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KOMATSU VOCABULARY / GLOSSARY

Including common acronyms and terminologies. 07/11/06 TERM or ACRONYM Accumulator DEFINITION A gas and oil pressure holding device; allows emergency use of PPC pilot controls in the event of a diesel power interruption. An approximate 7-10% advantage over previous H/O models and/or competitors as measured in cubic yards per unit of time. This is generally done with maximized engine speed, PEMC, faster functions, and/or harder digging. No Pressure increase is provided; Power Max is still available to boost hydraulic pressure. Komatsu's extended warranty program. Usually an air-to-air (CAC) radiator type thermal dissipating device for reducing heat formed in turbocharged intake air prior to use in combustion. Can also be an air-to-coolant unit. Alarm Indicating Device Alternator Automatic Retard Speed Controller Area Service Manager (Essentially same as a DSM.) Articulated Truck Advanced Technic Contest - an annual troubleshooting skills competition for service technicians hosted by Komatsu Automatic Transmission Controller French word for advanced 1. LS By-pass 2. LS EPC Valve 3. LS Select Valve 4. Merge / Divide Valve (Defined separately below) Battery Brake Cooling Valve Before Failure Backhoe Loader Acts as a load-check valve to boom up circuits. Prevents leakage of cylinder oil through control valve spools. Usually not hose burst protection. Charge Air Cooler (See After Cooler.) Komatsu Service Management System Computer Assisted Sales Training Crawler Dozer Compact Hydraulic Excavator Closed-center Load Sensing System. Opposite of OLSS or Open Center type of hydraulic system. Uses a closed center control valve and system to regulate pump flow. (Also see HYDRAUMIND.) A feature to permit full (HP balanced) main oil flow (even over relief), usually during traveling, Power Max, L/O or Active Mode. A hydraulic systems feature designed to save fuel and wear. As main oil pressures rise to very near the relief cracking pressure, either CO Valves (OLSS) or the PEMC system (CLSS) are utilized to reduce flows from all main pumps.

Active Mode

Advantage Extended Coverage After Cooler AID ALT ARSC ASM AT ATC ATC Avance Avance FOUR ACES (Hyd. Excavators) BATT BCV BF BHL Boom Holding Valve CAC CARE CAST CD CHE CLSS CO Cancel

CO or Cut Off

TERM or ACRONYM

CO Valve (OLSS only)

COMOSY Control Pump (Oil) Controller CRI CSDDM CSM CSP's CSS CSS Net CWL Cycle Times DAC DAD DataKom Destroke DISCUS DLS DSM DT e-CARE ECM ECMV ECN ECSS EIS EMI EMMS EO E-OLSS

DEFINITION A pressure sensing control which functions to reduce the control oil signal between the TVC Valve and the Servo Valve on OLSS pump systems. Normal function provides the Cut Off hydraulic system feature. A pilot oil chamber receives a solenoid oil signal from the CO Cancel Solenoid to lock this device open, which is referred to as C O Cancel or full, unmodified pump flow usually intermittent so as to keep heat generation to a minimum. COmmunication MOnitoring SYstem (Avance) See Pilot Oil. An electronic device (usually a microprocessor) such as used in pump, engine or governor, air conditioning, or engine emissions controls. Operates actuators based on inputs from sensors, switches or operator selections of modes or features. Common Rail Injection system for diesel engines - meets US EPA Tier II. Customer Support, Distributor Development Manager (former DSM) Customer Support Manager Customer Service Programs Customer Support System (Publications for support via CD-ROM) www.cssnetusa.com - A limited access product support web site featuring parts and service publications and links. Access is by CSS subscription with password. Compact Wheel Loader Standard unit of performance measurement for hydraulic functions that rely on oil flow (displacement) for proper movement speed. Care is required with respect to measurement postures or equipment positioning to ensure consistent results. (See also Flow.) Distributor Advisory Council Data Acquisition Device The publishing arm of Komatsu America Corporation (KAC). Applies to PPM. Reduce Flow; piston pumps and motors with variable displacement controlled by varying the piston stroke to reduce or neutralize the flow while the pump continues to rotate. (See also Neutral.) Distributor Information System for Customer Satisfaction Distance Learning System. A combination of video-based, web-based and satellite training system. District Service Manager (Effective 2000 - called CSDDM) Dump Truck Extranet based Service Management System Engine Control Module Electronic Control Modulation Valve Engineering Change Notice Electronic Controlled Suspension System. Ride control system in Komatsu wheel loaders. Engine Idle Switch Equipment Manufacturers Institute Equipment Management Monitoring System. A type of monitoring system in the latest Komatsu equipment. Emergency Order (Parts Depots) Electronic Open centered Load Sensing System

