Basic

Knowledge
All Products

No. BPK-A-005-EO
INTERNAL USE ONLY Dec. 1989

Technical terms and general terms

Introduction
This manual is a simple collection of basic technical terms used for construction equipment, so please use it as a
primer. The content are limited to basic terms that appear frequently in catalogs and product bulletins, and the
explanation is also limited to a simple outline. Therefore, for details of structure, function, etc., please refer to the
specialist manuals, such as product bulletins, shop manuals, and training aids.

Content

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2 Bulldozers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3 Hydraulic excavators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
4 Wheel loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5 Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

KOMATSU MARKETING DIVISION

 1 General
Contents
Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Machine model code (Basic) . . . . . . . . . . . . . . . . . . .10
CAD (Computer Aided Design) . . . . . . . . . . . . . . . . . .3 Machine model code (Construction machine) . . . . . . .11
CAM (Computer Aided Manufacturing) . . . . . . . . . . . .3 Machine model code (Engine) . . . . . . . . . . . . . . . . . .11
CIM (Computer Integrated Manufacturing) . . . . . . . . .3
Combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . .4 OEM (Original Equipment Manufacturing) . . . . . . . .12
Constant- mesh type transmission . . . . . . . . . . . . . . . . .4 OFR (Optimum Fleet Recommendation) . . . . . . . . . .12
Counterrotation turn . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Pivot turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
dB (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Planetary gear type transmission . . . . . . . . . . . . . . . . .12
Double locked connector . . . . . . . . . . . . . . . . . . . . . . .5 POC (Pilot Operated Control) . . . . . . . . . . . . . . . . . . .13
Ductile cast iron piston . . . . . . . . . . . . . . . . . . . . . . . . .6 PPC (Pressure Proportional Control) . . . . . . . . . . . . .13
PPM (Parts Per Million) . . . . . . . . . . . . . . . . . . . . . . .13
EDIMOS Pre-cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
(Electronic Display/Monitoring System) . . . . . . . . . . . .6 Pulse TIG (Tugsten Inert Gas) welding . . . . . . . . . . . .14

FEM (Finite Element Method) . . . . . . . . . . . . . . . . . . .6 ROPS (Roll-Over Protective Structure) . . . . . . . . . . .14

Flywheel horsepower . . . . . . . . . . . . . . . . . . . . . . . . . .7
FMS (Flexible Manufacturing System) . . . . . . . . . . . . .8 SAE (Society of Automotive Engineers) . . . . . . . . . . .15
FOPS (Falling Objects Protective Structures) . . . . . . . .8 Sliding-mesh type transmission . . . . . . . . . . . . . . . . .15
Fuel consumption ratio . . . . . . . . . . . . . . . . . . . . . . . . .9 Suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Syncro-mesh type transmission . . . . . . . . . . . . . . . . .15
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Ground pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Tire code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Torque converter structure . . . . . . . . . . . . . . . . . . . . .16
Hydroshift drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Torque rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

ISO Work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

(International Organization for . . . . . . . . . . . . . . . . . .10
Standardization)

JIS (Japan Industrial Standard) . . . . . . . . . . . . . . . . . .10

Availability
This is one term to express the reliability of products or compo-
nents. It shows the proportion of time that a machine is able to
function (working time) and the time that it cannot function
(downtime). It is expressed as a percentage. The following two
definitions are the most common.

A: Working time
A A+B
Availability = --------------- X 100 or --------------- B: Daily maintenance time
A+B+C A+B+C C: Down time

In addition to these two types, there are also definitions based on

calculations including periodic maintenance and waiting time.

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CAD (Computer Aided Design)
CAD is a method of using computers for design work to
produce high quality designs economically in a short time.
The design departments at Komatsu have been using CAD
since 1980, and it has proved effective in making draw-
ings, and also in various types of simulation and analysis.
The aims of CAD include the following:
( I ) More precise design.
(2) Reduction in development time.
(3)Creating a system to carry out the creative work that
forms the basis of design.
The diagram show a simulation of the movement of the
work equipment.

CAM (Computer Aided Manufacturing)

CAM is a system that uses computers for the preparatory
work for manufacturing to economically obtain high quali-
ty manufacturing information in a short time. The aim is to
reduce the lead time at the manufacturing preparatory
stage, for example, it is a manufacturing system that uses
computers to enable an integrated series of operations such
as machining, welding, assembly, and inspection to be car-
ried out without human labor. CAD (explained above) and
CAM are not separate systems; they form an integrated
part of the total system, and the words CAD and CAM are
frequently used joined together as CAD/CAM.

CIM (Computer Integrated Manufacturing)

Cl M is not simply an extension of manufacturing automa-
tion or factory automation. It is a system that uses comput-
ers to combine the basic three functions of manufacturing
(development, manufacturing, and sales), to improve the
efficiency of work and to make it possible to carry out
business strategy. The following are examples of effects
that CIM can produce:
(l) Company business can be made more efficient through
the integration of all work
(2) It becomes possible to swiftly respond to changes in
the environment and product development power, and the
quality of the enterprise can be strengthened.
(3) Operations can be carried out on a world-wide scale,
and overseas strategies can be strengthened.

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Combustion chamber
There are two types of combustion chamber in diesel engines: direct
injection type and auxiliary chamber type. With the direct injection type,
there is only one combustion chamber at the piston crown; with the auxil-
iary chamber type, there is an additional sub-combustion chamber at the
cylinder head. There are two types of auxiliary chamber type: pre-com-
bustion chamber type and swirl chamber type. The advantages of each
type are as follows.

1) Direct injection type

¥ Fuel is injected into the cylinder from an injection nozzle or
injector, and burns in the combustion chamber.
Its features are as follows.
Advantages: There are no places where heat stress can accmu
late or throttling loss at the injection port, such as with the pre-
combustion chamber type.
Therefore:
¥ The fuel consumption ratio is good
¥ Engine starting is good
¥ The structure is simple

2) Pre-combustion chamber type

¥ Fuel is injected into a pre-combustion chamber at the top of the
cylinder. 20 ~ 30 % of the fuel burns in the pre- combustion
chamber, and the resulting pressure injects the remaining fuel into
the cylinder to make it burn.
Advantages: Combustion is good.
Therefore:
¥ The exhaust color and exhaust gas is good.
¥ Slightly inferior fuels can also be used.
¥ There is no particular need to increase the fuel injection pressure,
and the shape at the top of the piston can be made simple.

3) Swirl chamber type

¥ To mix the fuel and air well, a chamber (swirl chamber) is provided
to form a swirling motion in the intake air, and the fuel is then injected
into this.
¥ Its features place it midway between the direct injection type and pre-
combustion chamber type.

Constant mesh type transmission

The gears for each speed range are meshed from the beginning. As shown
in the diagram, the gears on the countershaft rotate freely on a collar.
When needed, a dog clutch is moved sideways to engage the gear and
countershaft, so the main shaft rotates. This form of transmission is used
on medium and large-size bulldozers, large-size trucks and wheel loaders.

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Counter-rotation turn
With the counter-rotation turn, the two tracks rotate in opposite direc-
tions, so the machine can turn quickly on the spot.
This action cannot be carried out on normal bulldozers, but it is possible
on the HST drive dozer shovel (D66S) or on hydraulic excavators. With
the D66S, if the steering pedal on one side is depressed fully, the track
on that side rotates in the opposite direction to allow the machine to
carry out a spin turn. (With hydraulic excavators, the travel lever on one
side is pushed forward, while the travel lever on the other side is pulled
back.) Counter-rotation turns are extremely useful when working in
conf~ned spaces or when garbage processing.
(Note: when carrying out counter-rotation turns, the tracks slide to the
side, so the actual turning radius is slightly larger than radius R in the
diagram.)

dB(A)
The value measured by a noise meter is called the sound level, and is
expressed in dB (decibels) or phone. The noise meter has an auditory
compensation circuit to adjust the physical size of the noise to match
human feeling. This compensation circuit has different features (A, B,
C), and the level of the sound measured using A characteristics is
expressed as dB(A).
A characteristics are used in all cases regardless of the level of the
sound, but B characteristics are rarely used. C characteristics are used
when judging the quality of sound.

