KOMATSU VOCABULARY / GLOSSARY Including common acronyms and terminologies.

07/11/06 TERM or ACRONYM DEFINITION

Accumulator A gas and oil pressure holding device; allows emergency use of PPC pilot controls in the event of a diesel power interruption.

Active Mode

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.

Advantage Extended Coverage Komatsu's extended warranty program.

After Cooler 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.

AID Alarm Indicating Device

ALT Alternator

ARSC Automatic Retard Speed Controller

ASM Area Service Manager (Essentially same as a DSM.)

AT Articulated Truck

ATC Advanced Technic Contest - an annual troubleshooting skills competition for service technicians hosted by Komatsu

ATC Automatic Transmission Controller

Avance French word for “advanced”

Avance FOUR ACES (Hyd. Excavators)

1. LS By-pass 2. LS EPC Valve 3. LS Select Valve 4. Merge / Divide Valve (Defined separately below)

BATT Battery

BCV Brake Cooling Valve

BF Before Failure

BHL Backhoe Loader

Boom Holding Valve Acts as a ‘load-check’ valve to boom up circuits. Prevents leakage of cylinder oil through control valve spools. Usually not hose burst protection.

CAC Charge Air Cooler (See After Cooler.)

CARE Komatsu Service Management System

CAST Computer Assisted Sales Training

CD Crawler Dozer

CHE Compact Hydraulic Excavator

CLSS 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.)

CO Cancel A feature to permit full (HP balanced) main oil flow (even over relief), usually during traveling, Power Max, L/O or Active Mode.

CO or Cut Off 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.

TERM or ACRONYM DEFINITION

CO Valve (OLSS only)

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.

COMOSY COmmunication MOnitoring SYstem (Avance)

Control Pump (Oil) See Pilot Oil.

Controller 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.

CRI Common Rail Injection system for diesel engines - meets US EPA Tier II.

CSDDM Customer Support, Distributor Development Manager (former DSM)

CSM Customer Support Manager

CSP's Customer Service Programs

CSS Customer Support System (Publications for support via CD-ROM)

CSS Net www.cssnetusa.com - A limited access product support web site featuring parts and service publications and links. Access is by CSS subscription with password.

CWL Compact Wheel Loader

Cycle Times 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.)

DAC Distributor Advisory Council

DAD Data Acquisition Device

DataKom The publishing arm of Komatsu America Corporation (KAC).

Destroke 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.)

DISCUS Distributor Information System for Customer Satisfaction

DLS Distance Learning System. A combination of video-based, web-based and satellite training system.

DSM District Service Manager (Effective 2000 - called CSDDM)

DT Dump Truck

e-CARE Extranet based Service Management System

ECM Engine Control Module

ECMV Electronic Control Modulation Valve

ECN Engineering Change Notice

ECSS Electronic Controlled Suspension System. Ride control system in Komatsu wheel loaders.

EIS Engine Idle Switch

EMI Equipment Manufacturers Institute

EMMS Equipment Management Monitoring System. A type of monitoring system in the latest Komatsu equipment.

EO Emergency Order (Parts Depots)

E-OLSS Electronic Open centered Load Sensing System

TERM or ACRONYM DEFINITION

EPC

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.

EPTC Extended Power Train Coverage. A type of warranty policy.

ERL Engineering Release Letter

ESSU Engine Speed Sensing Unit

ETSI Electronic Technical Service Information. Input form and forum for product technical issues; see also MFR.

EXTRANET Komatsu information source that can be accessed via the world wide web by internal personnel as well as distributor personnel.

F or FWD Forward

FC Factory Campaign

Flow 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.

FOPS Falling Object Protection Structure

FST Field Service Training (See SFTAT.)

G2000 Global Manufacturing and Marketing Long Range Plan

GALEO Genuine Answers for Land & Environmental Optimization. New logo for the latest Komatsu equipment.

GIR General Information Request

Governor A controlling device used to maintain pre-established limits in various systems.

Governor Motor A stepping servo motor with gearbox attached to and operating a diesel engine’s throttle linkage providing electronically interfaced engine fuel control.

GTI Global Training Institute

HE Hydraulic Excavator

HEVI Heavy Equipment & Vehicle Institute at Oklahoma State University, where Komatsu and VICA jointly sponsor a 2-year Technician Scholarship program.

HMT Hydro Mechanical Transmission (hydrostatic and mechanical)

Horsepower 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.

