TRAINING

KOMATSU TECHNICAL AND

OPERATOR TRAINING
Covers Backhoe Loaders, Bulldozers, Crushers, Dump Trucks, Excavators,
Graders ,Wheel Loaders, Skidsteers, General Systems and Technologies
 Technical And
operator
training?
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
technology platform,
such as hydraulics,
electrics and engines.
Komatsu operator
training is aimed at
the skills required of
endorsed machine
operators and operator
trainers in the areas of
operator familiarisation
training on Komatsu
equipment for plant
operators and trainers.
UnEarth your potential
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’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
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
Machine Course Content
Level 1 Introduction and General Service
Duration 8 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 B. Describe the design concepts of each of the
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 systems on the Komatsu machine
Komatsu machine
F. Locate service points and describe the
specific service requirements for each point, as
stated in the machine operating manual
Level 3 Test and Adjust
Komatsu training programs are designed around our
Duration 8 hours. On completion of the module
“best practice” global standards model. Stringent
participants will be able to:
evaluation and review by our customers enables
us to offer practical programs that deliver results
A. Carry out safety precautions to be observed
to your business. Komatsu training provides a high
when tests and adjustments are conducted on
quality learning experience that delivers “next day”
the Komatsu machine
work place skills.
B. Test and adjust engine components on the Komatsu machine.
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 faults of the Komatsu machine.
and electrical components on the
Komatsu machine
G. Use Komatsu test equipment in maintaining
the machine
• 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
Level 2 Structure and Function
Duration 8-12 hours. On completion of this
module the participants will be able to:
A. Demonstrate safety precautions relevant to the
machine system being covered
machine systems
C. Identify and locate components of all
major systems on the Komatsu machine
D. Describe the principles of operation of all major
E. Demonstrate a working knowledge of circuit
diagrams relevant to the Komatsu machine
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
evaluating and diagnosing the Komatsu machine.
B. Used Komatsu test equipment in maintaining the
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
G. Evaluate and diagnose faults in the hydraulic
equipment of the Komatsu machine.
H. Interpret schematic drawings for hydraulic and
electrical components.
 Technical Skills Competency Map
4.1 Use the correct test equipment to 4.2 Use Komatsu literature to 4.3 Demonstrate troubleshooting techniques
troubleshoot system faults aid in problem resolution

4.1.1 4.1.2 4.1.3 4.2.1 4.2.2 4.2.3 4.3.1 4.3.2 4.3.3

Trouble shooting

Demonstrate the Demonstrate the Demonstrate the Describe the basic checks that Demonstrate the Use a Demonstrate the correct sequence Conduct tests and collect test data Analyse the test results and
LEVEL 04

correct selection of correct use of correct use need to be carried out before correct method combination of of troubleshooting communicate the failure diagnosis
tools/ monitor panel troubleshooting tool of electrical troubleshooting of using the literature and test
for specific tasks testing troubleshooting chart data to pinpoint
instruments the cause of the
failure

3.1 Explain the Komatsu recommended 3.2 Perform machine testing to 3.3 Compare test results with Komatsu specifications and make recommendations
procedures for testing of system Komatsu recommendations
components

3.1.1 3.1.2 3.1.3 3.2.1 3.2.2 3.3.1 3.3.2

Test & Adjust
LEVEL 03

Describe the tests Select the correct Explain the Use tools, monitor panel and Record all test results Compare all test results with Observe and comment on results not meeting specification
that can be carried instruments and advantages of instruments correctly and safely to Komatsu specifications
out on each machine tools for machine completing a gain readings from test procedures
system system testing PM-Clinic sheet

2.1 Using the Shop Manual obtain information 2.2 Explain the operating principles
relevant to the operation of components and of each of the functional machine 2.3 Using circuit diagrams show the systems operation
specifications systems
Test & Adjust
LEVEL 02

2.1.1 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 Use the Shop Describe the Describe the Describe the operation of selected Using hydraulic circuit diagrams Using electric circuit diagrams show the flow of current in
components and describe their operation Manual to obtain operation of different parts of components using a diagram or actual show the flow and operation of selected systems selected circuits and explain the operation of that circuit
selected each of the components/ component
component systems used monitor panel as
specifications on the machine indicated
using reference in the practical
material worksheet