Double locked connector

Double locked connectors are connectors with two locks. One lock holds
the wiring terminals to the connector case, and the other lock prevents
the wiring terminal from coming out.
The advantages are as follows.
1. When putting together the wiring and installing the terminal to the
connector case, the disconnection prevention lock cannot be installed
unless the terminal is pushed in far enough for the holder lock to take
fully effect.
Therefore, the quality when making the wiring is greatly improved.

2. When installing the wiring to the chassis and connecting the male
and female terminals, the terminals try to come out of the connector
case. However, they cannot come out because of the disconnection
prevention lock, so they remain securely connected. Therefore, the
quality when installing the wiring is greatly improved.

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Ductile cast iron piston
Compared with aluminum, ductile cast iron is a stronger material and is
superior in heat resistance. Engines using ductile cast iron pistons have the
following advantages.
1. The material strength is high, so there is no need for
any ring insert that is essential for aluminum pistons,
and the top ring can be placed in a high position. By
reducing to the minimum the waste space apart from
the combustion chamber formed by the top ring, liner,
and side face of the piston head, it is possible to
achieve efficient combustion, thereby further improv
ing fuel economy and exhaust gas color.
2. Compared with aluminum, the heat expansion ratio is
small, so the clearance between the piston and liner
can be made smaller. Therefore, it is possible to
reduce problems such as knocking caused by piston
play.
3.The material strength at high temperature is high, so
this makes high output possible.
These pistons are used on the Komatsu 125 and 140 Series engines with tur-
bochargers.

EDIMOS (Electronic Display/Monitoring System)

This system is used to operate a machine under the best conditions. It is
composed of sensors and switches, installed at various places of the
machine, which check the condition of the machine and the monitoring
panel which shows the information sent from those sensors and switches to
the operator. If a serious problem occurs in the machine, this system turns
on the warning buzzer and warning lamp.
Daily check items: Caution items:
1 Brake and fluid level 10 Battery charging
2 Engine oil level 11 Fuel level
3 Coolant level 12 Brake oil pressure
4 Transmission cut-off brake 13 Engine oil pressure
Gauges: 14 Coolant level
5 Coolant temperature 15 Coolant temperature
6 Transmission oil temperature 16 Torque converter oil temperature
7 Fuel level 17 Parking brake, applied
8 Speedometer 18 Working light pilot
9 Service meter 19 Engine preheating

FEM (Finite Element Method)

This is a system of using computers to break down the structural into sepa-
rate elements, such as hydraulic excavator booms and arms, or wheel loader
frames and loader linkage, as shown in the diagram and to calculate the
strength of each element.
The finite element method has its origins in the move towards precision
structural analysis of aircraft centered in the USA in the early 1950's. With
the increase in the power and speed of computers, there was rapid progress,
and this system is nowadays used for precision stress analysis for extreme-
ly complex structures such as high-rise buildings, jumbo jets, and nuclear
reactors.

Strength analysis of wheel loader frame

using matrix finite element method.
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Flywheel horsepower
The flywheel horsepower of the engine has been expressed in various ways, and these are based upon the following elements.
. Standards employed (each standard is determined under different conditions, such as temperature, barometric pressure,
water vapor pressure, etc.)
. Rated or Maximum horsepower
. Used units, such as HP, PS, kW.
. Gross or Net horsepower (with or without generator, air cleaner, cooling fan and other accessories)
1.Standards
Principal standards are; JIS (Japan Industrial Standard), DIN (Deutschs Industries Norm) and SAE (Society
Automotive Engineers.)
Differences between these standards are the result of varying test conditions, as listed below.
2.Rated or maximum horsepower
Rated horsepower:
The output of an engine in one hour of continuous operation at an engine speed designated by the manufacture
Maximum horsepower:
The highest output developed by an engine run normally at a given speed. This horsepower is generally used
to describe automobile engine output.

The difference between the rated and maximum horsepowers shows the engine output allowance. Maximum
horsepower is attained at the speed and torque representing the limit of its durability and reliability, while the
rated horsepower is obtained at a lower speed and torque.

3. Units
The engine output is shown with PS, HP or kW. The JIS
and DIN employ PS.
The SAE uses HP. Recently, the ISO has determined that the
use of kW is an obligation.

The relationship between these units is as follows:

4. Gross or Net Horsepower

Gross Power is the power output of a "basic" engine which is an
engine equipped only with the built-in accessories essential to its
operation: fuel pump, oil pump, coolant pump and built-in emis-
sion control equipment.
Net Power is the power output of a "fully equipped" engine which
is an engine equipped with all the accessories necessary to perform
its intended functions unaided. This includes, but is not restricted to
the basic engine of Gross Power plus intake air system, exhaust
system, cooling system, generator or alternator, starter and emis-
sion control equipment.
FMS (Flexible Manufacturing System)
FMS is an efficient automated manufacturing system for manufacturing a large range of products in small or medium
quantities. In concrete terms, it is an automatic assembly and machining line consisting of MC (Machining Center) +auto-
matic machine tools, various kinds of robots, unmanned warehouses, and automatic materials handling equipment.
Behind the emergence of FMS are the following factors.
( 1 ) The move to an era of manufacturing a wide range of products in small quantities.
(2) The need for a manufacturing system that could flexibly cope with various needs and demands.
(3) The development of sophisticated NC machine tools and robots
Komatsu has also been energetically introducing FMS since 1982, and has achieved excellent results.

FOPS (Falling Object Protective Structure)

FOPS is a structure installed to a machine to protect the

operator from objects such as trees or rocks that may fall
on the operator from above. There are ISO standards
(IS03449) regarding FOPS.
(The strength of FOPS must be sufficient to protect the
operator when a test weight of approx. 227 kg height of
approx. 5.2m (17'1").

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Fuel consumption ratio
Nothing could be more economical than to produce a high horse-
power from a small amount of fuel. The fuel consumption ratio is
an index to identify the level of fuel consumption: it expresses the
hourly fuel consumption for one horsepower, and the units used are
g/HP.h or Ib/ HP.h. For example, a certain engine has an output of
54H P, and when it is run for one hour, it uses 10 liters (2.6
U.S.gal) of fuel. This is approx. 8500g ( 18.7 lb), so the fuel con-
sumption ratio is calculated as follows.

The smaller this value, the more economical the fuel consumption.
The fuel consumption ratio changes according to the engine speed,
so in specification sheets, the minimum fuel consumption ratio and
fuel consumption ratio at rated speed are given.

Gradeability
Grade ability is the ability of machine to drive up a slope under its
own power. Generally speaking, this is expressed as the angle of
the slope or as % (height/ horizontal distance expressed as % .)
The value for automobiles is expressed as tan a.
The grade ability is the maximum grade ability calculated from the
capacity of the engine. Actually, slippage of the tracks or tires on
the road surface may mean that it is impossible to travel up a slope
of that angle.

Ground pressure
The ground pressure given in sales materials and catalogs is calcu-
lated using the following formula.

However, the definition of length of track on ground used for cal-

culating the ground contact area is different for bulldozers, dozer
shovels, and hydraulic excavators.

(1) Length of track on ground (L) = l + 0.35 H W :Operating weight

for hydraulic excavator B: Track shoe width
l Distance between center of idler and center of sprocket
H: Height of track shoe
(2) Length of track on ground (L) = l L: Length of track on ground

for bulldozer and dozer shovel

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Hydroshift drive
Hvdroshitt drive is a system consisting of a combination of a plane-
tary gear transmission (see separate item) and a damper, and it
combines the advantages of direct drive machines and
TORQFLOW machines.
In other words. the transmission of motive force is efficient as with
direct drive, and it is easy to shift gear as with TORQFLOW
machines. The damper is installed to absorb the vibration of the
engine and the shock when suddenly accelerating or carrying out
heavy-duty digging, thereby protecting the power train. However,
there is a limit to the capacity of the damper, so it is difficult to
mount a large engine. therefore' this system is used for medium and
small-size bulldozers or motor graders.

ISO (International Organization for Standardization)

ISO stands for the International Organization for Standardization.
The purpose of ISO is to promote the establishment of world-wide
standards in order to promote international exchange of materials
and information.
The ISO uses the International System of Units (Sl), such as Pa
(pressure), N (force), J (amount of work, energy, heat), kW
(power).

