of full deployment in
Komatsu vehicles, plus the advantage of employing the
Komatsu Groups electronics engineering arm. With these
strengths, IPA is now developing control systems that will
allow the engine to always operate at maximum efficiency
yet ensure practical use of the vehicle itself.

Energy-saving automatic transmissions help improve

access for the physically challenged
Komatsu is working on fuel conservation in areas other than
engines for construction equipment. To provide better access
for the physically challenged, low-floor buses are rapidly
being adopted. Komatsu ZF Automotive* manufactures and
sells the energy-saving ZF-Ecomat automatic transmission,
which includes a fuel-saving idling stop system that stops the
engine while the bus is idling. Moreover, to make low-floor bus
designs possible, these transmissions can be mounted transversely at the rear of the bus along with the engine.
IPA, which is located on the premises of the Oyama plant, is engaged in the
research and development of diesel engines.
Komatsu ZF Automotive Co. manufactures and sells automatic transmissions for
large buses and trucks.

23

5.9-3 00.5.10 5:08 PM 24

3.2.2

decreasing. Moreover, we are conducting the following developments with the aim of reducing emissions.

Reduction of Exhaust Emissions

In 1996, Tier I of federal exhaust emission standards for offroad diesel engines came into effect in the U.S. In diesel
engine technology, reduction of NOx leads to increase of
particulates, so it is not easy to reduce both NOx and particulates. Nevertheless, due to its high thermal efficiency and
ease of integration, it is more than likely that diesel engines
will remain the most common power source used in heavy
vehicles and construction equipment, for many years to
come. For this reason, development of low emission engines
is a priority in Komatsu.
Delayed fuel-injection timing is widely used as a means
of reducing NOx. However, the use of this method alone
causes combustion conditions to deteriorate, resulting in
higher levels of particulates and diminished fuel economy.
That is why Komatsu has adopted a high-pressure injection
system, which itself embodies a technology designed to
reduce fuel consumption. This will enable us to prevent the
particulate level from increasing and fuel economy from

Komatsus Low-emission Diesel Engine

The pressurized supply air in a turbocharged engine can

reach temperatures exceeding 150C, depending on the output. Not only does that increase NOx due to higher combustion temperatures, but it also reduces the density of air
intake. As a result, improvement of performance factors such
as fuel efficiency and horsepower output are limited, compared to the increase in pressure provided by turbochargers.
Considering this problem, Komatsu has addressed Tier I
emission regulation by adopting a water cooled aftercooler
that is chilled by the engine coolant. Consequently, the temperature of the supply air drops, which in turn reduces the
emission of NOx. We are currently developing engines with
air-cooled aftercoolers that provide a significant effect in
order to meet Tier II emission regulation.
An air-cooled aftercooler can reduce the temperature of
supply air through the use of outside air, the temperature of

State of Emission Control for

Construction Equipment and
Diesel Engines

Air-cooled aftercooler

Turbocharger
+
Intake-air cooler

Before measures
were taken

Fuel-injection-type
FCD piston

Particulates (g/HPh)

0.6

High-pressure
fuel-injection pump
Increased
air flow

Adoption of an Air-cooled Aftercooler

U.S. EPAs* Tier I emission

regulation (from 1996)

0.4

0.2

During mass
production

U.S. EPAs Tier II

emission regulation
(beginning in 2001)
Under
development

10
NOx
g/HPh
U.S. EPA: Environment Protection Agency of the United
States

24

5.9-3 00.5.10 5:08 PM 25

which is lower than that of the engine coolant.

Therefore, not only can it reduce NOx but it is also
expected to help in the reduction of particulates and
improvements in fuel economy. At Komatsu, we have
already begun installing air-cooled aftercoolers in certain
models. Our target is to expand use of this technology by the
time Tier II emission regulation takes effect.

Optimized Combustion-chamber Shape through Use of

FCD Pistons
The reduction of particulates requires the optimized mix of
fuel and air within the combustion chamber. Komatsu has
met this challenge by combining two factors: an enhanced
combustion-chamber profile via the adoption of highstrength ductile cast iron (FCD) pistons as well as increased
air flow, thanks to an improvement in the shape of the
intake path.

Preparations for Tier III Emission Regulation

Even stricter Tier III emission regulation are scheduled to
take effect in 2005. Accordingly, Komatsu is engaged in
advanced research projects that will allow us to meet the
regulation.

