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Komatsu A12001 Shop Manual
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Komatsu A12001 Shop Manual

Komatsu A12001 Shop Manual

Hydraulic excavator
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Shop
Manual
PC210LC
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
May 2015
PC210LC-11 A12001
6D107E-3
-11
and up
Copyright 2015 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM029400

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Summary of Contents for Komatsu A12001

  • Page 1 6D107E-3 ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 INDEX 00 INDEX AND FOREWORD INDEX 00 INDEX AND FOREWORD ........................00-1 FOREWORD, SAFETY, BASIC INFORMATION ................... 00-19 HOW TO READ THE SHOP MANUAL................... 00-19 SAFETY NOTICE FOR OPERATION..................... 00-21 PRECAUTIONS TO PREVENT FIRE..................... 00-29 ACTION IF FIRE OCCURS......................00-31 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ............
  • Page 3 00 INDEX AND FOREWORD INDEX COOLING SYSTEM..........................10-75 LAYOUT DRAWING OF COOLING SYSTEM ................10-75 FAN SPEED CONTROL SYSTEM OF FAN CLUTCH ..............10-77 ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH............10-79 COMPONENT PARTS OF COOLING SYSTEM................10-81 CONTROL SYSTEM..........................10-82 LAYOUT DRAWING OF CONTROL SYSTEM PARTS..............
  • Page 4 INDEX 00 INDEX AND FOREWORD TEST BOOST PRESSURE......................30-15 TEST EXHAUST GAS COLOR ...................... 30-17 TEST AND ADJUST VALVE CLEARANCE ..................30-20 TEST COMPRESSION PRESSURE....................30-22 TEST BLOWBY PRESSURE ......................30-27 TEST ENGINE OIL PRESSURE ....................30-29 TEST EGR VALVE AND KVGT OIL PRESSURE ................30-30 TEST FUEL PRESSURE .......................
  • Page 5 00 INDEX AND FOREWORD INDEX ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION ..........40-54 PROCEDURE FOR TESTING AND TROUBLESHOOTING ............40-64 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ..........40-67 INFORMATION IN TROUBLESHOOTING TABLE ................. 40-71 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN- SOR SYSTEM..........................
  • Page 6 INDEX 00 INDEX AND FOREWORD FAILURE CODE [CA153] Charge Air Temperature Sensor High Error ..........40-222 FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error...........40-225 FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error ............40-227 FAILURE CODE [CA221] Ambient Pressure Sensor High Error............40-229 FAILURE CODE [CA222] Ambient Pressure Sensor Low Error ............40-231 FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error .............40-233 FAILURE CODE [CA234] Engine Overspeed................40-234...
  • Page 7 00 INDEX AND FOREWORD INDEX FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error........40-326 FAILURE CODE [CA1691] Defective Regeneration ..............40-327 FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error..........40-330 FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error ...........40-333 FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error ............40-334 FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error ............40-336 FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error......40-339...
  • Page 8 INDEX 00 INDEX AND FOREWORD FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error .......40-457 FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration....40-461 FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error........40-463 FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error ........40-466 FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error ............40-469 FAILURE CODE [CA3251] KDOC Inlet Temperature High Error ...........40-472 FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration ........40-474...
  • Page 9 00 INDEX AND FOREWORD INDEX FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error ...........40-597 FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error ........40-601 FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error ........40-603 FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error........40-605 FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error ..........40-607 FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error ..........40-610 FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error..........40-612...
  • Page 10 INDEX 00 INDEX AND FOREWORD FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller)................................40-731 FAILURE CODE [DAF0MB] Monitor ROM Abnormality..............40-732 FAILURE CODE [DAF0MC] Monitor Malfunction ................40-733 FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit ..........40-734 FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor)........40-736 FAILURE CODE [DAFGMC] GPS Module Malfunction ..............40-737 FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor) ........40-738 FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor) ........40-740...
  • Page 11 00 INDEX AND FOREWORD INDEX FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit ..40-865 FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit ..........40-867 FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit ..........40-869 FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit .........40-871 FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit .........40-873 FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit .........40-875 FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit......40-877...
  • Page 12 INDEX 00 INDEX AND FOREWORD E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING..............................40-971 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....40-972 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING......40-973 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ..40-974 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN- NING ............................40-975...
  • Page 13 00 INDEX AND FOREWORD INDEX E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..............................40-1026 E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION................................40-1027 E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1028 E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..............................40-1029 E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
  • Page 14 INDEX 00 INDEX AND FOREWORD H-32 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW ..............................40-1101 H-33 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK.......40-1102 H-34 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ......40-1103 H-35 UNUSUAL NOISE IS HEARD FROM AROUND FAN ............40-1104 H-36 ATTACHMENT CIRCUIT CANNOT BE CHANGED............40-1105 H-37 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CONTROLLED .......40-1106...
  • Page 15 00 INDEX AND FOREWORD INDEX REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ..........50-120 REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..............50-141 REMOVE AND INSTALL ENGINE REAR OIL SEAL..............50-148 REMOVE AND INSTALL FUEL COOLER ASSEMBLY ..............50-152 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY ..............50-154 REMOVE AND INSTALL FUEL TANK ASSEMBLY ...............50-161 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............50-169 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY......50-181...
  • Page 16 INDEX 00 INDEX AND FOREWORD REMOVE AND INSTALL SEAT BELT ...................50-493 REMOVE AND INSTALL FRONT WIPER ASSEMBLY ..............50-495 ELECTRICAL SYSTEM ........................50-508 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...........50-508 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY............50-511 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ............50-520 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ............50-527 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ......50-529 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........50-531...
  • Page 17 00 INDEX AND FOREWORD INDEX AIR CONDITIONER COMPONENT ....................80-5 SPECIFICATIONS OF AIR CONDITIONER ..................80-7 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ..........80-8 OUTLINE OF REFRIGERATION CYCLE ..................80-9 COMPONENT PARTS OF AIR CONDITIONER SYSTEM ..............80-11 AIR CONDITIONER UNIT.......................80-11 COMPONENT PARTS OF AIR CONDITIONER UNIT..............
  • Page 18 INDEX 00 INDEX AND FOREWORD METHOD FOR REPLACING DESICCANT ................... 80-84 90 CIRCUIT DIAGRAMS ..........................90-1 CONTENTS ............................90-2 HYDRAULIC CIRCUIT DIAGRAM ......................90-3 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM ..............90-3 HYDRAULIC CIRCUIT DIAGRAM ....................90-7 ELECTRICAL CIRCUIT DIAGRAM ......................90-9 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM..............