JIS (Japan Industrial Standard)

JIS is the domestic standard for Japan set by the Japanese govern-
ment.
JIS has been used to standardize a wide range of items from the
manufacture, distribution, and use of mining, industrial, and other
products, and each standard is reviewed at least once every five
years. The standards are confirmed, revised, or abolished as neces-
sary.
Products satisfying JIS can carry the JIS mark shown in the dia-
gram.

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Machine model code (Basic)
Meaning of model names and numbers
¥ The model names and numbers are displayed in accordance with KES (00.518.0-1985).
Model name and type number must be a maximum of 15 characters, excluding hyphens.

Machine model (Max. 11 characters)

Auxiliary model code

(Used when making Minor variation code (Max. 2 characters)
finer definition of (Expressed using letters starting from A)
model type)
Model number (Max. 2 digits)
(Version of machine indicated in numerals)
Size code
(Size, capacity, performance, etc. of product displayed in numerals)

Machine model code

(Type of product indicated by letters of the alphabet)

Machine model code (construction machines) [Example]D1 55A-2 (Bulldozer)

. The model names are displayed in accordance with KES (00.518.1-1981) BP500 2 (Power splitter

(1)The machine model code is expressed with 2 letters, but crawler tractors use only the letter D, which the
single letter D has been retained because of its long history in the company. The first letter gives the broad
category of the type of product as shown in the following table.

(2)The second letter indicates the structure, but the details for each product are given in accordance with KES
for machine model codes.
Machine model code (Engine)
The engine machine mode codes are displayed in accordance with KES (00.518.2-1987)

S 6 D 1 55 Ñ 4 -----------------------------------------
Special specification code

Type code Type:

D, V, T indicate
diesel; G, K
indicate gasoline
Minor variation
code
(Max. 2 characters)
ÑModel number
(Version of machine indicated in numerals)
Output (A, B) combustion method (D: Direct
injection, W: Whirl chamber type), mounting
position (H: Horizontal) etc.
ÑNumber of cylinders
Stroke (S: Short stroke, L: L: Long stroke
Supercharging method code
None : Natural aspiration Cylinder bore (The bore size in mm)
S : Standard turbocharger,
SL: Light turbocharger
SA : With turbocharger and aftercooler

SAA : With 2-stage turbocharger and aftercooler Ñ 11

OEM (Original Equipment Manufacturing)
Supplying one 's own company's brand parts or finished products
under another company's brand. When a company has a sales net-
work but no manufacturing facilities, it may ask another compa-
ny to manufacture the products and supply on an OEM basis. It
often happens that small manufacturers rely on famous brands and
take on OEM work on a sub-contractor basis. but big manufactur-
ers often use this system as a way of avoiding wasteful competi-
tion in the industry.

OFR (Optimum Fleet Recommendation

OFR means selection of the optimum combination of machines.
First. the method of executing the project is established, and the
number and type of machines expected to be used, is input into a
computer together with data on the working conditions. The com-
puter then calculates the most economical combination of
machines to use.

Pivot turn
If the steering lever on one side is pulled fully (or the steering
pedal is depressed fully), the steering clutch is disengaged, and
the steering brake is applied, so the track on one side stops and
the machine can turn. This is called a pivot turn. With hydraulic
excavators, if the travel lever on one side is placed in neutral, and
the other travel lever is pushed forward (or pulled back), a pivot
turn can be performed. (This can also be carried out by returning
one of the travel levers to the neutral position when the machine
is traveling in a straight line.)

Planetary gear type transmission

A planetary gear type transmission consists of a combination of a
planetary gear and multiple-disc clutch. Hydraulic pressure is
used to engage and disengage the clutches to accelerate or decel-
erate.
The combination of this planetary gear type transmission and a
torque converter is called TORQFLOW (the general term is pow-
ershift). The structure is complex and the cost is high, but
gearshifting is easy, and it is used on machines such as medium
and large-size bulldozers, wheel loaders, dump trucks, and motor
scrapers.

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POC (Pilot Operated Control)
This is one method of operating a control valve by hydraulic
power. (See PPC)
The pressure rises according to the amount the lever is moved,
and this operates the spool. As a result, the operating effort is
small, and operator fatigue is reduced.

PPC (Pressure Proportional Control)

There are various methods of operating control valves: mechani-
cal type (direct linkage), pneumatic type, and hydraulic type. The
hydraulic type can also be divided into the POC type and PPC
type. PPC stands for Pressure Proportional Control, and as shown
in the diagram, the pressure rises steplessly in proportion to the
amount the lever is moved, so operation is smooth and there is
excellent i fine control. Compared this with POC, where the pres-
sure rises in steps in proportion to the movement of lever, so fine
control reduced.

ppm (Parts Per Million)

The unit used to express the amount of any substance in small
quantities is ppm. In the same way as per cent (%) is used to
express one hundredths, ppm is used to express one millionths.
For example, 2 ppm means one ten-thousandth of 2%. This unit
has recently become commonly used in pollution problems to
express the quantity of substances such as sulfur dioxide in the
atmosphere, or to measure BOD (Biochemical Oxygen Demand)
to show the degree of pollution of rivers.

Pre-cleaner
The device using vanes to spin intake air in a whirling motion to
separate dust from the air is called a pre-cleaner. This device is
used to prevent early clogging of the paper element in the cleaner.
A pre-cleaner can remove 50 ~ 85% of the dust in the alr.
There are the following types of the cleaner.
1. U.S. pre-cleaner
This consists of guide vanes (cyclone) and the dust
case and cover. It is installed at the inlet port of the air
cleaner. The dust that collects inside the dust case must
be cleaned out when carrying out maintenance.

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2. Cyclone pack with dust vacuator valve
This has guide vanes (cyclone) that whirl the air, and is installed inside
the air cleaner. The dust separated from the air accumulates in a dust
cap.
A vacuator valve is often installed to automatically eject the dust' so it
is unnecessary to remove the dust cap and clean the dust out.
The vacuator valve is made of rubber, and automatically ejects the
dust. When the engine is running, the negative pressure keeps the out-
let port closed, and when the engine stops, the outlet port opens to
eject the dust.

3.Multi-cyclone pre-cleaner with automatic dust evacuator

(Komaclone type)
This pre-cleaner has several pipes containing guide vanes.
The intake air is whirled inside the pipe, the centrifugal force separates
the dust from the air, and it then falls into the dust case. Using the
principle of an atomizer, the dust in the dust case is automatically
ejected in the exhaust gas.

Pulse TIG welding (Pules Tungsten Inert Gas Welding)

Pules TIG welding is a method of welding that generates an arc
between a tungsten electrode and the base metal in an inert gas, such
as argon or helium. Argon gas does not react with other materials at
high temperature, so it is possible to prevent the formation of oxides
and nitrides that arise from reaction with the oxygen and nitrogen in
the air, thereby providing excellent welds.

ROPS (Roll-Over Protective Structure)

ROPS is a roll-over protective structure for the operator.
In ISO and SAE, it is a structure installed to a machine with the pur-
pose of preventing an operator who is wearing a seat belt from being
crushed if the machine should roll over.
The performance and test methods for ROPS are described in detail in
IS03471, and SAE J395a and J1040a.

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SAE (Society of Automotive Engineers)
SAE standards are the standards set by the American Society of
Automotive Engineers. They are not compulsory, but they are
widely used in the USA. Furthermore, they are widely used as
the standard in the automobile and construction equipment indus-
try in countries other than the USA.
These standards are used to define a wide range of conditions,
test methods, and technical terms used for materials, mechanical
elements, parts, motors, and other components or finished
machines.

Sliding-mesh type transmission

This method slides the gear on the main shaft to mesh with the
gear on the rotating countershaft. The gears are meshed when
rotating at different speeds, so this operation needs skill, and
often it produces a grating noise or shock.
This type of transmission is often used on old machines or on
small and medium-size machines.

Suspension seat
The suspension seat has a weight adjustment function, so it can
be adjusted to match the operator's weight to provide a comfort-
able ride.