HSS Hydro Static Steering

HST Hydro Static Transmission (Also see KomStat.)

HYDRAUMIND HYDRAUlic Mechanical Intelligence New Design (CLSS)

ICSS Improving Customer Satisfaction through Support

Jet Sensor

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.

JMP Joint Marketing Plan. A joint marketing plan between Komatsu and individual distributors.

JoiFUL 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.

TERM or ACRONYM DEFINITION Junction Valve (See Merge/Divide Valve or Travel Junction Valve.)

KAC Komatsu America Corp.

KAIC Komatsu America International Company

KCE Komatsu Component Exchange

KDB Komatsu de Brazil

KE Komatsu Europe

KIRD Komatsu Information on Reliablity & Durability

KLMS Komatsu Learning Management System

KLTD Komatsu Ltd. (Parent corporation, Japan)

KMMD Komatsu Mining Marketing Division

KomStat Hydrostatic line of products, primarily dozers featuring full hydrostatic drive.

KomTrax Komatsu (satellite and GPS) tracking system

KOWA Komatsu Oil Wear Analysis program

KSS 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.

KTPK Komatsu Technical Presentation Kit

KUK Komatsu United Kingdom

KUMD Komatsu Utility Marketing Division

LAD Latin American Division

LAR Latin American Region

LMS Learning Management System

LOAMS Lube Oil Analysis Management System

LS

Load Sensing. Used with CLSS to signal hydraulic demands for use by the pump’s 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).

LS By-pass 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.

LS Check Valves 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.

LS EPC 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.).

LS Relief / Main Unload Valve

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/cm²). During actuated operation, LS pressure rise causes unload section to close, as relief section rises to nominal system pressure (325 kg/cm²). Also features a pilot-operated relief cut-off to temporarily close relief during “Power-Max” use. Abolished in 1996.

LS Select Solenoid Operates the LS Select Valve.

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.

TERM or ACRONYM DEFINITION

LS Shuttle Valve 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).

LS Valve 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 pump’s oil output flow.

MADAM Marketing Administration Data Mart

Main Oil Circuit Usually “working” or “actuator” oil representing the majority of the pump’s or system’s flow or horsepower capacity, but can vary from low to maximum flow as well as low (unloader) to maximum relief pressures.

MAPT Blade Mechanical Angle Power Tilt Blade

MAS Market-oriented Active Support

MC Mobile Crusher

MDR Machine Down Report Merge / Divide Solenoid

Sends a pilot signal to “divide” pump flows at the Merge/Divide Valve as directed by the controller logic, which varies according to model.

Merge / Divide Valve 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.

MFR Major Failure Report (usually but not exclusively a result of many common problems reported via ETSI). MFR inputs requests for product improvements.

MG Motor Grader

Minor Change (m/c) Not a Model change, but significant enough to track and announce with distinct serial number breaks. Usually several features or product improvements.

MOM Message for Operation & Maintenance

Monitor Codes 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.

MRA Material Return Authorization

MSV Mobile Service Vehicle - Self-contained service shop on wheels.

NC Negative Control (an OLSS pump control device) - a.k.a. "Neutral Control"

Neutral

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.

OFR Optimum Fleet Recommendation

OLSS Open-center Load Sensing System

OSS One Stop Shopping - Factory installation of common options and attachments for Chattanooga sourced machines

PA Policy Adjustment

PADS Printing and Distribution System

PAT Blade Power Angle Tilt Blade

P-BOSS Parts BOok Search System (Also see CLSS.)

PC 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.

TERM or ACRONYM DEFINITION

PC EPC A variable solenoid valve used to change the controller’s 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.)

PCCS Palm Command Control System. Joystick steering system found in the latest Komatsu dozers.

PDC Parts Distribution Center

PEMC

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”).

Pilot Oil Circuit Circuit and/or pump (also known as control oil used at a lower pressure (25-50 kg/cm²) than “main oil”) used for the purpose of remotely controlling (piloting) Hydraulic Control Valves using Proportional Pilot Control valves (PPC).

PIPS Parts Information Product Support - the PDC parts computer network.

PLM Pay Load Meter

PM Preventive Maintenance

PMC Powertrain Management Controller

PMI Preventative Maintenance Inspections (PM Clinic, PM Tune-up)

PM-Pro Planned Maintenance

Power (See Horsepower.)

PPASR Product Problem & Action Status Report

PPC 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.

