TRAINING
KOMATSU TECHNICAL AND KOMATSU OPERATOR OPERA TOR TRAINING Covers Backhoe Loaders, Bulldozers, Crushers, Dump Trucks, Excavators, Graders ,Wheel Loaders, Skidsteers, General Systems and Technologies
Komatsu’s team of technical trainers are: Australian Trade qualified and experienced Nationally accredited Certificate IV Workplace Training and assessment qualified • Komatsu field service experience • Komatsu factory trained • Komatsu certified
TECHNICAL AND OPERATOR TRAINING?
All machine programs are based on Komatsu’s 4 level training and assessment system based on the Technical Skills Competency map (shown on next page) Each level develops and builds the skills and knowledge in the participants and each Level is a prerequisite to the next Employee skills assessment and gap analysis is available via skills audits developed from the competency map
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Komatsu technical training is aimed at the skills required of mechanical and electrical tradespeople in the areas of technical service and maintenance training, arranged by machine type and model or technolog y platfor m, such as hydraulics, electrics and engines.
Komatsu’s Training Programs: • The Komatsu Total Technical Picture (KTTP) is a four day bridging program for those new to Komatsu product and the earthmoving industry
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MACHINE COURSE CONTENT Level 1 Introduction and General Service Duration 8 hours. On completion of this module the participants will be able to:
Komatsu operator training is aimed at the skil ls requir ed of endorsed machine operators and operator trainers in the a reas of operator familiarisation training on Komatsu equipment for plant operators and trainers.
UNEARTH YOUR POTENTIAL
Level 2 Structure and Function Duration 8-12 hours. On completion of this module the participants will be able to:
A. Identify the specific safety requirements for maintenance and repair of the Komatsu machine B. Demonstrate knowledge of the design features and characteristics of the Komatsu machine C. Locate and identify major components D. Describe the operational differences between previous model Komatsu machines E. List the optional equipment available for the Komatsu machine F. Locate service points and describe the specific service requirements for each point, as stated in the machine operating manual
A. Demonstrate safety precautions relevant to the machine system being covered B. Describe the design concepts of each of the machine systems C. Identify and locate components of all major systems on the Komatsu machine D. Describe the principles of operation of all major systems on the Komatsu machine E. Demonstrate a working knowledge of circuit diagrams relevant to the Komatsu machine
Level 3 Test and Adjust Duration 8 hours. On completion of the module participants will be able to:
Level 4 Troubleshooting Duration 8 hours. On completion of the module the participants will be able to:
A. Carry out safety precautions to be observed when tests and adjustments are conducted on the Komatsu machine B. Test and adjust engine components on the Komatsu machine C. Test and adjust the powertrain of the Komatsu machine D. Test and adjust hydraulic system components of the Komatsu machine E. Test and adjust the electrical system components on the Komatsu machine F. Interpret schematic drawings for the hydraulic and electrical components on the Komatsu machine G. Use Komatsu test equipment in maintaining the machine
A. Carry out safety precautions to be observed when evaluating and diagnosing the Komatsu machine. B. Used Komatsu test equipment in maintaining the Komatsu machine. C. Evaluate and diagnose engine faults of the Komatsu machine. D. Evaluate and diagnose powertrain faults of the Komatsu machine. E. Evaluate and diagnose undercarriage faults of the Komatsu machine. F. Evaluate and diagnose electrical control system faults of the Komatsu machine. G. Evaluate and diagnose faults in the hydraulic equipment of the Komatsu machine. H. Interpret schematic drawings for hydraulic and electrical components.
High Quality Learning Komatsu Technical and Operator Trainers are highly qualified learning and development professionals who have worked in service, maintenance and operation roles prior to development in the adult learning and training area. They are factory trained in our product range and required to undertake rigorous professional development activities here and overseas in order to maintain their competence and certification.