Synchro-mesh type transmission

Even with the constant mesh type transmission (see separate
item), if the dog clutch and gear are not rotating at the same
speed when shifting gear, there will be a grating noise and it will
be difficult to engage the clutch. The system of rotating the
clutch and gear at the same speed to make it easy to mesh is
called a synchro-mesh type transmission.
This transmission is often used on automobiles or machines such
as forklift trucks or motor graders.

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Tire code
Tire size is generally expressed in inch dimensions for the
width and rim diameter (inner dia. of tire), together with ply
rating (PR) which indicates carcass strength.
14.00-2-=12PR . . . . . . . . . . . . .Ordinary tire
17.5-25-12PR . . . . . . . . . . . . . . . . . . . . . . . .wide-bare tire
33.25-35-24PR . . . . . . . . . . . . . . . . . . . . . . .Wide-bare tire
Strength of tire (Ply rating)
Rim outer diameter (inch)
Width (inch)

35/65-33-24PR 65 series tire

Strength of tire (Ply rating)

16.00 R26 ¥¥ Radial tire

29.5 R 29 ¥¥ Radial tire (wide base)
Ply rating or strength index
Rim outer diameter (inch)
Width (inch)

Note: The ply rating or strength index of radial tires is

indicated with the Michelin three-grade system of
* (one star),** (two stars), and *** (three stars).

Torque converter structure

The structure of a torque converter is expressed using the
terms element, stage, and phase.
"Element" refers to the number of pumps, turbines, and sta-
tor. If there is one pump, turbine, and stator each, this gives a
total of 3, so the torque converter structure is described as 3-
element. If the turbine is divided into two parts, this gives
one more element, so it becomes a 4-element type. "Stage"
refers to how many parts the turbine is divided into. "Phase"
expresses the efficiency properties of the torque converter.
If the stator is fixed, it is single-phase (one-phase), if there is
one stator with a free wheel, it is called 2-phase, if there are
two stators with free wheels, it is called 3-phase.

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Torque rise
It is frequently said that the torque rise has a tenacity of x
percent, but "tenacious" engines refers to engines that carry on
running even when the load increases during work, giving a big
time lag before the engine finally stalls. The larger the torque
rise, the more tenacious the engine is.
The torque rise is calculated using the following formula.

Torque rise = T2ÑT1 X 100 (%)

T2

T1 : Torque at rated output

T2 : Max. torque

The greater the difference between T1 and T2, or the greater the dif-
ference in engine speed between T1 and T2, the more the engine will
resist stalling, and the more tenacious the engine will be.

Work equipment
The work equipment is the equipment used for various work such as
digging, hauling, leveling, and loading. It includes blades, buckets,
sacrifiers, other equipment such as booms, arms, and yokes that sup-
port these components, and the hydraulic equipment (removable
hydraulic pumps, piping, control valves, etc.) that come with this
equipment.

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 Bulldozers
Contents 18 PAT (Power Angle Tilldozer) 20
Blade capacity 18
Bogie type undercarriage 19 Power turn 21
Booster 19 PTO (Power Take Off) 21

Floating floor 19 Rigid type suspension 21

Rigid type undercarriage 21
High drive 19
HST (Hydro Static Transmission) 20 Semi-rigid type idler 22
Semi-rigid type sprocket 22
Low drive 20 Semi-rigid type suspension 22

Modular design 20 Torque converter with lock up 22

Blade capacity
Blade capacity is determined by SAE J 1285 as follows.
Straight or angle blade= 0.8 LH2
Semi-U or full U blade = 0.8 LH2 + ZH(L-Z) tan X

L = Blade width exclusive of end bits.

H = Effective blade height considering tapered top corners, etc.
Z = Wing length measured parallel to blades width.
X = Wing angle.

Bogie type undercarriage

Structurally, the Track rollers have a built-in elastic body (rubber
pad) and are supported by two minor bogies each, and the rollers
move up and down like a balancing toy.
The minor bogies are supported in turn by major bogies. The
external force from the ground surface is absorbed by the balanc-
ing of the minor bogies and the rubber pads built into the major
bogies to reduce the shock. The bogie type undercarriage is
effective for giving a good ride and improving durability, but
there is frequent shoe slippage and the operating performance is
inferior to the rigid type undercarriage. In particular on hard
rock, the ripping performance is poor.
(Used on CAT 1)8N and larger machines)

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Booster
When operating the main clutch or steering clutch, if it is not easy
to operate just with the force of the hand or foot, the force of a
spring or hydraulic pressure is used to reduce the operating effort,
thereby reducing operator fatigue. Such a mechanism is called a
booster.
Boosters using the force of a spring are called spring boosters, and
those using hydraulic force are called hydraulic boosters.

Floating floor
Vibration and noise transmitted from the undercarriage or power
train are extremely unpleasant for anyone sitting inside the cab
mounted on the machine. To prevent this unpleasant vibration and
noise from being transmitted to the cab, the operator's seat is sus-
pended from the cab. In other words, as seen from the chassis, it
has a floating structure. Actually, the cab and chassis are separated
by rubber cushions to give a structure that prevents vibration from
being transmitted from the chassis.
(Used on D41, D50, D53, etc.)

High drive
"High drive" is an undercarriage where the sprocket is located in a
high position. This system is also called "elevated sprocket".
When the track is installed, it forms a triangular shape. The aim of
this system is to improve the durability of the final drive and to
make maintenance of the power train easier. However, the fact that
the center gravity becomes higher and the stability is reduced is a
major disadvantage.
(Used on CAT D4H and up medium and large machines)

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HST (Hydro Static Transmission)
HST is a transmission consisting of a combination of hydraulic
pump and hydraulic motor. It is different from direct drive
machines or 'TORQFLOW OW machines in that the power is
transmitted hydraulically from the engine to the final drive.
Therefore, the travel hydraulic line closely resembles the system
on hydraulic excavators. However, the main difference is that
hydraulic excavators have an open circuit in which the oil from the
hydraulic motor returns to the tank, whereas the HST has a closed
circuit in which the oil returning from the motor enters the suction
side of the pump directly.

Low drive
With low drive, the position of the sprocket is more or less at the
same height as the idler, and when the track is installed, it forms
an ellipse. Komatsu has always used this system because it has the
following advantages.
1 The center of gravity is low, so the stability is good.
2 There is little shoe slippage, and the machine can display its
drawbar pull to the full.

Modular design
To make it easy to remove and install the power train, the units or
parts that were formerly installed individually to the main frame
are designed to be assembled together to form function modules.
For examples: The power train module (including torque convert-
er, transmission, steering clutches and brakes), and the final drive
module (formally, the hub parts were assembled in the steering
case, but they can now be installed or removed as an assembly. )

PAT (Power Angle Tiltdozer)

With the PAT, the hydraulic cylinders can be operated freely from
the operator's compartment to raise, angle, or tilt the blade. With
its high versatility, this is mainly used on small and medium-size
machines.

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Power turn
If one of the steering levers is pulled slowly (or the steering pedal
is depressed), the rotating speed of the track on the side which is
pulled will drop. The machine will then change direction according
to the difference in the rotating speed, while power drive force is
still being transmitted to both the left and right tracks. This is
called a power turn. In other words, both the left and right tracks
are rotating in the same direction, but one of the tracks is rotating
more slowly than the other. When carrying out side cuts or when
there is more soil on one side of the blade than on the other, this
power turn can be used to improve efficiency

PTO (Power Take Off)

The power pick-up device to transmit motive force to attachments
(winch, agricultural tools, etc.) installed to the rear of the machine
is called the PTO. Normally, the motive force is taken from the
transmission, but depending on the machine, it may also be taken
directly from the engine.

Rigid type suspension

This is a track frame installation method in which the left and right
track frames are fixed with a bar. It is impossible for the left or
right track frames to move independently, so the machine tilts
greatly when traveling on rough ground. This system is used on
small bulldozers rend hydraulic excavators.

Rigid type undercarriage

The track rollers are fixed to the track frame with pins, and the
rollers do not move up and down. Komatsu has always used this
type of undercarriage. Compared with the bogie type undercarriage,
the ride for the operator is less comfortable, but there is little shoe
slippage, so the operating performance is excellent. The ease of
operation on hard rock is particularly good, so productivity increas-
es.