TERM or ACRONYM

EPC

EPTC ERL ESSU ETSI EXTRANET F or FWD FC Flow FOPS FST G2000 GALEO GIR Governor Governor Motor GTI HE HEVI HMT Horsepower HSS HST HYDRAUMIND ICSS

DEFINITION Electronic Proportional Control. A variable solenoid valve; an electrically operated hydraulic valve which varies the oil pressure output in direct proportion to the amount of electrical current input flowing to the operating solenoid on the valve. Used to electronically control some hydraulic functions (i.e.: LS-EPC to input controller command to trim pump flow to 80% to permit 3 speed travel with 2 speed travel motors). Also a style of cab/ controls. Extended Power Train Coverage. A type of warranty policy. Engineering Release Letter Engine Speed Sensing Unit Electronic Technical Service Information. Input form and forum for product technical issues; see also MFR. Komatsu information source that can be accessed via the world wide web by internal personnel as well as distributor personnel. Forward Factory Campaign The volume of oil displaced in a hydraulic circuit. Measured in volume over time units, such as GPM (Gallons per Minute) or Liters per minute, but in Komatsu Hydraulic Excavators with known volumes of actuators simply measured in units of cycle times. Falling Object Protection Structure Field Service Training (See SFTAT.) Global Manufacturing and Marketing Long Range Plan Genuine Answers for Land & Environmental Optimization. New logo for the latest Komatsu equipment. General Information Request A controlling device used to maintain pre-established limits in various systems. A stepping servo motor with gearbox attached to and operating a diesel engines throttle linkage providing electronically interfaced engine fuel control. Global Training Institute Hydraulic Excavator Heavy Equipment & Vehicle Institute at Oklahoma State University, where Komatsu and VICA jointly sponsor a 2-year Technician Scholarship program. Hydro Mechanical Transmission (hydrostatic and mechanical) A FORCE moving at a RATE of speed, used to accomplish work. In Avance Excavators, engine power produced is matched to pump horsepower absorbed using the PEMC system, which does this through pump regulation. Hydro Static Steering Hydro Static Transmission (Also see KomStat.) HYDRAUlic Mechanical Intelligence New Design (CLSS) Improving Customer Satisfaction through Support A hydraulic venturi type and orifice type device used to signal increase / decrease in OLSS open center (Neutral) flow to the NC Valve, which then destrokes or strokes the variable volume piston pump system in that circuit. This reduces flow, and therefore fuel consumption and wear, when controls are in neutral. Joint Marketing Plan. A joint marketing plan between Komatsu and individual distributors. Joint Follow Up Log. A systematic, structured customer satisfaction and issue resolution system comprised of a triad of customer, distributor and factory members who join as a team to resolve issues and improve products and services.

Jet Sensor

JMP

JoiFUL

TERM or ACRONYM Junction Valve KAC KAIC KCE KDB KE KIRD KLMS KLTD KMMD KomStat KomTrax KOWA KSS KTPK KUK KUMD LAD LAR LMS LOAMS