Manufacture and Delivery of Engines That Meet

Regulations

3.2.3

Reduction of Noise and Vibration

Komatsu has been working to reduce equipment noise, and
our efforts have resulted in the development of a prototype
low-noise vehicle (hydraulic excavator PC128UU) with a
level of operating noise representing a decrease of 10 dB
from that of the conventional model. (The noise level measured at 7 meters from the vehicle was 70 dB with the conventional model and 60 dB with the prototype.) That translates
into a reduction of humanly audible noise to just one-tenth.
To apply this technology to equipment other than
hydraulic excavators, we are now developing low-noise
devices that can be installed in bulldozers, dump trucks, and
all other mass-production vehicles. Moreover, we are achieving a high degree of standardization of their design specifications.
Specifically, Komatsu is promoting the reduction of
equipment noise by adopting sound-absorbent blades and
ventilators, along with high-performance sound-absorbent
materials to reduce noise from the air inlets of engine compartments. We are even developing high-performance
exhaust pipes. In fiscal 1999, low-noise devices were placed
in two types of hydraulic excavators, and to promote recycling, sound-absorbent materials made from PET fiber were
utilized for the first time ever in construction equipment.

Komatsu has established the Engine Environmental Group at

the Oyama plant, where our engines are manufactured.
Regular testing of engine exhaust gas and other steps are
undertaken voluntarily to ensure that the engines we manufacture and ship are always in compliance with regulations.
Ultra low noise Hydraulic
Excavator (PC128UU)

Example of noise reduction measures

Noise-reduction measures
at exhaust systems
High-performance soundabsorbent ventilator
Sound-absorbent
manifold duct

Measures for the reduction of

exhaust noise
Large, two-way exhaust muffler
Tailpipe with a built-in silencer
High-performance
sound-absorbent
compound materials

FCD Piston

Noise-reduction measures at
intake systems
High-performance soundabsorbent blade

Measures for the reduction of

engine noise
Rigid cylinder block
Light-weight FCD piston
Noise-absorbent, soundproof cover

25

5.9-3 00.5.10 5:08 PM 26

3.2.4

Reduction of Environmentally Burdensome

Substances
Komatsu has responded quickly to environmental concerns.
In 1998, we eliminated the use of asbestos in our products
and adopted MSDS* maintenance in compliance with
OSHA* recommendations. In 1992, we introduced a marking
system for the classification/recycling of plastic parts under
a company-wide initiative. As such achievements demonstrate, we have set forth our commitment to environmental
issues from an early stage.
Our awareness of environmental conservation grew further with the 1992 institution of Komatsus Earth
Environment Charter. In 1999, we began a new initiative
regarding the comprehensive reduction of environmentally
burdensome substances, calling for the evaluation and
understanding of the overall environmental impact represented by our construction equipment. According to those
findings, our technology subcommittee has established the
following policies on environmentally burdensome
substances. Those policies will be fully implemented by our
Development Division.

Specific Substances for which Use Will Be Completely

Eliminated
Three types of substancesPCBs, asbestos, and specified
CFCswere selected for complete elimination. (These substances are no longer used but were specified as a means of
reaffirming our commitment.)

Substances for which Use Will Be Limited

Environmentally burdensome substances such as heavy metals (mercury, lead, cadmium, arsenic, selenium, hexavalent
chromium, alternative CFCs, and triethanolamine) shall not
be used other than in current applications for which no alter-

natives exist (solder, et al.). Moreover, with regard to the

current applications, we will work wholeheartedly toward
reductions in their use.

Plastic Materials that Are Difficult to Recycle

We will limit the use of FRP (fiberglass reinforced with plastic), polyvinyl chloride, and halogen-based, flame-retardant
plastic in new applications. With particular regard to FRP,
we will actively promote a change to alternative, easily recycled materials. Furthermore, we are working to replace materials containing chlorinea substance that can produce
dioxinby encouraging our Purchasing Department and
parts suppliers to use alternative materials that are free of
chlorine.

Other Hard-to-Recycle Materials

Komatsu is now promoting the use of alternatives to glass
wool and composite materials. With respect to glass wool,
which is used for purposes of sound and/or heat insulation,
we are studying a possible switch to urethane and PET (polyethylene terephthalate). Regarding the rubber shoes made
from composite materials, we are examining a new, easy-torecycle road liner that facilitates partial repair, and are
reviewing the actual method of recycling.
Komatsu has endeavored to achieve the aforementioned
objectives as part of a standardization effort known as KES*,
which we completed in fiscal 1999. Given the fact that similar measures are needed for articles we purchase, we have
added the section, List of Controlled Substances under
Environment-Conscious Procurement Regulations to our
Guidelines for Environment-Conscious Procurement, which
was issued in 1999. This section explains the controlled substances contained in secondary materials, such as packing
and wrapping materials.