Technical Training Komatsu is an Australian Registered Training Organisation (RTO) and the only organisation with registration to deliver UEENEEP022A Disconnect and Reconnect 3.3kV Electric Propulsion Components of Self Propelled Earth Moving Vehicles, to satisfy the requirement to obtain a Restricted Electrical Permit or Licence in Western Australia and Queensland.
Komatsu training programs are designed around our “best practice” global standards model. S tringent evaluation and review by our customers enables us to offer practical programs that deliver results to your business. Komatsu training provides a high quality learning experience that delivers “next day” work place skills.
TECHNICAL SKILLS COMPETENCY MAP 4.1 USE THE CORRECT TEST EQUIPMENT TO TROUBLESHOOT SYSTEM FAULTS
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n i 4 t 0 o o L h E s e l V b E u o L r
4.1.1 Demonstrate the correct selection of tools/ monitor panel for specific tasks
4.1.2 Demonstrate the correct use of troubleshooting tool
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g n i c i v r e S l 1 a 0 r e L n e E G V & E n L o i t c u d o r t n I
4.3 DEMONSTRATE TROUBLESHOOTING TECHNIQUES
4.2 USE KOMATSU LITERATURE TO AID IN PROBLEM RESOLUTION
4.1.3 4.2.1 Demonstrate the Describe the basic checks that correct use need to be carried out before of electrical troubleshooting testing instruments
4.2.2
4.2.3
4.3.1
4.3.2
4.3.3
Demonstrate the correct method of using the troubleshooting chart
Use a combination of literature and test data to pinpoint the cause of the failure
Demonstrate the correct sequence of troubleshooting
Conduct tests and collect test data
Analyse the test results and communicate the failure diagnosis
3.1 EXPLAIN THE KOMATSU RECOMMENDED PROCEDURES FOR TESTING OF SYSTEM COMPONENTS
3.2 PERFORM MACHINE TESTING TO KOMATSU RECOMMENDATIONS
3.3 COMPARE TEST RESULTS WITH KOMATSU SPECIFICATIONS AND MAKE RECOMMENDATIONS
3.1.1
3.1.3
3.2.1
3.2.2
3.3.1
3.3.2
Explain the advantages of completing a PM-Clinic sheet
Use tools, monitor panel and instruments correctly and safely to gain readings from test procedures
Record all test results
Compare all test results with Komatsu specifications
Observe and comment on results not meeting specification
3.1.2
Describe the tests Select the correct that can be carried instruments and out on each machine tools for machine system system testing
2.1 USING THE SHOP MANUAL OBTAIN INFORMATION RELEVANT TO THE OPERATION OF COMPONENTS AND SPECIFICATIONS
2.2 EXPLAIN THE OPERATING PRINCIPLES OF EACH OF THE FUNCTIONAL MACHINE SYSTEMS
2.3 USING CIRCUIT DIAGRAMS SHOW THE SYSTEMS OPERATION
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2.1.2
2.1.3
2.2.2
2.2.3
2.3.1
2.3.2
Use the Shop Manual to locate selected components and describe their operation
Use the Shop Manual to obtain selected component specifications
Describe the operation of each of the systems used on the machine using reference material
Describe the different parts of components/ monitor panel as indicated in the practical worksheet
Describe the operation of selected components using a diagram or actual component
Using hydraulic circuit diagrams show the flow and operation of selected systems
Using electric circuit diagrams show the flow of current in selected circuits and explain the operation of that circuit
1.1 EXPLAIN OR DEMONSTRATE 1.2 USE OPERATION AND MAINTENANCE MANUAL, SHOP MANUAL COMPLIANCE WITH ALL SAFETY AND PARTS BOOK TO LOCATE INFORMATION PROCEDURES RELATED TO SERVICING THE MACHINE
1.3 DESCRIBE AND LOCATE SELECTED COMPONENTS OF A MACHINE
1.4 LOCATE SERVICE POINTS AND PERFORM A SERVICE
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1.1.2
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1.2.4
1.3.1
1.3.2
1.3.3
1.4.1
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1.4.3
Using the operation and Maintenance Manual explain safety procedures related to machine operation for service personnel
Demonstrate awareness of the need to know and comply with different site specific safety procedure
Using The Shop Manual demonstrate understanding of the page revision system
Using the Parts Book identify parts required to perform a selected periodic maintenance service
Using the Operation and Maintenance Manual, locate specific information relating to machine operational controls
Using the Shop or Operation and Maintenance Manual, locate details on the basic servicing requirements of the machine
Using the machine locate selected components and record on the machine component identification sheet