DEFINITION (See Merge/Divide Valve or Travel Junction Valve.) Komatsu America Corp. Komatsu America International Company Komatsu Component Exchange Komatsu de Brazil Komatsu Europe Komatsu Information on Reliablity & Durability Komatsu Learning Management System Komatsu Ltd. (Parent corporation, Japan) Komatsu Mining Marketing Division Hydrostatic line of products, primarily dozers featuring full hydrostatic drive. Komatsu (satellite and GPS) tracking system Komatsu Oil Wear Analysis program Komatsu Sales Solutions - A multi-part product and selling skills program designed to supply both our internaal sales and distributor sales personnel with the knowledge necessary to meet distributor sales goals. Komatsu Technical Presentation Kit Komatsu United Kingdom Komatsu Utility Marketing Division Latin American Division Latin American Region Learning Management System Lube Oil Analysis Management System Load Sensing. Used with CLSS to signal hydraulic demands for use by the pumps flow control system. The LS circuit operates at nearly the same pressure as the highest main circuit pressure in use. L S oil also is used as an input to the pressure compensation valves to throttle oil flow in the lower pressure circuits, allowing the initiation of compound functions simultaneously. LS also signals closure of the CLSS unload valves as main oil is being opened for use moving a function(s). Device venting metered oil flow out of LS circuit to enhance dynamic stability and fine control by reducing speed of rise (shock) of LS pressure. Same device vents LS pressure to tank in neutral, allowing unload valves to open. Provides front / rear isolation of LS circuits at a common passage to the LS By-pass plug, permitting LS pressure to bleed off in neutral. Variable Solenoid Valve outputting a regulated pilot pressure oil signal to the LS Valve. Allows precise, electronic pump flow control (i.e. 80% flow for Mi. travel, etc.). During neutral operation this 2-function valve acts to unload (relieve) 2 circuits: LS is unloaded to zero; Main is relieved at unloader set pressure (usually 30-50 kg/cm). During actuated operation, LS pressure rise causes unload section to close, as relief section rises to nominal system pressure (325 kg/cm). Also features a pilot-operated relief cut-off to temporarily close relief during Power-Max use. Abolished in 1996. Operates the LS Select Valve. Device to isolate the swing LS signal during compound functions by using a pilot signal (from the LS Select Solenoid or other pilot circuit) to close off the swing LS circuit.

LS

LS By-pass LS Check Valves LS EPC

LS Relief / Main Unload Valve

LS Select Solenoid LS Select Valve

TERM or ACRONYM LS Shuttle Valve

LS Valve MADAM Main Oil Circuit MAPT Blade MAS MC MDR Merge / Divide Solenoid Merge / Divide Valve

DEFINITION Devices that simultaneously carry and allow only the highest LS pressure to affect the pressure compensation valves and the pump control system. Flow is only in direction toward the LS check valves and LS end cover (the LS manifold). Load Sensing Valve housed inside a variable displacement hydraulic pump (PPM) assembly. Function is to control main circuit oil draining out of or pressurizing one end (the larger end) of the servo piston, thereby controlling swash plate angle and the pumps oil output flow. Marketing Administration Data Mart Usually working or actuator oil representing the majority of the pumps or systems flow or horsepower capacity, but can vary from low to maximum flow as well as low (unloader) to maximum relief pressures. Mechanical Angle Power Tilt Blade Market-oriented Active Support Mobile Crusher Machine Down Report Sends a pilot signal to divide pump flows at the Merge/Divide Valve as directed by the controller logic, which varies according to model. Solenoid operated device allowing separate hydraulic systems to share oil supply from the other pump. Divides to dedicate oil flow for exclusive use during certain functions and for testing and adjusting and troubleshooting. Consists of Main spool and LS spool with springs, housing. Major Failure Report (usually but not exclusively a result of many common problems reported via ETSI). MFR inputs requests for product improvements. Motor Grader Not a Model change, but significant enough to track and announce with distinct serial number breaks. Usually several features or product improvements. Message for Operation & Maintenance Data for Service Technicians including BITS revealing circuit or sensor abnormalities and Service or Failure codes including SMR hours since occurrence was logged by the system. Material Return Authorization Mobile Service Vehicle - Self-contained service shop on wheels. Negative Control (an OLSS pump control device) - a.k.a. "Neutral Control" In hydraulic systems this refers to a Zero Flow or minimum flow condition caused by the pumps being destroked to permit continued rotation with minimal fuel consumed or horsepower used. (Also see Swash.) Komatsu Avance Excavators require approximately 3% - 10% flow at neutral for reliable CLSS pump control and ensures readiness to respond when work is begun. Optimum Fleet Recommendation Open-center Load Sensing System One Stop Shopping - Factory installation of common options and attachments for Chattanooga sourced machines Policy Adjustment Printing and Distribution System Power Angle Tilt Blade Parts BOok Search System (Also see CLSS.) Power Control valve (same function as TVC, but uses the variable solenoid PC-EPC pilot oil signal instead of solenoid plunger force directly applied to the TVC spool). A mechanical/hydraulic control valve.