About Environmental KES

Every Komatsu Group company participated in examining the

The Komatsu Engineering Standard (KES) is an in-house stan-

content of the environmental standards. The results of that

dard for all companies in the Komatsu Group, as discussed in

assessment were compiled in the Environmental KES, which was

the Technical Standard Committee and officially announced by

officially announced to the Komatsu Group as an original, new

the officer in charge of engineering. Among Komatsus propri-

set of standards.

etary technologies, items and contents that are not regulated by

the ISO and JIS standards are standardized by the KES.

The institution of the Environmental KES means the environ-

Established in accordance with company objectives, this stan-

ment is officially included in our corporate agenda. It also

dard not only serves as things that we can rely on to improve

means the environmental guidelines are drawn as things that

product quality, reduce costs, and streamline engineering work

we can rely on in specific engineering operations as well as

in our repeated operations but also serves as things that we

things that we should observe.

should observe.
* MSDS: Material Safety Data Sheet
* OSHA: Occupational Safety and Healthy Administration
* KES: Komatsu Engineering Standard

26

5.9-3 00.5.10 5:08 PM 27

3.2.5

With construction equipment, which is of course the mainstay product line at Komatsu, we are extending our effort to
promote recycling over the lifecycle of every machine we
build. Again, it is an effort based on the Three Rs.

Improvements in Recyclability
Indication of Material Identification Codes on Plastic
Parts
The late 1980s saw an increase in the demand for construction equipment used in urban civil-engineering projects.
Consequently, the requirements for these machines-including exterior design and operator comfort-grew proportionately, and manufacturers began using plastic parts in order
to address such requirements. To facilitate the disposal of
these parts, Komatsu introduced a system in 1992 to indicate
the material identification code on plastic parts. It was the
first such system in the industry.

Toward Greater Recyclability

Komatsu established the Standard Definitions for
Recyclability in fiscal 1998, as outlined below, to ensure a
common understanding on behalf of more thorough recycling.
1. Use materials that are easy to recycle
2. Adopt structures that are easy to recycle
3. Use recycled materials wherever possible
4. Reduce the use of substances that are environmentally
burdensome

Birth of a New Concept in Recycling

In fiscal 1993, Komatsu established the Three Rs, a statement defining our basic approach to recycling activities. The
Three Rs were aimed at safeguarding and conserving our
global environment and natural resources.
1. Reduce: Reduce the amount of waste generated.
Consumables: Reduce the usage.
Durable goods: Extend the life.
2. Reuse: Reuse directly as a product or part.
Increase the products value in the resale market.
Broaden the use of rebuilt components and parts.
3. Recycle: Convert recyclables into new resources by
changing their original form.
Materials recycling: Reuse as materials
Thermal recycling: Reuse as a source of thermal
energy.

Initiatives by the Development Division

Our Development Division is working to set design standards
that embody the above definitions. Moreover, it is conducting trial calculations to grasp problems present in the current models. Our ideas and information on the current problems regarding recycling are communicated to the
material/parts vendors, in order that we might devise solutions based on our mutual understanding. To further
improve the recycling rate, we will also be tackling new
issues such as the facilitation of disassembly.

Lifecycle of Construction Equipment and the Three Rs

3 Recycle

Recyclability of Main Products

Construction equipment

In-process recycling
(Material and energy)

2 Reuse

Sales/service

Used equipment

Can be recycled

81%

Manufacturing
(Manufacturer)

Usage (Customer)

1 Reduce
3 Recycle

Example of a hydraulic excavator

PC200-6

2 Reuse

Extend life
Reduction
Material

Used parts
Regenerated parts

Energy

Disassembly
(Disassembly companies)

Ferrous and
nonferrous metals

Rubber,
plastic

Equipment out of service

Can be recycled

92%

Equipment frame

Example of a wheel loader

WA100-3

27

5.9-3 00.5.10 5:09 PM 28

3.2.6

3.2.7

Development of Biodegradable Hydraulic Oil

Recycling of Rubber Crawler Shoes

Unique Characteristics of Construction Equipment and

Biodegradable Oil

Among various used parts, the rubber crawler shoes commonly used in small- to mid-sized hydraulic excavators represent a greater environmental impact due to their large
quantities and high disposal costs. Accordingly, we have designated them one of the highest priority targets in our recycling initiative. The following explains the contents of our
rubbercrawler shoe recycling effort.