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Semi-rigid type idler
With the semi-rigid type idler, an elastic body (reinforced rubber
pad) is installed to the idler shaft support to absorb the shock
bearing on the idler, thereby improving the riding comfort and
durability.
The undercarriage that is equipped with a semi-rigid sprocket
and semi-rigid idler is also called a semi-rigid undercarriage.
(Used on D375A, D475A)

Semi-rigid type sprocket

A semi-rigid type sprocket has elastic bodies (rubber bushings)
assembled in a radial direction like spokes inside the sprocket,
and these absorb the shock when traveling over rocks or when
dropping, thereby giving a more comfortable ride and improving
the durability.

Semi-rigid type suspension

This is a track frame mounting method in which the left and right
track frames are not fixed, but an equalizer bar or leaf springs are
used to allow movement in the up-down direction.

Torque converter with lockup

A torque converter in which the action of the torque converter is
stopped (locked) and the power of the engine is transmitted
directly to the transmission in the same way as direct drive is
called a torque converter with lockup. This system acts to lock up
the torque converter and switch to direct drive to increase the
efficiency of the transmission of power, thereby improving pro-
ductivity and reducing fuel consumption. It is effective when car-
rying out the hauling of loads over medium or long distances, or
when traveling over flat ground. However, in work where there
are sudden changes in the load, for example, in ripping work, this
system is not suitable. (Used on D375A, D475)
A lockup system is also installed to the torque converter on
Dump truck, motor scraper and rough terrain crain.

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Ð1Ð
Auto-deceleration
Auto-deceleration is used to automatically lower the engine
speed to reduce fuel consumption at times when the work
equipment control levers are at neutral, such as when waiting
for dump trucks. Since the engine speed drops, it can also be
used for reducing noise
When using the control levers for operations needing small
movements, there will be sudden changes in the engine speed,
so a selector switch is provided to allow the auto-deceleration
to be canceled.

Bucket capacity
There are two ways of expressing the bucket capacity: struck
capacity and heaped capacity.
Because of the difference in the method of calculation, there are
two types of heaped capacity: SAE heaped capacity and CECE
heaped capacity.

Struck Capacity
Volume actually enclosed inside the outline of the sideplates
and rear and front bucket enclosures without any consideration
for any material supported or carried by the spillplate or bucket
teeth.

SAE heaped capacity

Volume in the bucket under the strike off plane plus the volume
of the heaped material above the strike off plane, having an
angle of repose of 1: I without any consideration for any mater-
ial supported or carried by the spillplate or bucket teeth.

CECE heaped capacity

Volume in the bucket under the strike off plane plus the volume
of the heaped material above the strike off plane, having an
angle of repose of 1: 2 without any consideration for any mater-
ial supported or carried by the spillplate or bucket teeth.

Bucket digging force

Maximum radial tooth force due to bucket cylinder (bucket
curling force) is the digging force generated by the bucket
cylinder(s) and tangent to the arc of radius C. The bucket shall
be positioned to obtain maximum output moment from the
bucket cylinder(s) and connecting linkages.

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CO function
When the bucket contacts hard places during digging opera-
tions, and the hydraulic pressure is relieved, large amounts of
oil are lost and drained to the tank. When such kinds of
hydraulic relief occur, the discharge volume of the pump is
suppressed to prevent wasteful relief of oil, and to reduce fuel
consumption. This function is called the CO function.

EMACC (Electronic Monitor And Control Console)

This is a monitor panel and control console that combines liq-
uid crystal display gauges and monitors with the selector
switches for the functions in the full-choice system employed
on the Dash-5 Series.
All the controls are carried out by pressing a button, so opera-
tion is extremely easy, and the indicator lamps light up to show
the working mode being used.

Engine overheat prevention system

When the engine wafer temperature goes above 102¡C (215.6¡
F), the electronically controlled engine overheat prevention sys-
tem automatically switches the power mode selection H or S
mode to L mode to reduce the engine load and protect the
engine.

EOLSS (Electronic Open-center Load Sensing System)

See OLSS (Open-center Load Sensing System)

In-line filter
If the pump should break, and the broken pieces of the pump
should flow to the main valves and cylinders, it will be come
necessary to replace the main valves and cylinder, and the sys-
tem will also have to be flushed, thereby incurring high repair
costs. The in line filter is installed between the pump and valve,
so any broken pieces are removed before they enter the main
valves. Even if the pump should break, repair costs are kept to
the minimum.

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Ð1Ð
Power mode selection (Power set)
The power mode selection is used to switch the absorption
horsepower of the hydraulic pump in 3 stages and use it
according to the operating conditions and purpose.
H mode (Heavy-duty mode): Used when high speed and large
operating power (capacity) is needed.
S mode (Standard mode): Used when carrying out general
operations, such as normal digging and loading.
L mode (Light-duty mode): Used for light-duty operations such
as leveling; can provide big reductions in fuel consumption.

Straight travel system

When the machine is traveling, if the swing, boom, arm, or
bucket are operated at the same time, the oil flowing to the left
or right travel circuits is also used for the the swing, boom,
arm, or bucket. As a result, the amount of oil flowing to the left
and right travel circuits is different. To prevent the machine
from deviating to one side, a straight travel valve is used to
interconnect the left and right travel circuits so that an equal
amount of oil flows to both the left and right travel circuits.
This enables the machine to continue traveling in a straight line
even when other circuits are operated.

TVC valve (Torque Variable Control Valve)

This is a valve which functions to change the pump drive
horsepower to match the conditions and nature of the operation.
It is used in cases such as when it is desired to increase the
production, or when emphasis is placed on fine control.
For example, if the mode is switched from S mode to L mode,
the absorption horsepower of the pump becomes smaller. This
improves the fine control ability, and at the same time reduces
fuel consumption. It is the TVC valve that acts in this way to
change horsepower setting.

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Working mode selection
The working modes are the modes that set the movement and
power of the work equipment to match the content or purpose of
the operation. As shown in the diagram, there are four mode
switches to enable the desired mode to be selected.
This is one of the biggest advantages of the Dash-S Series. The
table on the right shows the default settings for the combination of
power mode and auto-deceleration when the working mode is
selected, and the type of work that is suited for each working
mode.

Heavy-duty operation mode (H. O)

The heavy-duty operation mode can be selected when the work
needs power, such as when digging bedrock or ditches.
General operation mode (G. O)
When the engine is started, the most frequently used general oper-
ation mode is automatically selected.
Finishing operation mode (F. O)
The finishing operation mode is selected for work requiring accu-
racy, such as leveling and grading operations.
Lifting operation mode (L. O)
The lifting operation mode is selected when even more fine con-
trol is needed than in the finishing operation mode.

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Breakout force
Breakout force in kilograms is the maximum sustained vertical
upward force exerted 100 mm (4 in) behind the tip of the bucket
cutting edge and is achieved through the ability to lift and/or roll-
back the bucket about the specified pivot point under the follow-
ing conditions:
(1) Machine with transmission in neutral.
(2) All brakes released.
(3) Unit at standard operating weight, rear of machine not
tied down.
(4) Bottom of cutting edge parallel to and not more than 25 mm
(I in) above or below the ground line.
(5) When bucket circuit is used, the pivot point must be specified
as the bucket hinge pin, and the unit blocked under the bucket
hinge pin pivot point in order to minimize linkage movement.
(6) When the lift circuit is used the pivot point must be specified
as the lift arm hinge pin.
Wheel loaders shall have front axle blocked to eliminate change
in position of pivot pins due to tire deflection.
(7) If both circuits are used simultaneously, the dominating pivot
point listed in (5) or (6) must be specified.
(8) If the circuit used causes the rear of the machine to the leave
the ground, then the vertical force value required to raise the rear
of the machine is the breakout force.
(9) For irregular shaped buckets, the tip of the bucket cutting
edge referred to above shall mean the farthest forward point of
the cutting edge.

Bucket positioner
The bucket positioner is a device to automatically stop the move-
ment of the bucket when the bucket reaches the previously set
digging angle. In other words, the bucket returns to its original
digging posture after dumping the load, so there is no need to
spend time setting it to the digging angle each time. This makes
scooping operations easy and improves efficiency. Structurally,
there are two types of bucket positioner: one type uses a cam
roller, and the other type is an electrical type using a proximity
switch.

