Building the First Komatsu PC9000: Inside the Assembly of Komatsu’s Largest Hydraulic Mining Excavat

Building the First Komatsu PC9000: Inside the Assembly of Komatsu’s Largest Hydraulic Mining Excavator

January 21, 2026

What does it take to assemble the first machine of its kind, unlike anything built before?

For the team behind the world’s first Komatsu PC9000, it required weeks of around-the-clock work, thousands of combined person-hours, and the coordinated efforts of three industry partners with a shared vision to transform the future of mining.

The historic build unfolded in the winter of 2025, less than a year after SMS Equipment and Komatsu Germany Mining Division (KGM) announced the PC9000. In northern Alberta, SMS Equipment’s build crew worked alongside Komatsu engineers to complete the assembly with zero incidents — testament to the collective team’s expertise, discipline and unwavering commitment to safety.

Overcoming First-of-its-Kind Challenges

The assembly of any large mining machine is a logistical feat, and the PC9000 introduced a new set of complexities. As the first machine in a new class of excavator, many details were unfamiliar, even to the experienced build crew.

“Understanding what was new was really the biggest challenge,” says Ron Fetzko, Major Project Specialist at SMS Equipment, who led the build. “The design and layout were different from what our crews had seen before and keeping the machine’s specs confidential was a top priority.”

The PC9000 is the next class of hydraulic mining excavator, and it incorporates numerous enhancements over previous models to improve efficiency, productivity and operating cost. Its modular design includes bulkheaded structures and segment-based construction, a configuration unique to this model and new to the build crew.

To prepare, Fetzko traveled to the KGM factory in Germany to observe the first PC9000 being disassembled. He returned with key insights that allowed him to shape the project plan and reassure the crew that this machine, though larger, represented an evolution of equipment they already knew well.

A Build on a Massive Scale

The PC9000’s size and weight demanded a different approach from the start.

Receiving the machine on site alone was a logistical puzzle — it came in across 31 truckloads and nine sea cans over the span of 10 days. Overhead cranes were required to unload the super-sized components, with some days seeing up to eleven deliveries. A nimble, four-person pre-assembly crew received the shipments, managed the load order, prepared the assembly pad for each load and organized inventory. Their site preparations laid the groundwork for the weeks ahead.

A powerhouse team was brought together for the assembly itself. KGM strengthened its typical on-site presence to support the landmark project, bringing six service specialists to guide critical phases of the build. SMS Equipment deployed a dedicated crew of 16, including Heavy Equipment Technicians, welders, electricians and two experienced project leads. The teams worked hand in hand throughout the assembly, running in two, 12-hour shifts each day to keep progress efficient, safe, and on schedule.

Even with that pace, the sheer scale of the task demanded additional heavy-duty solutions. Larger cranes, specialized rigging, and significant pre-dressing of the boom structure were required to handle the machine’s major assemblies safely.

“Our team had to pivot some processes because of PC9000’s scale,” explains Fetzko. “For instance, we developed a protocol to assemble all cylinders and hosing on the boom while it was still on the ground. By reducing the amount of work done in the air, we drastically minimized risk for working under suspended load, which was our priority. With that, efficiency followed.”

The collaboration established early in the project remained through to commissioning. KGM deployed its full testing department from Germany along with operator trainers, quality inspectors, engineers and service specialists—13 experts in total—while SMS Equipment provided onsite support with two additional specialists. Together, the joint team ensured the PC9000 was thoroughly tested, commissioned and ready for operation.

Global Collaboration

Few machine builds involve a level of cross-continental collaboration seen in the PC9000 project.

KGM service specialists and electricians worked directly with the SMS Equipment crew throughout the assembly. Junior engineers gained valuable field experience, while senior specialists oversaw the mechanical, electrical, and welding systems.

Among them was Mark Schedel, design engineer in KGM’s maintenance department and a member of the PC9000 project team since 2023. On site, Schedel served as a vital link between the construction team and Komatsu’s service and development departments in Germany. He provided documentation, answered technical questions and used Komatsu’s 3D models to help the crew visualize complex assemblies.

“As a young engineer, it was my first international experience, and the teamwork made it incredibly rewarding,” says Schedel. “It was particularly exciting to see the motivation and commitment shown by everyone involved around the world.”

“Good communication is key on these major projects,” adds Fetzko. “Whether in our orientations or daily check-ins with the customer, our entire build team communicated early and often to get the job done."

Data That Will Shape the Future of the PC9000

The PC9000’s development is a strong example of Komatsu’s continuous improvement model. Many refinements were based on feedback from customers, operators, mechanics and distribution partners who worked with earlier PC-series machines. In turn, data during the first PC9000’s assembly was shared back to Komatsu to guide future models. Some recommendations were even implemented on the second PC9000 delivered to Suncor later in the year.

One enhancement holds particular significance for Schedel. “I’m most proud of the newly designed door at the fuel tank,” he says. “It shields the fuel filters behind durable steel protection and minimizes the risk of fuel escaping in the event of a leak, which enhances operational safety and machine uptime.”

“It is special for me because this was my very first independent project at KGM,” he adds. “And now, the PC9000 lettering is proudly displayed on that very door.”

Memories to Last a Lifetime

For many involved, assembling this inaugural machine wasn’t just a professional milestone — it was a career highlight.

“We got to help with the very first machine of the largest hydraulic excavator for mining on the planet,” muses Fetzko. “I was proud to lead the team that assembled it. I’ve done a lot of cool things in my career, but this might be the top.”

“What stuck in my head was the motivation of the Canadians in the build,” adds Schedel. “Whether working 12-hour shifts or working in minus-35-degree temperatures, no one complained.”

The build also forged new friendships and working relationships across different nationalities, cultures, and technical backgrounds — connections that will carry forward into future projects.

A Safe, Successful Build

Despite the unprecedented scale of the machine and the complexity of its inaugural assembly, the PC9000 was assembled safely and predictably, supported by strong communication among all three partners. At times, small delays were introduced deliberately — always in the interest of safety and reliability — and the customer was engaged proactively throughout.

“The safety standards in Canada’s oil sands are among the highest in the world,” adds Fetzko. “Through this build, we were able to raise the bar globally for safety expectations in the assembly process, influencing how all future PC9000s will be assembled.”

In fact, in recognition of its leadership, process improvements, and safety record, SMS Equipment’s build team was later named Contract Safety Team of the Year at the 2025 Alberta Mine Safety Association Awards.

With more PC9000s already being built, the collective experience of the OEM, distributor and customer team is helping shape the next generation of ultra-large hydraulic mining excavators.