PPC Shuttle Houses the shuttle valves for pilot signals as well as the location of pressure switch ports for each function.

PPL Price & Policy Letter

PPM Piston Pumps (and/or) Motors (piston motors) of fixed or variable displacements.

Pressure

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/cm². 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.

Pressure Compensation Valve (IF - InFeed type)

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 user’s wishes (inputs) and NOT be load influenced. Also where LS signal is created (IF type).

Pressure Compensation Valve (port 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 user’s wishes (inputs) and NOT be load influenced. Uses LS oil to meter flows.

Prolix By-pass switch permitting a function (pump, swing), which needs repair to be operated.

PSI Product Service Information

Psi Pressure staying Inside (A good thing!)

Pso Pressure squirting out (A bad thing!)

PSSR Product Support Sales Representative

TERM or ACRONYM DEFINITION QTQA Quick Technical Question & Answer

R or REV Reverse

R&M Contract Repair and Maintenance Contract

RAMP Repair and Maintenance Program

RCM Retarder Control Module

Relief Valve

Device designed to protect the pump side of main oil circuits from over pressurizing beyond their designed “cracking pressures” (i.e. 325 kg/cm² STD, or 355 kg/cm² ‘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/cm² cracking pressures. (Certain older serial numbered products.)

REMAN Remanufactured components

ROPS Roll Over Protection Structure

RT Rigid Truck

SAC Support Aggregate (sand/gravel) Customers Safety + Suction Valve

A combined assembly of two operating devices, which provide (safety) circuit relief and (suction) anti-cavitation protection to each circuit.

SAP Enterprise software for controlling accounting, manufacturing, inventory, etc., used by Komatsu.

Self-Pressure Reducing Valve

An automatic device to reduce main pump oil pressure to be used as pilot oil (control oil). Allows elimination of a control pump.

Servo Piston A linear actuator hydraulically powering swash plate angle changes to stroke or destroke a variable volume piston pump or motor (PPM).

Servo Valve Similar to servo piston but including a mechanically linked spool arrangement to aid in servo oil control.

SEST Sales Engineering Support Team

SFR Special Feature Request

SFTAT Structure, Function, Testing, Adjusting & Troubleshooting – which are the primary education elements provided at FST Service schools.

SMD Service Market Development

SMR Service Meter Reading (hours of engine runtime)

SOD Service Operation Development

Solenoid Valve

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).

SOMR Service Operation Monthly Report

SOS Service Operation Study

SPA Special Policy Adjustment

SPAR Special Price Assistance Request

SPK Sales Presentation Kit

SPPM Service Policy and Procedure Manual

SQP Serious Quality Problem – a product issue reported via numerous ETSI for which countermeasures are being researched or designed.

TERM or ACRONYM DEFINITION SQP Serious Quality Problem

SSL Skid Steer Loader

STEP Skill & Training Evaluation Program

Sub Unload Valve 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.

Swash Plate An angled sliding surface which dynamically causes piston pumps or motors (PPM) to stroke (flow more), or destroke (flow less).

Swing Brake

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.

Swing Brake (Release) Solenoid

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).

Swing Lock Switch (See Swing Brake Solenoid.)

Swing Prolix (By-pass) Switch

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.

TAC Technical Assistance Center

TAP Training Administration Program

TIPS Technical Information Product Support (KAIC Service Department Computer network)

TMS Track Management System

TPI Technical Parts Inquiry

TPK Technical Presentation Kit

TQI Total Quality Initiative

Travel Junction Valve

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.

Travel Speed Solenoid Valve

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.

TSI (See ETSI.)

TSR Technical Service Request

TSS Troubleshooting System

TVC 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.)

Unload Valve (See both LS Relief and SubUnload Valve)

User Code (Avance Excavators)

An automatic warning to the operator or user deemed important enough to alert, due to risk of damage related to abnormalities sensed by the machine’s self diagnostics network.

VHMS Vehicle Health Monitoring System. An on-board data collecting system from the vehicle controllers and additional sensors. It’s designed for large size equipment such as HD785/985, 930E, PC1800, PC4000, and WA1200

TERM or ACRONYM DEFINITION

WebCARE A web-based global database for VHMS, Pm-Clinic and Oil Analysis (KOWA) data.

Webcast A web-based medium for presenting training content or other information to multiple locations throughout the world.

WL Wheel Loader

WPG Warranty Procedure Guide