1.1 Explain or demonstrate 1.2 Use Operation and Maintenance Manual, Shop Manual 1.3 Describe and locate selected 1.4 Locate service points and
compliance with all safety and Parts Book to locate information components of a machine perform a service
procedures related to
Introduction & General Servicing

servicing the machine

1.1.1 1.1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.3.1 1.3.2 1.3.3 1.4.1 1.4.2 1.4.3
Using the operation Demonstrate Using The Shop Using Using the Using the Shop or Operation and
LEVEL 01

Using the machine Using the Shop Describe Describe service Locate selected Perform/describe a basic
and Maintenance awareness of the Manual the Parts Operation and Maintenance Manual, locate details on the locate selected Manual locate component requirements for service points serviceto Komatsu machine
Manual explain need to know and demonstrate Book identify Maintenance basic servicing requirements of the machine components selected differences selected service and record on specifications including monitor
safety procedures comply with different understanding parts required Manual, and record on components between intervals and complete service point panel use
related to machine site specific safety of the page to perform locate specific the machine of the machine different a service/warranty identification
operation for service procedure revision system a selected information component model report sheet
personnel periodic relating to identification machines
maintenance machine sheet of this type
service operational
controls
Recommended Komatsu Technical Typical Machine Specific Technical
Training Structure and PathWAYS Training Rollouts
Depending on the variety of machines and fleet size familiar, we would then follow up with the Structure
Machine Types Module Timeframe
we would recommend a couple of different options and Function module which would provide in depth
for machine training. knowledge of how each of the machine systems
work. Again this would be followed up three months
TRUCK 4) Troubleshooting After 12 month For a diversified group of machinery and based on later with the Testing and Adjusting module whereby
previous experience we have found that the best the training would cover machine testing and
way to ensure high level of skills take up across adjusting procedures.
a broad range of machines, it is best to run each
tier separately. This allows the participants to learn the product in
After 9 months of conjunction with their exposure and experience with
BULLDOZER 3) Testing and Adjusting
delivery In this circumstance we would suggest a progressive the machine.
approach whereby the Introduction and General
Service module would be run across the suite of For sites with a smaller variety of machines it
machines within the first 3 months of delivery. is recommended to combine the Introduction and
This would give the technicians an introduction to General Service and Structure and Function modules
On delivery or
2) Structure and Function – the machine and give them the skills to service the at the initial machine delivery followed by Testing and
EXCAVATOR can be combined with 1
within 6 month
machines when they first arrive. Then after 3 months, Adjusting training within 6 months of delivery.
of delievery
giving the technicians a chance to get some hands
on experience with the machinery and become more

1) Introduction and
WHEEL LOADER General Service
On delivery

Komatsu Total
BACKHOE Technical Picture
(KTTP)

Mechanically and/or
GRADER Electrically Qualified
Trades people

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:
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
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
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.
Komatsu Total Technical Picture (KTTP)
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.
The KTTP covers
• Komatsu Literature and Manuals - This section • Komatsu Electrical Fundamentals - The
provides participants with the fundamental electrical module provides participants with the
knowledge of Komatsu manuals and their fundamental knowledge of electricity applied to
contents. In addition it provides the knowledge earthmoving and Komatsu equipment. In addition
of other sources of information and provides an it will provide the skills to apply and use test
understanding of the correct paperwork and equipment using diagrams and circuit principles.
forms to use and their application.
• Troubleshooting Fundamentals - The
• Komatsu Hydraulics Fundamentals - The troubleshooting module provides participants with
hydraulics module provides participants with the the fundamental knowledge of troubleshooting
fundamental knowledge of hydraulics applied to techniques relevant to earthmoving and Komatsu
earthmoving and Komatsu equipment. In addition equipment. In addition it will provide the skills and
it will provide the skills to be able to use circuit techniques to troubleshoot hydraulic and electrical
diagrams and understand fundamental operating circuits using schematics and other information.
principles of the main hydraulic circuits.

Mining Operator Training
Komatsu’s team of operator trainers covering
mining equipment in Australia, New Zealand
and New Caledonia are:
• 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 expected fashion.
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
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
• Optional refresher training three months
following on from initial training
• Competency based operator training is available
on request
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
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
Competency Based Training
relevant to the Komatsu machine
Where required by the customer the relevant
F. Demonstrate correct walk around inspection
performance criteria of this Komatsu
technique for the Komatsu machine
familiarisation training will be mapped to and
G. Demonstrate safe operating practices on the
assessed against the relevant Training Package.
Komatsu machine
This will be provided as part of the training package
H. Demonstrate effective operating procedures for
materials that cover the entire competency.
the Komatsu machine
 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