THE PIONEER DIFFERENCE - Pioneer Solutions,...

The Most Qualified Resource for Effective and Immediate Heavy Equipment Engineering Services

A broad base of engineering skill sets and decadesof experience provide valuable turnkey solutions to our customers.

THE PIONEER DIFFERENCE

Heavy Equipment Engineering Services

ANALYSIS • BRAKES • CAD • ELECTRICAL and SOFTWARE • FIELD INSTALLATIONS • GEARING • HYDRAULICSMACHINE INTEGRATION • METALLURGY • POWER TRAIN • PROTOTYPE MANUFACTURING • STRUCTURAL • TESTING

24800 Rockwell Drive • Cleveland, OH 44117-1203 • 216-383-3400 • [email protected] www.pioneersolutionsllc.com

We made our mark as the Engineering and Design Department of the Euclid-Hitachi HaulTruck Product Line. Now, as Pioneer Solutions, LLC we have taken our 30+ years of offhighway haul truck design experience and created a broad based engineering, design, andproject management company.

In the process we have become the Off Highway Haul Truck Experts. In fact, our customerbase includes many of the largest haul truck manufactures in the world!

Haul Truck Design Experience and Capabilities:• Mechanical Drive Trucks: 25 to 150 tons• AC/DC Electric Drive Trucks: 170 to 400 tons• Articulated and Rigid Frame Trucks

Decades of Haul Truck Engineering Experience in All Systems and Components:• Frame (Chassis)• Front Axle• Rear Axle• Suspensions• Planetary/Differential Gearing• Brakes• Power Train

Here are some of Pioneer Solutions’ Completed Projects: • New Product Development: Design and engineering of an ultra class electric drive haul

truck from machine and systems specifications, concept layouts, detailed design, andBOM/drawing package, including engineering calculation and analysis reports, supplierdevelopment, manufacturing interface, prototype support, testing, and technical manuals.

• Design Optimization: Reliability improvement, weight, and cost reduction projects redesign-ing and analyzing structural components such as frame and axle castings and fabrications.

• Axle Development Project: Design of complete front axle and rear axle systems for 100ton mechanical drive haul truck. Included structural components, suspension cylinders,steering mechanism, differential and planetary gearing, and brakes.

• Hydraulic hoist system performance issue and field failure resolutions: Performed on-site investigation of machine and failed components, analyzed existing hoist system,designed new hydraulic valve and manifold, manufactured prototypes, and completed fieldinstallation and testing to verify solution.

• Product Line Development Projects: Designed common reversible access systems formultiple machines in a product line that met numerous international standards.

• ROPS/FOPS Certifications: ROPS/FOPS structure design, analysis, testing management,and certification report with PE approval.

• Power Train Integration: Selection and installation of multiple engine options into amachine. Includes the engineering and design of layout/space claim, mounting, cooling, airintake, exhaust, fuel, and electrical systems.


HEAVY EQUIPMENT ENGINEERING SERVICES

• Steering• Hoist• Brake Apply/Cooling• Sheet Metal/Hand Rails/Access Systems• Electrical/Software• Cab ROPS/FOPS• Dump Body

Our Tracks in Off Highway Haul Truck Engineering… Run Deep


OUR BACKGROUND, INCLUDING KNOWLEDGE and EXPERIENCEis the difference in providing technical solutions to our customers quickly and effectively.

Pioneer Solutions, LLC is a broad based engineering services andproject management company based in Cleveland, Ohio, USA. Weprovide technical solutions to the heavy equipment and off highwayequipment industries. We are a flexible, complementary, and valueadded engineering resource to help you complete your projects ontime and within budget.

Pioneer Solutions was formed in September of 2004 and primarilyconsists of the former Euclid-Hitachi off highway haul truck engineering department. Four key engineering managers capitalizedon an opportunity to utilize their experience when Hitachi ConstructionMachinery discontinued their construction and mining truck operations in the United States. The new company retained a largegroup of senior level engineers and designers with decades ofexperience in designing and engineering all the major machine systems incorporated in heavy and off highway equipment.

Due to our background and experience in off highwayapplications and equipment functionality, we understand:

• Product life cycle and requirements of developing new products

• Improving existing products and supporting products in the field toobtain end user satisfaction.

• Design engineering, product development, engineering manage-ment, and product management

• All phases of developing and designing off highway products including supplier selection, qualification, and auditing, manufac-turing processes, prototyping, testing, and product support




YOUR SINGLE SOURCE for technical expertise, to be considered an extension of your company,and for establishing long term and effective working relationships.

The engineering team of Pioneer Solutions, LLC covers the complete range ofengineering disciplines required to design and support heavy and off highwayequipment.

Our real value is high level development engineering. Combining over 30 years ofheavy and off highway equipment engineering and design experience with athorough understanding of equipment applications and functionality provides a keyadvantage for the company.