Cross loading
This is one method of loading. Every time the loader loads one
bucket, the dump truck moves forward or backward. If the timing
between the loader and dump truck is good, the operating cycle
time is short and the work is effective.
With this method of operation, the loader does not turn, so there
is little wear of the tires or spillage of the load, making this the
most effective method of loading.
If the number of loads is comparatively small, or if the ground
surface is hard and it is easy for the dump truck to move in and
out, this method is advantageous.

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Ð1Ð
Breakout force
Breakout force in kilograms is the maximum sustained vertical
upward force exerted 100 mm (4 in) behind the tip of the bucket
cutting edge and is achieved through the ability to lift and/or roll-
back the bucket about the specified pivot point under the follow-
ing conditions:
(1) Machine with transmission in neutral.
(2) All brakes released.
(3) Unit at standard operating weight, rear of machine not
tied down.
(4) Bottom of cutting edge parallel to and not more than 25 mm
(I in) above or below the ground line.
(5) When bucket circuit is used, the pivot point must be specified
as the bucket hinge pin, and the unit blocked under the bucket
hinge pin pivot point in order to minimize linkage movement.
(6) When the lift circuit is used the pivot point must be specified
as the lift arm hinge pin.
Wheel loaders shall have front axle blocked to eliminate change
in position of pivot pins due to tire deflection.
(7) If both circuits are used simultaneously, the dominating pivot
point listed in (5) or (6) must be specified.
(8) If the circuit used causes the rear of the machine to the leave
the ground, then the vertical force value required to raise the rear
of the machine is the breakout force.
(9) For irregular shaped buckets, the tip of the bucket cutting
edge referred to above shall mean the farthest forward point of
the cutting edge.

Bucket positioner
The bucket positioner is a device to automatically stop the move-
ment of the bucket when the bucket reaches the previously set
digging angle. In other words, the bucket returns to its original
digging posture after dumping the load, so there is no need to
spend time setting it to the digging angle each time. This makes
scooping operations easy and improves efficiency. Structurally,
there are two types of bucket positioner: one type uses a cam
roller, and the other type is an electrical type using a proximity
switch.

Cross loading
This is one method of loading. Every time the loader loads one
bucket, the dump truck moves forward or backward. If the timing
between the loader and dump truck is good, the operating cycle
time is short and the work is effective.
With this method of operation, the loader does not turn, so there
is little wear of the tires or spillage of the load, making this the
most effective method of loading.
If the number of loads is comparatively small, or if the ground
surface is hard and it is easy for the dump truck to move in and
out, this method is advantageous.

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Demand valve
The demand valve acts to use the oil from the hydraulic pump (or
main pump) to make up for any lack of oil from the steering pump
when the engine is running at low speed. In this way, a constant
amount of pressurized oil is always supplied to the steering circuit,
and any excess is sent to the work equipment circuit. Therefore, even
when the engine is running at low speed, steering operations are
always light.
Demand valves may also be used on dump trucks or bulldozers in
addition to wheel loaders.

ELECTRAN (Electrically Controlled Transmission)

ELECTRAN is a transmission with an electrically controlled control
valve. The gear change of transmission with ELECTRAN is shifted
by changing the electric switch.
ELECTRAN is composed of an electric switch on the direction con-
trol lever and speed control lever and a solenoid valve which actuates
the transmission control valve.

Lifting capacity
The maximum mass in kilograms (pounds) at the center of gravity of
SAE rated load in the bucket that can be lifted at a specified height
with the bucket positioned to retain maximum load under the fol-
lowing conditions:
(1) Machine with rear end tied down.
(2) Machine at operating weight and equipment as specified. This
force is determined by the hydraulic lifting capacity.
There are two major methods of displaying a machine's capacities.
They are "at the maximum hinge pin height," and "at SAE carry posi-
tion." When this lifting capacity is high, the hydraulic force will be
ample and, in the case of work like logging and the like, the adding
of a counter weight to the rear of the vehicle expands it's range of
application and increases the recommended load.

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Ð1Ð
Rated loadThe rated load (operating load) will not exceed 50% of the TIP-
PING LOAD (full turn) for wheel loaders and 35% of the TIPPING LOAD
for crawler loaders, and will be considered as operating under the following
conditions:
1. Lifting ability of the machine in all bucket positions to be no less
than the specified operating load.
2. Bucket attachment of specified size and type.
3. Maximum travel speed of 6 km/in (3.7 mph).
4. Operating surface.
(a) Shall be hard, moderately smooth and level for wheel loaders.
(b)General operating conditions of crawler loaders are such that
they normally are not operating on hard, moderately smooth
level surface. For this reason, the rating on crawler loaders is
set at the lower figure of 35%.

Stability
Stability: Static tipping load divided by rated load.
(The stability shows how many times the rated load can be loaded before the
rear wheels start to come off the ground. The machine is set with the lift arm
horizontal and bucket tilted back.)

Static tipping load

The minimum mass in kilogram (pounds) at the center of gravity of the SAE
rated load in the bucket which will rotate the machine to a point where, on
the crawler units, the front track rollers are clear of the track and, on wheel
loaders, the rear wheels are clear of the ground under the following condi-
tions:
1. Loader on hard level surface and stationary.
2. Unit at standard operating weight.
3. Bucket tilted back.
4. Load at maximum forward position during raising cycle.
5. Unit with standard equipment as described in specifications
unless otherwise noted under the heading.

Torque proportioning differential

A torque proportioning differential is an absolutely ideal differential. When
the tire on one side starts to slip, the torque is automatically moved to the
tire on the other side. By giving the differential pinion an odd number of
teeth, and by making the teeth a special shape, the left and right wheels both
rotate at the same speed until the resistance differential between the left and
right wheels reaches 38%. Therefore, in mud, where a normal differential
would immediately start to slip, a machine with a torque proportioning
mechanism can prevent the tire from slipping, allowing the machine to dis-
play its rim pull effectively. Therefore, such machines can make full use of
their strong penetrating force, and can also prevent tire wear, thereby reduc-
ing tire costs. (Used on WA100~ 470)
Working mode selection
V-shape loading
This is one method of loading. As the name implies, the loader moves
in a V shape to load the dump truck. First, the loader faces at right
angles to the digging face, and the dump truck is set at an angle of 30¡
to 60¡ (normally about 45¡ ). The loader digs, drives in reverse, turns,
drives forward and loads the dump truck, performing the V-shape move-
ment shown in the diagram.
This method is advantageous when the dump body is large and a large
number of loads are needed to fill it, or when the loading area is con-
fined, or when the ground is soft and it is difficult for the dump truck to
move.

Z-bar linkage
The link mechanism of the loader is given this name because of its
resemblance to the letter Z. Compared to the conventional parallel link,
it has the following advantages.
(1) The front view is good.
(2) Application of the lever principle gives strong digging force.
(3) The number of greasing points is few, and maintenance is easy.
Even with the same Z-bar linkage, the Komatsu WA Series has one
bucket cylinder, but some machines have two bucket cylinder (CAT988,
etc.).Working mode selection

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Actuator
Devices that produce power such as DC (direct current) motors, AC
(alternating current) motors, hydraulic motors, and hydraulic cylin-
ders, are called actuators. Devices that control the position and speed
according to a command are particularly called servo actuators.
Actuators are needed to convert the command sent by an electric sig-
nal to power that is used to move larger things.

Aeration
The phenomenon where liquids (oil or water) contain air in the form
of small air bubbles, or the condition of containing these bubbles is
generally called aeration.
It is well known that, generally speaking, if there is air in the brake
oil. that portion (the bubble portion) is compressed, and the force
pushing the wheel cylinder piston weakens, causing a drop in the
braking effect.

A-frame
This is another name for the side arm forming the McPherson strut
suspension used on Komatsu dump trucks, and it takes its name from
the fact that it resembles the letter A.
Use of the A-frame means that the steering angle of the tire can be
made larger, and this enables the machine to turn with a smaller turn-
ing radius.