Since construction equipment is frequently used outdoors, it

may cause environmental pollution should oil leakage occur
during oil exchange, or failure of high-pressure hoses.
Concern for such a risk of environmental damage
resulted in the enactment of administrative guidelines in
Europe in the 1980s. The guidelines require that all construction equipment operated within the confines of designated
nature reserves use biodegradable hydraulic oil in order to
prevent the pollution of valuable water sources and forests.
Unlike regular oil, biodegradable oil is broken down naturally by bacteria present in the soil.

Measures at Komatsu
We responded to the issue with the development of Komatsu
Genuine Biodegradable Hydraulic Oil BO46-G4, the first of its
kind in the world. This allows us to use biodegradable oil in
the cutting-edge construction equipment currently in operation. Combining the environmentally safe properties of conventional biodegradable oil with added functions designed to
uphold the equipments original capabilities, BO46-G4 provides the following features:
1. Completely biodegradable, with less environmental
impact.
2. Maintains the designed durability of construction
equipment being operated in harsh conditions.
3. No need for design change or dedicated parts.
4. Provides sufficient braking force compared to that of
ordinary biodegradable oil.
5. No problems will occur even if new product is mixed
with leftover oil during an oil change.
6. Easy to collect and will not cause environmental damage in the event that leakage should occur.

Processing of Used Rubber Crawler Shoes

Approximately 14,000 used rubber crawler shoes are generated each year. They are processed by the distributors in the
following ways:
(1) Regeneration or recycling
(2) Recycling in electric furnaces
(3) Incineration (The iron part is salvaged as scrap following incineration.)
(4) Treatment as industrial waste (manifest control)

Recycling with a Vulcanizing Press

BO46-G4, recognized for the superior quality and

performance as summarized above, has been honored with
encouragement prizes by the Japan Construction
Mechanization Association in fiscal 1997 and the Japan
Society of Mechanical Engineers in
fiscal 1998 on behalf of its technical
merit. In fiscal 1999, BO46-G4 was
awarded the new Eco Mark, which
requires higher standards than ever
before.

Biodegradable Oil Cans

28

Loading of Non-recyclable Parts at the Collection Facility

5.9-3 00.5.10 5:09 PM 29

Of the above, incineration and industrial-waste treatment are

the likely cause of the environmental impact. Therefore, at
Komatsu, we are recommending regeneration and recycling
as the preferred processing methods for rubber crawler shoes.

furnace manufacturers throughout Japan, as well as reduction in transportation costs.

Recycling Initiatives
Rubber crawler shoe before recycling

The key issues in the recycling of used rubber crawler shoes

are as follows:
1. Collection of parts in good condition for recycling
2. Realization of a lower distribution cost
Komatsu is addressing these issues through the
establishment of an original recycling channel in cooperation with Komatsu Parts*. Through this channel, we have
become the first in the industry to recycle used rubber
crawler shoes and sell recycled parts as a viable business.
Today, approximately 3,000 used rubber crawler shoes are
recycled annually at our two facilities.

Processing of Non-recyclable Parts in Electric Furnaces

Rubber shoes that are in poor condition are processed in an
electric furnace that allows the collection of iron. Initiated
by the Japan Construction Equipment Manufacturers
Association, this operation is now being implemented in
Tohoku, Kanto, and Kansai/Chubu areas. In fact, approximately 200 tons of rubber shoes were processed in this manner in fiscal 1999. The further promotion of this processing
method, however, would require collaboration with electric

Processing Flow of Used

Rubber Crawler Shoes

Rubber crawler shoe after recycling

Building in Recyclability During the Development Phase

Komatsu has also developed highly recyclable load liner-type
rubber crawler shoes and is promoting their utilization.
Compared to conventional one-piece rubber crawler shoes,
load liner-type rubber crawler shoes enable only damaged
parts to be replaced and are much easier to dispose of
because they can be easily dismantled.

Recycling into new rubber

crawler shoes

Regeneration/
recycling

Recycling in
electric furnaces

Recycling iron

Used rubber
crawler shoes
Environmental impact

Recycling as scrap iron

Incineration

Decreasing final-treatment facilities/remote location

Treatment
as industrial waste

Manifest control

Komatsu Parts Ltd. specializes in the sale of parts and equipment, product design,
and distribution/logistics.