Using the Shop Manual locate selected components of the machine
Describe component differences between different model machines of this type
Describe service requirements for selected service intervals and complete a service/warranty report
Locate selected service points and record on service point identification sheet
Perform/describe a basic serviceto Komatsu machine specifications including monitor panel use
RECOMMENDED KOMATSU TECHNICAL TRAINING STRUCTURE AND PATHWAYS MACHINE TYPES
TRUCK
BULLDOZER
MODULE
4) Troubleshooting
3) Testing and Adjusting
TYPICAL MACHINE SPECIFIC TECHNICAL TRAINING ROLLOUTS TIMEFRAME
After 12 month
After 9 months of delivery
EXCAVATOR
2) Structure and Function – can be combined with 1
On delivery or within 6 month of delievery
WHEEL LOADER
1) Introduction and General Service
On delivery
BACKHOE
Komatsu Total Technical Picture (KTTP)
GRADER
Mechanically and/or Electrically Qualified Trades people
Depending on the variety of machines and fleet size we would recommend a couple of different options for machine training. For a diversified group of machinery and based on previous experience we have found that the best way to ensure high level of skills take up across a broad range of machines, it is best to run each tier separately. In this circumstance we would suggest a progressive approach whereby the Introduction and General Service module would be run across the suite of machines within the first 3 months of delivery. This would give the technicians an introduction to the machine and give them the skills to service the machines when they first arrive. Then after 3 months, giving the technicians a chance to get some hands on experience with the machinery and become more
familiar, we would then follow up with the Structure and Function module which would provide in depth knowledge of how each of the machine systems work. Again this would be followed up three months later with the Testing and Adjusting module whereby the training would cover machine testing and adjusting procedures. This allows the participants to learn the product in conjunction with their exposure and experience with the machine. For sites with a smaller variety of machines it is recommended to combine the Introduction and General Service and Structure and Function modules at the initial machine delivery followed by Testing and Adjusting training within 6 months of delivery.
KOMATSU TOTAL TECHNICAL PICTURE (KTTP)
ELECTRIC DRIVE TRUCK TRAINING When it comes to Electric Drive Trucks, Komatsu training is able to provide mechanical and engine training spanning the four modules on the Machine Course Content page with the same durations as listed. Additionally we are able to train on the electrical propulsion systems of both our AC and DC trucks – which are Invertex and Statex systems respectively. The course content for our 3 day electrical propulsion courses are as per below: On the completion of this module the participants will be able to:
A. Identify the specific safety aspects for maintenance andrepair of the drive system B. Demonstrate an overview of the drive control system C. Identify components and function of drive system D. Locate service points and describe the specific maintenance requirements for the drive system E. Describe the overall operation of the drive system F. Demonstrate a working knowledge of circuit diagrams relevant to the Komatsu Electric Dump Truck G. Demonstrate knowledge of Invertex or Statex software H. Carry out basic faultfinding on the drive system
RESTRICTED ELECTRICAL LICENCE (REL) MOBILE MINING PERMIT (MMP) COURSE CONTENT After successfully completing this 5 day course the participants will have obtained the underpinning knowledge, skills and practices that will enable them to safely carry out the following tasks: A. Monitor, interpret and action control system input and output signals B. Identify various truck isolation protocols C. Effectively isolate electrical propulsion components D. Safely inspect propulsion system components and assess their suitability for service E. Safely disconnect electrical propulsion components F. Select the correct replacement parts G. Correctly reconnect electrical propulsion components H. Test for a safe and operational electrical propulsion system
This course fulfils all the Department of Commerce - Energy Safety (WA), the Department of Justice and Attorney General (QLD) regulatory requirements with regard to the disconnection and reconnection of HV electric components and satisfies the requirement for respective licence and permit in those states.