Engineering and Design Capabilities

Metallurgy• Material & Heat Treatment Selection, Optimization, & Specification Development• Casting & Forging Design• Foundry Selection, Qualification, & Auditing• Welding Technology & Design• Weld Joint Analysis & Transition Optimization

Structural• Frames (Chassis): Fully fabricated, fully cast, and partial fabricated/cast designs• Front Axles: spindle, A-arm, trail arm, beam, fixed kingpin, MacPherson, wheel,

linkages• Rear Axles: cast & fabricated boxes, spindle, wheel, bolted joint designs• Heavy Fabrications: dump bodies, buckets, trailers• Light Fabrications: enclosures, sheet metal, decks, platforms, railing, cabinets• ROPS/FOPS• Weight & Cost Optimization• Design for Manufacture

Analysis• Linear & Non – Linear FEA Capability• Stress, Fatigue, & Modal• Cast & Welded Structures

- Complex Contact- Impact- ROPS/FOPS- MIL-209

• Thermal



• Multi-Body Dynamic Modeling- Total Vehicle- Steering Geometry- Suspensions- Linkages

• Vehicle & System Simulations • Design Verification• Weight & Cost Optimization


YOUR SINGLE SOURCE

Hydraulics• System Specification

& Schematic Development• Steer Systems• Hoist Systems• Brake Systems• Suspension Systems• Closed Center, Load Sense,

& Motion Control Systems• Portable Power Units

Power Train• Engines

- Performance & Specification Development

- Installation- Radiator Sizing & Selection- Cooling Systems- Fuel Systems- Exhaust Systems- Air Intake Systems

• Transmissions- Performance

& Specification Development- Installation- Torque Converter Matching

Electrical & Software• System Specification

& Schematic Development for High & Low Voltage

• Harnesses• Instrumentation Selection

- Controllers- Panels- Displays- Sensors- Gages

Machine Integration• Complete Machine Development• Systems Integration• Standards & Regulations Compliance

Computer Aided Design • Conceptual Layouts• Detailed Designs• Drafting


• Cylinders- Double Acting- Multi-Stage- Suspension

• Accumulators• Custom Manifold & Valves• Advanced Sealing Techniques• Reservoirs• Filtration

• Brakes- Dry Disc- Oil Cooled Disc

• Gearing- Differential- Planetary- PTO

• Complete Final Drives for Mechanical and Electric Machines- Spindle- Gearing- Shafts- Bearings- Wheel- Brake

• Engine, Transmission, DC,& AC System Integration

• Circuit Board Development• Logic & Code Development

- Machine Control & Monitoring - Traction & Downhill Speed Control - Payload Monitoring - Hoist Control

• Vibration• Stability

• GD&T• Skilled in multiple

software packages; willingness to match client needs.


BROAD RANGE OF PROJECT OPPORTUNITIESare possible because of our extensive application knowledge and experience.

In addition to our engineering capabilities, Pioneer Solutions, LLC hasthe experience to actively contribute and interact with a full rangeof business functions, such as marketing, manufacturing, purchas-ing, product support, and testing. All of our senior personnel havedirect experience in various roles as part of a large multi-nationalequipment manufacturer. As a result, our people have the credibilityto effectively add technical value across your entire business.

Range of Solutions Delivered:

• Machine and System SpecificationDevelopment

• Market Research & Analysis• Complete Machine Design• Major Development Projects• System and Component Design• Product Upgrades• Design Optimization



• Supplier Development• Technical Manuals• Reverse Engineering• Remanufacturing Engineering• Failure Analysis• Prototyping• Lab and Field Testing• Field Installations

“...Pioneer Solutions, LLC can provide engineering services based onyears of experience in the design and testing of mining and constructionequipment. I highly recommend Pioneer Solutions to meet your needs.”

Walter Fox, Former CEOHitachi Construction Manufacturing LTD


UNIQUE BUSINESS MODEL provides qualified resources, effective project management, and customer satisfaction.

The goal of Pioneer Solution’s business model is to provide asmuch flexibility and value to our customers as possible. Toachieve this, we utilize a variety of business engagement options.We are a matrix organization which allows us to effectively allocatequalified resources to meet customer requirements. Our project man-agers drive project accuracy and schedule.

Fixed Price Contracts simplify managing your outside engineer-ing process: We are an atypical engineering services business byoffering to perform our project work for a fixed price. The majority ofour customers prefer this model because it defines the total proj-ect cost prior to project start, removes the burden of managingand tracking contractor resources and hours, and guaranteesschedule and quality at no additional cost. Other relationshipopportunities include long term retainers, exclusive alliances, andteaming arrangements.

Quality Management System ensures projects are completed accurately the first time by:

• Assisting in selecting qualified project team members from ourmatrix organization

• Defining types and frequency of internal and customer technicalreviews

• Facilitating efficient communication and data transfer with thecustomer

• Utilizing a tracking system that assigns project tasks and monitorsthe status of projects in real time

• Providing management review and oversight to ensure customersatisfaction

Our Project Managers make a difference by:

• Fully understanding customer’s project objectives, requirements,and schedule

• Sequencing and executing project tasks, utilizing manpower efficiently, and driving projects to completion on time and within budget

• Utilizing the experience of managing large scale, multi-million dol-lar projects from the machine specification phase through design,prototype, test, production, and support

• Working proficiently with multiple parties from remotelocations and with many different equipment manufacturersthroughout North America and internationally



We provide value to your organization by:

• Serving as an extension to your company andadding specialized engineering depth to meetproject objectives and deadlines

• Offering unique technical skill sets to enhanceand broaden your capabilities

• Providing high level engineering for new product development

• Offering parallel path solutions to resolve critical design issues

• Using decades of experience to analyze and solve field failures

• Modifying products for sale in global markets


Pioneer Solutions, LLC 24800 Rockwell DriveCleveland, OH 44117-1203216-383-3400info@pioneersolutionsllc.comwww.pioneersolutionsllc.com

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Construction

Material Handling

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Quarry and AggregateGovernment and Military

Surface Mining

Forestry

Underground Mining

ANALYSIS • BRAKES • CAD • ELECTRICAL and SOFTWARE • FIELD INSTALLATIONS • GEARING • HYDRAULICSMACHINE INTEGRATION • METALLURGY • POWER TRAIN • PROTOTYPE MANUFACTURING • STRUCTURAL • TESTING

THE PIONEER DIFFERENCE - Pioneer Solutions,...

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