29

5.9-P30 00.5.11 10:39 AM 30

3.2.8

Reman
What is Reman?
Reman is an abbreviation for remanufacturing.
Through the processes described in the poster below,
components are revived to near-new quality and reassembled as replacement parts during repairs and routine overhauls. At the same time, the worn components replaced in
this process are remanufactured at our Reman Centers. This
allows us to bring them back to the market as reman components. This is Komatsus concept of remanufacturing operations.
Rebuilding is another concept similar to remanufacturing. Essentially, rebuilt components are those that have been
repaired only upon the request of the customer. Therefore,
with a rebuilt component, the degree of performance may or
may not be guaranteed in the same way as a new part, since
the level of quality differs from one component to another.
Moreover, with rebuilt components, the machine must cease
operating while the components are repaired. For these reasons, reman components are preferable to rebuilt parts.

Features of Reman Components

Komatsus reman components offer the following benefits:

Poster showing the remanufacturing process

30

1. Quality: Can be used reliably, with a guarantee of quality/performance equivalent to a new part.
2. Cost: Cheaper than new components, requiring loweroperating costs.
3. Delivery: Machine downtime can be reduced by a
quick replacement of the defective component with a
Reman component taken from properly controlled
stock.
4. Ecology: Reman components can contribute to
resource conservation and to reduce waste through the
reuse and recycling of components and parts.
As shown, Komatsus Reman operation offers numerous
advantages, not to mention a significant contribution to the
conservation of our environment.

Expansion of Komatsus Remanufacturing Operation

Komatsu is expanding its remanufacturing operation
through Reman Centers located in the worlds six principle
regions. In Japan, Komatsu Remanufacturing Company*
leads the remanufacturing of engines, transmissions, torque
converters, hydraulic cylinders, and other major
components used in construction equipment under the CR
designation. The following describes an example of engine
remanufacturing in Japan from the perspective of resource
savings.

31-33 00.5.11 1:09 PM 1

Extended Life for Engine Parts

Recycling

The relevant Komatsu companies are engaged in an effort to

improve engine durability by jointly developing engines that
are easy to remanufacture. Items under scrutiny are the
durability of the engine, proper overhaul timing, and the
final durability target needed to improve remanufacturing.
To find answers, they are collaborating with our Reman
Centers in six regions worldwide. This is resulting in the
collection of data on construction equipment operation and
the establishment of specific targets for individual parts in
order to develop products that offer high durability and easier remanufacturing.

Components that were no longer usable were previously disposed of by the customer or distributor. Now, however, they
are returned to our Reman Centers for processing into
reusable components. In 1999, the engine return rate
exceeded 98 percent.
Komatsu Remanufacturing Company Ltd. repairs and
reuses these components in order to make CR units. Cast
parts that cannot be repaired or reused by Komatsu
Remanufacturing are forwarded to the Oyama
Manufacturing Department of Komatsu Castex* where they
are melted for the manufacture of new parts.

Reuse

Preparation of Remanufacturing Manuals

The components returned from the customer are disassembled, and reusable parts are selected by checking each part
against our strict standards of reusability. Increasing the
number of reusable parts not only contributes to resource
savings and waste avoidance, but also leads to cost reductions.
With our 12V140-series engines, for example, the reuse
rate of parts increased 26 percent over the level obtained
when we began remanufacturing, thanks to improvements
in inspection, screening and repair in fiscal 1999.

To improve the reusability of parts, we are collaborating with

our Development Division, manufacturing facilities and
Komatsu Remanufacturing to create manuals that define the
reusability standards and repair procedures for individual
parts. The manuals will also address the environmental measures to be practiced globally, as in the recommendation that
our Reman Centers overseas use cleaning solvents having
less environmental impact.

Komatsus Reman Centers Worldwide

Newcastle, England
KEISA Reman Center
Japan
Komatsu Remanufacturing
Training Center

Komatsu

Lexington, Virginia, U.S.

Komatsu Reman North
America Inc.
Balikpapan, Indonesia
P.T. Komatsu Remanufacturing Asia

Johannesburg, South Africa

KSA Reman Center

Brisbane, Australia
NSK East Coast Reman Center

Pearth, Australia
NSK West Coast Reman Center

Komatsu Remanufacturing Company Ltd. remanufactures engines, transmissions,

and hydraulic equipment, and also sells regenerated components.
Komatsu Castex Ltd. produces castings for use in construction and industrial
machinery. The company has also developed and marketed a range of production
facilities/equipment based on its advanced casting technologies.

31