Automatic three-mode suspension

This is one type of suspension used on dump trucks.
This system switches the damping force of the suspension to three
modes soft (S), medium (M), and hard (H) according to the load
being carried and the travel condition of the machine. The selection
operation is carried out automatically, so the operator can concentrate
on operation.
The present damping force mode is displayed on the electronic dis-
play panel.

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AVR (Automatic Voltage Regulator)
An AVR is a device to maintain the terminal voltage of a generator at
a constant level. lt detects the terminal voltage of the generator, and
when the value is low, it increases the exciting current of the gener-
ator; when it is high, it reduces the exciting current of the generator.
In this way it acts to automatically maintain the terminal voltage at a
constant level.
Because of this action of the AVR, there is no longer any problem
with changes in voltage (variations in rotation, etc.) in the terminal
equipment (underwater pumps, internal vibrators for concrete, con-
veyors, etc.) of generators, and they can run smoothly.
The new Komatsu EG Series are equipped with AVRs, so one of their
advantages is that the ratio of change in voltage is small.

Bank cut
When a motor grader cuts the soil from a slope face, this is called a
bank cut (slope-face cut).
If the earth is pushed up the slope face, it is called a reverse bank cut.
In both cases, the blade is in a vertical position at the side of the
machine (normally the left side), and the operation of cutting the
slope face is carried out with the blade protruding and following the
cutting angle of the slope face (bank-cut posture).

Blade base
This is a term used for the specifications of a motor grader.
When the blade is lowered to the ground at right angles to the center
line of the chassis, distance A from the blade to the center line of the
front axle is called the blade base. The longer this distance is, the
greater the blade load ratio becomes. This improves the penetration
ability of the blade and increases the earth moving volume.

Body capacity
This is the amount that can be loaded into the body of a dump truck,
and is expressed in two ways: struck and heaped.
Struck capacity
This is the capacity when the body is fully loaded to the top rim of
the body, but the rear opening is defined as being connected by a line
with an angle of repose of 1: I from the rear tip of the body to the top
rim of the body.
Heaped capacity
The heaped capacity is the struck capacity, with the addition of the
volume obtained by lines drawn with an angle of repose of 1: 2 from
the front, rear, left, and right of the body.

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Cavitation
When the cap is removed from a bottle of beer, the pressure inside
the bottle drops. and bubbles appear. In the same way, there are
places in the flow of fluids where the pressure drops, so bubbles can
form. This is called cavitation. If cavitation occurs, the bubbles flow
to the high pressure portions, and when they burst, they generate
ultra-high pressure in places. This causes noise and vibration, and
also damages the metal. If cavitation occurs at the suction side of a
hydraulic pump, the efficiency of the pump drops.

Chattering
The phenomenon where hydraulic vibration occurs and noise is gen-
erated is called chattering. With this type of self- excited vibration, a
comparatively high noise is caused by the relief valve or other valves
hitting the valve seat. In other words, this is a phenomenon that
occurs when the relief valve is actuated. The pressure suddenly
drops, and when it drops too far, the valve closes again; when it clos-
es, it suddenly opens, and when it opens, it suddenly closes again.

Cone index
The cone index is used when machines are working on poor ground
to measure the hardness of the ground and judge if the machine can
travel over it (traffic ability). The cone index can be found simply by
using a cone penetrometer, and the higher the cone index the harder
the ground.
The cone index needed for various types of construction equipment
is as shown in the table below.

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Control box (controller)
When electronics are used and a machine takes over part of the work
of humans, the parts that correspond to human eyes and ears are
called sensors (see separate item). The part that corresponds to the
human brain by making judgments based on the information from the
sensors (electric signals), and giving commands (giving signals to
move the actuators) is the control box (also called the controller).
Recently, except for comparatively simple functions, microcomput-
ers are used.

Electronic modulation
This is a method that uses a microcomputer to control the modulat-
ing valve, to reduce the shock when shifting gear, and to carry out
gear shifting smoothly without any delay.
Compared with the conventional method, it has the following fea-
tures.
. A valve is installed for the electronic control of each clutch and
each carries out independent control.
. The hydraulic pressure wave pattern of each clutch can be changed
to match the travel condition (starting, acceleration, driving uphill,
coasting) of the machine.

Exhaust brake
The is one type of retarder, and is a device to increase the braking
effect of the engine. A valve is installed in the engine exhaust pipe,
and this blocks the exhaust pipe to act as a compressor for the engine
to provide braking power.

Hold function
This is a function of the automatic transmission on the H D325-5 and
H D465-3 dump trucks. When the transmission shift lever is set to
positions 2 ), the ranges for automatic shift are as shown in the table
on the right.
For position 5 the range is from F I to F5, and for position 2 the
range is limited to F I and F2. The transmission will not shift up
above the maximum position, so the maximum travel speed for each
position is maintained.
As a result, it is easy to travel down hills or on job sites where there
are speed limits.

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Hold pedal
When this pedal is kept depressed during machine travel, the trans-
mission is maintained in the set speed range, preventing automatic
shifting up or down. As the pedal permits the machine to operate at a
constant speed irrespective of load variation, digging, loading and
spreading operations and rough-ground traveling can be effectively
performed.
(This is installed to WS 16S, WS23, and WS23S motor scrapers with
automatic transmission.)

Kick-down device
When shifting down to accelerate on uphill slopes, if the accelerator
pedal is depressed fully, the transmission is automatically shifted
down and it is possible to accelerate.
This system is called the kick-down device, and is a big feature of the
Komatsu automatic transmission.
This device is used on the H D325-5, HD465-3 and other machines.

kVA
kVA is the unit used to indicate the output of a generator. This figure
obtained by multiplying the voltage (V) by the current (A). The k
stands for kilo, and means 1000. If a current of IOA (amperes) flows
in single phase IOOV (volts), this gives I kVA.
However, in 3-phase, the calculation is as follows: kVA =:x V x A .
1000.
The amount of power used for household purposes is indicated by
kW. The relationship between kW and kVA is as follows:
kW = kVA x power factor

kW (kilowatts)
kW is the international unit (ISO) used to indicate power, and is
used as a unit to express the output of an engine or motor.
Horsepower can be converted into kilowatts using the following for-
mula.
1 HP = 0.746 kW
The output of the engine on the D85A-21 is expressed as 225 HP (168
kW)/2000 rpm.

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Leaning
The action of tilting the front wheels of a motor grader to the left or
right is called leaning.
1 Motor graders have a long wheelbase, and generally speak
ing, the turning radius is large, but if the wheels are leaned.\
the turning radius becomes smaller.
If a barrel is rolled, the barrel will deviate to the side which
has the smaller diameter. If the principle of the barrel is used
for the front wheels, and they are leaned to one side, the
machine will turn to that side.
In this way, if the wheels are leaned, the turning radius can
be made smaller.
2 The load on the front wheels of motor graders is small, and
particularly with operations using the blade at an angle, the
tires tend to slip to the side. Leaning can be used to prevent
the tires from slipping in this way.

McPherson strut suspension

This is a suspension method for the front wheels. In this method, the
shock absorber is used as part of the suspension link, and combines a
side arm and sliding pillar that acts also as the steering king pin.
This kind of suspension is frequently seen on automobiles, and is also
used for Komatsu dump trucks.
It has the following advantages.
. There is no need to adjust the camber or caster, so mainte
nance is easy.
. It is possible to make a big clearance between the wheel and
frame, so the steering angle of the wheels becomes larger,
thereby making the turning radius smaller.

40
The N value
is used on tunneling construction sites etc. to judge the hardness of
deep, hard bedrock. 'The N value is measured by driving a pile into
the ground and counting the number of blows to determine the hard-
ness of' the ground,
The index of' hardness measured by this method is expressed by the
N value, and this is used widely as a survey method for bedrock and
soil quality.
If the soil quality has an N value of 20 or below, it is possible to carry
out digging with a PC60 hydraulic excavator or below but if the N v
value is 30 ~ 50, a PC 100 hydraulic excavator or above is suitable.