MFR MG Minor Change (m/c) MOM Monitor Codes MRA MSV NC

Neutral

OFR OLSS OSS PA PADS PAT Blade P-BOSS PC

TERM or ACRONYM PC EPC

PCCS PDC

PEMC

Pilot Oil Circuit PIPS PLM PM PMC PMI PM-Pro Power PPASR PPC PPC Shuttle PPL PPM

DEFINITION A variable solenoid valve used to change the controllers variable electrical current (input) into a variable pilot pressure. This helps operate the PC Valve in sending main oil through the LS Valve drain to destroke a loaded pump to match available engine horsepower. (Also see PEMC.) Palm Command Control System. Joystick steering system found in the latest Komatsu dozers. Parts Distribution Center Pump Engine Mutual Control. The use of TVC or PC valve and controller systems to best match pumps' horsepower demand to available engine power. This maximizes fuel efficiency and hydraulic system reliability. Also enables different modes of excavator operation (H/O, G/O, F/O, L/O, B/O and Active Mode). Circuit and/or pump (also known as control oil used at a lower pressure (2550 kg/cm) than main oil) used for the purpose of remotely controlling (piloting) Hydraulic Control Valves using Proportional Pilot Control valves (PPC). Parts Information Product Support - the PDC parts computer network. Pay Load Meter Preventive Maintenance Powertrain Management Controller Preventative Maintenance Inspections (PM Clinic, PM Tune-up) Planned Maintenance (See Horsepower.) Product Problem & Action Status Report Proportional Pilot Control valves. Pilot oil signals are proportioned in accordance with the amount the operator moves each lever. Also a style of cab/controls. Houses the shuttle valves for pilot signals as well as the location of pressure switch ports for each function. Price & Policy Letter Piston Pumps (and/or) Motors (piston motors) of fixed or variable displacements. In basic hydraulic circuits, pressure equals resistance to flow. In Komatsu Avance Excavators pressure is measured in three hydraulic circuits: main, pilot and load sense (LS). Pressures are measured in Kilograms per square centimeter or kg/cm. Monitor panels on Avance Excavators can produce digital outputs of main circuit pressures for main PPM pumps (front and/or rear). Also commonly referred to as the load on a hydraulic actuator. Metering valve installed prior to each spool to balance the load of unequally loaded actuators. This allows oil flows to be directed according to the users wishes (inputs) and NOT be load influenced. Also where LS signal is created (IF type). Metering valve installed at each port of each control spool to balance the load of unequally loaded actuators. This allows oil flows to be directed according to the users wishes (inputs) and NOT be load influenced. Uses LS oil to meter flows. By-pass switch permitting a function (pump, swing), which needs repair to be operated. Product Service Information Pressure staying Inside (A good thing!) Pressure squirting out (A bad thing!) Product Support Sales Representative

Pressure

Pressure Compensation Valve (IF - InFeed type) Pressure Compensation Valve (port type) Prolix PSI Psi Pso PSSR

TERM or ACRONYM QTQA R or REV R&M Contract RAMP RCM

DEFINITION Quick Technical Question & Answer Reverse Repair and Maintenance Contract Repair and Maintenance Program Retarder Control Module Device designed to protect the pump side of main oil circuits from over pressurizing beyond their designed cracking pressures (i.e. 325 kg/cm STD, or 355 kg/cm Hi for 2-stage types). Usually designed to accommodate full designed flow capacity. (PC300/400) However, certain single-stage relief valves have dynamics, which allow nominal resistance at nominal flow rates, so that at maximum flows they exhibit a higher resistance (pressure) due to their dynamics acting as a full flow orifice. This thereby increases Main circuit pressure with no extra stage or pilot signal, but using the increased flow as the signal. Main Relief valves are used with (solenoid blocked) LS Relief Valves for 355 kg/cm cracking pressures. (Certain older serial numbered products.) Remanufactured components Roll Over Protection Structure Rigid Truck Support Aggregate (sand/gravel) Customers A combined assembly of two operating devices, which provide (safety) circuit relief and (suction) anti-cavitation protection to each circuit. Enterprise software for controlling accounting, manufacturing, inventory, etc., used by Komatsu. An automatic device to reduce main pump oil pressure to be used as pilot oil (control oil). Allows elimination of a control pump. A linear actuator hydraulically powering swash plate angle changes to stroke or destroke a variable volume piston pump or motor (PPM). Similar to servo piston but including a mechanically linked spool arrangement to aid in servo oil control. Sales Engineering Support Team Special Feature Request Structure, Function, Testing, Adjusting & Troubleshooting which are the primary education elements provided at FST Service schools. Service Market Development Service Meter Reading (hours of engine runtime) Service Operation Development An ON or OFF hydraulic valve. Usually found in the pilot circuit, providing electrical over hydraulic control of certain system features. Solenoids may be operated either by the controller computer control (2-stage relief; LS select), or by manual operation of an electrical switch (PPC Lock; Push Up Switch), or both (Swing Lock). Service Operation Monthly Report Service Operation Study Special Policy Adjustment Special Price Assistance Request Sales Presentation Kit Service Policy and Procedure Manual Serious Quality Problem a product issue reported via numerous ETSI for which countermeasures are being researched or designed.