The Komatsu Total Technical Picture (KTTP) is a 4 day course covering the basic principles required to undertake further Komatsu technical training. This course combines shorter courses available as part of the technical & systems training group, giving the participant a holistic view of technical training basics. It is highly recommended that employees new to Komatsu products or the earthmoving industry complete the KTTP before they enrol in further technical machine based training.
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Komatsu Literature and Manuals - This section provides participants with the fundamental knowledge of Komatsu manuals and their contents. In addition it provides the knowledge of other sources of information and provides an understanding of the correct paperwork and forms to use and their application. Komatsu Hydraulics Fundamentals - The hydraulics module provides participants with the fundamental knowledge of hydraulics applied to earthmoving and Komatsu equipment. In addition it will provide the skills to be able to use circuit diagrams and understand fundamental operating principles of the main hydraulic circuits.
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Komatsu Electrical Fundamentals - The electrical module provides participants with the fundamental knowledge of electricity applied to earthmoving and Komatsu equipment. In addition it will provide the skills to apply and use test equipment using diagrams and circuit principles. Troubleshooting Fundamentals - The troubleshooting module provides participants with the fundamental knowledge of troubleshooting techniques relevant to earthmoving and Komatsu equipment. In addition it will provide the skills and techniques to troubleshoot hydraulic and electrical circuits using schematics and other information.
MINING OPERATOR TRAINING COURSE OVERVIEW Our operator training provides participants with the knowledge and skills to: • Plan and prepare for operations • Operate machine (load shifting) Carry out basic operator maintenance Conduct housekeeping activities • •
MINING OPERATOR TRAINING Komatsu’s team of operator trainers covering mining equipment in Australia, New Zealand and New Caledonia are: •
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Experienced operators and trainers with Certificate IV in Workplace Training and Assessment Resources and Infrastructure Industry (RII) competency qualified and hold work credentials for our customer’s areas of activities
Komatsu Operator Training Programs offer: Train the trainer or train the operator programs available to meet customer requirements. Content designed to provide maximum productivity and efficiency Productivity increases and downtime decreases Full Theory and Practical training followed by assessment before endorsed to operate •
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The structure of the training is classroom instruction covering safety, operation, maintenance and inspections followed by a written assessment. The second phase is a walk around inspection and carrying out pre-operational checks along with instruction on the controls and monitor operations. This is followed by practical assessment and observation and instruction as required to ensure each operator is operating the machinery in a safe manner and in an efficient and industry expected fashion. •
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Optional refresher training three months following on from initial training Competency based operator training is available on request
Machine Familiarisation On the completion of the module the participants will be able to: A. Demonstrate safety precautions when operating the Komatsu machine B. Demonstrate the safe mounting and dismounting of the Komatsu machine C. Identify and locate major components of the Komatsu machine D. Locate and identify functions of cab fixtures on the Komatsu machine, including monitor panel E. Demonstrate an understanding of emergency warning systems, steering and brake systems as relevant to the Komatsu machine F. Demonstrate correct walk around inspection technique for the Komatsu machine G. Demonstrate safe operating practices on the Komatsu machine H. Demonstrate effective operating procedures for the Komatsu machine
Competency Based Training Where required by the customer the relevant performance criteria of this Komatsu familiarisation training will be mapped to and assessed against the relevant Training Package. This will be provided as part of the training package materials that cover the entire competency.
TRAINING
FOR MORE INFORMATION:
Australia - Ph: 1300 566 287 | Web: www.komatsu.com.au New Zealand - Ph: 0800 566 2878 | Web: www.komatsu.co.nz New Caledonia- Ph: +687 43 53 06 FORM NO. ZESB014400