Simple method of estimating N value

Softness of soil Judgment method N value
Extremely soft A clenched fist penetrates about 10cm easily. Under 2
Soft A thumb penetrates about 10cm. 2-- 4
Normal A thumb penetrates about 10cm when pushed 4---8
with medium force.
Hard Force is needed to make a dent with the thumb 8--15
Extremely hard It can be dug with a shovel 15-30
Compacted t is necessary to strike down when digging Over 30

Power factor
With AC power, the phase of the voltage and current gradually devi-
ates (changes) with time. If this deviation in phase (or phase differ-
ence) occurs, the electric power cannot be used unless it is made v
voltage x current x phase difference. This phase difference is called
the power factor, and generally expressed as a percentage. When the
phase difference is O (voltage and current are the same phase), the
power factor is IOO%, and as the phase difference becomes bigger,
the power factor value becomes smaller. In the diagram on the right,
Cos is the power factor, and it is expressed by the following formu-
la.
Power (kW)
Power factor =-----------------------------------(%)
Apparent power (kVA)

When expressing the output of a generator, the power factor is fixed

at 0.8 (80 %). With normal light bulbs or electric heaters, it is I 100%,
but with fluorescent lamps it is 50 ~ 60%, with terminals using motors
(underwater pumps, internal vibrators for concrete, conveyors, mix-
ers, winches, etc.) it is 40 ~ 80%, and with welding machines it is
approx. 50%.

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Retarder
A retarder is a deceleration device mainly used on dump trucks trav-
eling loaded downhill to eliminate the acceleration generated by the
grade of the slope.
Unlike the service brake, it can be used continuously or repeatedly,
because its structure is designed to prevent drum overheating, lining
wear, or brake fade.
There are the following types of retarder.

1. Exhaust brake
2. Electric retarder
3. Fluid retarder
4. Force-oil-cooled type disc brake also used as service brake

Komatsu dump trucks are equipped with an oil-cooled multiple disc

brake that acts as a retarder and service brake.

Seismic speed test

The vibration transmitted through the bedrock is called a seismic
wave. The speed at which is transmitted shows the hardness of the
ground: if the ground is soft, the speed is slow, and if it is hard, fine
bedrock, the speed is fast.
The seismic wave is also refracted or reflected at the border between
rock layers. Using these characteristics of seismic waves, it is possi-
ble to estimate the hardness and depth of strata. This method is called
the seismic speed test (or ripper meter test). To carry out this test, a
steel plate is laid on the surface of the ground to be measured, and this
plate is struck with a sledge hammer to generate the vibration. A
microphone is set at a fixed distance from this point, and the time it
takes for the vibration (seismic wave) to be transmitted through the
ground to the microphone is measured. The microphone is gradually
moved ( I ~ 3 m intervals), and the time taken for the seismic waves
to reach the measuring point from the point of origin of the vibration
is measured. The distance to each measuring point and the time taken
for the seismic wave to reach it are entered on a graph to obtain the
seismic speed.

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Sensor
Sensors (detection devices) are elements (components) with the func-
tions of detecting, judging, and measuring various physical quantities
(for example, temperature, pressure, speed).
Human receive outside signals with their five senses (sight, hearing
touch, smell, taste), and transmits these to the brain, where the signals
are processed. Sensors correspond to the five senses of humans. If we
use construction equipment as an example, sensors act to observe the
condition of various parts of the machine, and to convert the condi-
tion of the machine into a electric signal which is transmitted to the
controller (see separate item). Sensors are used to observe about 20
different items, such as temperature, pressure, and rotating speed.
Of these, the sensors used on construction equipment include the fol-
lowing types: temperature sensors, pressure sensors, throttle sensors,
level sensors, speed sensors, position sensors, and angle sensors.

Side wing
The side wing is a snow-clearing attachment for motor graders. As
shown in the diagram, a wing is protruding from the machine. This
cuts the snow piled on the road shoulder, and pushes it up to the out-
side to widen the road.
Generally speaking, if snow-clearing is carried out repeatedly on
fresh snow, the piles of snow on the road shoulder become higher and
higher, and snowdrifts tends to form against the piles of snow. As a
result, the road gradually becomes narrower and narrower. In such
cases, if a side wing is also called a snow wing.

Skip function
The skip function is a function used to shift down in one move to a
gear range suited to the slope. It is used when traveling at high speed
and starting to go up a slope. If the skip function is used on a road
such as shown in the diagram, it is possible to shift down in one move
from F7 to F3 and to drive smoothly up the slope. (In conventional
systems, it is necessary to shift F7 - - F6 FS F3 in turn, so there is
a big time lag.)
When approaching an uphill road, select the position to match
the slope (for example, F3), and move the gearshift lever slowly
to that position.
The skip function is used for the HD325-5, HD465-3 and other
dump trucks.

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Solenoid valve
A device using the pulling force of an electromagnet to move a valve
and control the flow of a fluid is called an solenoid valve, and it is
used for electronic control of hydraulic equipment.
There are two types of solenoid valve: direct movement type and pilot
control type. With the direct movement type, when current is passed
to a solenoid wound with electric wire in a coil, it becomes a magnet
that pulls iron in a constant direction, and moves the spool to open the
valve. When the current is cut, the pulling power is lost, and a spring
or pressure from a fluid is used to close the valve. With the pilot oper-
ation type, a sub-spool is moved by a magnet, and this actuates the
main valve. The structure is complex, but the principle is the same.
For both the direct movement type and pilot operation type, the actu-
ation is an ON/OFF system for fully closed or fully open.

Three-phase tour-wire system

Three-phase AC current generally uses three wires to transmit the
electricity. However, if one more wire is added to these to make a total
of four wires in order to make it possible to detect another type of
voltage, this system is called a three- phase four-wire system. This is
used for the single-phase load of electric lamps, etc.
The Komatsu EG Series has a three-phase four-wire system, and there
are four lead wires.

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Z-screw type air compressor
The compressors on rotation type compressor units can be broadly
divided into two main types: screw type and movable vane type
(rotary type). The screw type can be further divided into the Z-screw
type and two-axis screw type Z-screw type air compressors are
absolutely ideal types as shown below.
Their advantages are as follows:

1 The compression chambers are vertically symmetrical, so

the balance is good' and there is no excess thrust or radial
load, so the life of the bearing is semi-permanent.
2 The wear resistance of the blade (gate rotor) is high, so there
is almost no drop in the amount of discharged pressurized
air caused by wear.
3 Because of its high efficiency? it can be combined with a
one-class-lower engine. This makes it lightweight and com
pact, and it is also economical with low fuel consumption.
4 As it is connected directly to the engine, there are no multi
plying gears, so the reliability is high.

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INDEX (Electrically Controlled Transmission)

Accumulator 15 Electronic modulation

Actuator 36 EMACC
A-frame 36 (Electronic Monitor And Control Console) .
Arm crawed force 36 Engine overheat prevention system
Arm merged circuit 23 EOLSS
Auto-deceleration 24 (Electronic Open-center Load Sensing System)
Automatic three mode suspension 36 Exhaust brake
Availability 2
AVR (Automatic Voltage Regulator) 37 FEM (Finite Element Method
Floating floor
Bank cut 37 Flywheel horsepower
Blade base 37 FMS (Flexible Manufacturing System)
Blade capacity 18 FOPS
BOC (Bolt-On Cutting edge) 29 (Falling Objects Protective structure)
Body capacity 37 Fuel consumption ratio
Bogie type undercarriage 18
Boom kick out 29 Grade ability
Booster 19 Ground pressure
Breakout for 30
Bucket capacity 24 High drive
Bucket digging force 24 Hold function
Bucket positioner 30 Hold pedal
HST (Hydro Static Transmission)
CAD (Computer Aided Design) 3 Hydroshift drive
CAM (Computer Aided Manufacturing)
Cavitation In-line filter
Chattering ISO
CIM (Computer Integrated Manufacturing) (International Organization for Standardization)
CO function
Combustion chamber JIS (Japan Industrial Standard)
Constant-mesh type transmission
Cone index Kick down device
Control box (controller) kVA
Counter rotation turn kW ( kilowatts)
Cross loading
Leaning
dB (A) Lifting capacity
Demand valve Load and carry
Double locked connector Low drive
Ductile cast iron piston
Machine model code (Basic)
EDI MOS Machine model code (Construction machine)
(Electronic Display/Monitoring System) Machine model code (Engine) 11
ELECTRAN McPherson strut suspension 41

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