Relief Valve

REMAN ROPS RT SAC Safety + Suction Valve SAP Self-Pressure Reducing Valve Servo Piston Servo Valve SEST SFR SFTAT SMD SMR SOD

Solenoid Valve

SOMR SOS SPA SPAR SPK SPPM SQP

TERM or ACRONYM SQP SSL STEP Sub Unload Valve Serious Quality Problem Skid Steer Loader

DEFINITION

Swash Plate

Swing Brake

Swing Brake (Release) Solenoid Swing Lock Switch Swing Prolix (Bypass) Switch TAC TAP TIPS TMS TPI TPK TQI Travel Junction Valve Travel Speed Solenoid Valve TSI TSR TSS TVC Unload Valve User Code (Avance Excavators)

Skill & Training Evaluation Program Device designed to relieve a small quantity (about 3%) of main oil during neutral while dumping/unloading LS circuit to zero or tank circuit. In operation, the LS circuit rise in pressure closes the unload valve to allow LS circuit and main circuits to build pressures. An angled sliding surface which dynamically causes piston pumps or motors (PPM) to stroke (flow more), or destroke (flow less). A multiple disc friction brake designed to HOLD the swing function (static, not dynamic), unless hydraulically released. Spring applied in the absence of release oil, which the controller timer stops at the release solenoid approximately 4 seconds after the swing PPC has been returned to neutral; thereby preventing any inadvertent swing brake application as the swing motion ceases. Pilot oil solenoid (ON/OFF) valve used by the controller computer every time swing pilot pressure closes the swing pressure switch, unless the Swing Lock switch is ON causing an interruption in the electrical ON signal from the controller (attempting to release the swing brake). (See Swing Brake Solenoid.) In the UP position, causes uninterrupted battery voltage to power the Swing Brake Release Solenoid. This will continuously release the swing brake (a potential hazard on a slope), unless the Swing Lock Switch is ON interrupting this battery direct circuit. Technical Assistance Center Training Administration Program Technical Information Product Support (KAIC Service Department Computer network) Track Management System Technical Parts Inquiry Technical Presentation Kit Total Quality Initiative Device in parallel to travel motor main oil circuits (forward or reverse), to allow shared oil crossover to compensate for any slight travel oil variations, thus ensuring straight travel. Valve closes during steering commands so shared oil crossover does not hamper the steering results. Sends pilot oil to the travel motors regulator/servo control, changing the displacement to MINIMUM for medium and high speeds. In low speed solenoid is OFF. (See ETSI.) Technical Service Request Troubleshooting System Torque Variable Control valve. An electric/mechanical/hydraulic control valve used to limit pump stroke (flow) to keep within the available power setting of the engine. (Also see PC Valve.) (See both LS Relief and SubUnload Valve) An automatic warning to the operator or user deemed important enough to alert, due to risk of damage related to abnormalities sensed by the machines self diagnostics network. Vehicle Health Monitoring System. An on-board data collecting system from the vehicle controllers and additional sensors. Its designed for large size equipment such as HD785/985, 930E, PC1800, PC4000, and WA1200

VHMS

TERM or ACRONYM WebCARE Webcast WL WPG

DEFINITION A web-based global database for VHMS, Pm-Clinic and Oil Analysis (KOWA) data. A web-based medium for presenting training content or other information to multiple locations throughout the world. Wheel Loader Warranty Procedure Guide