  • Page 19: Troubleshooting

    REMARK • Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor. • The materials and specifications are subject to change without notice. • Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.

  • Page 20: How To Read The Shop Manual

    HOW TO READ THE SHOP MANUAL 00 INDEX AND FOREWORD Symbol Item Remark This signal indicates an extremely hazardous situation which will result in Danger death or serious injury if it is not avoided. This signal indicates a potentially hazardous situation which will result in Warning death or serious injury if it is not avoided.

  • Page 21: Safety Matters

    Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purpos- •...

  • Page 22: Precautions During Work

    SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD • Always wear the protective eyeglasses when hitting parts with a hammer. • Always wear the protective eyeglasses when grinding parts with a grinder, etc. • When performing any operation with multiple workers, al- ways agree on the operating procedure before starting.
  • Page 23 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION • The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.
  • Page 24 SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD • When assembling or installing parts, always tighten them to the specified torques. When installing protec- tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.
  • Page 25 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION REMARK When slinging a load with 2 or more ropes, the force sub- jected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} ...
  • Page 26 SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD Precautions for using overhead traveling crane When raising a component heavier than 25 kg), use a hoist or crane. REMARK Weight of component which is heavier than 25 kg is shown with symbol in "DISASSEMBLY AND ASSEM- BLY".
  • Page 27 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION Nominal diameter of rope ( mm) Allowable load ( kN { t} ) 318.3 {32.4} Precautions for disconnecting air conditioner piping NOTICE When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.
  • Page 28 SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD REMARK • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Pre- cautions for disconnection and connection of air conditioner piping".
  • Page 29 Fire around the machine due to highly heated exhaust gas This machine is equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re- generation), the temperature of discharged exhaust gas may be higher than that of conventional models.
  • Page 30 PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD • When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa- ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused by KDPF regeneration.

  • Page 31: Action If Fire Occurs

    00 INDEX AND FOREWORD ACTION IF FIRE OCCURS ACTION IF FIRE OCCURS • Turn the starting switch to OFF position to stop the engine. • Use the handrails and steps to get off the machine. • Do not jump off the machine. You may fall and suffer serious injury. •...
  • Page 32 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00 INDEX AND FOREWORD PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution, pay full attention to the way to dispose of waste materials. • Always drain the oil from your machine in containers. Nev- er drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.
  • Page 33 This machine is equipped with the following two exhaust gas treatment systems: • Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu- rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
  • Page 34 PRECAUTIONS FOR AdBlue/DEF 00 INDEX AND FOREWORD PRECAUTIONS FOR AdBlue/DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING AdBlue/DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require immediate action: •...
  • Page 35 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.

  • Page 36: Cleaning Operation

    PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD Replacing hydraulic oil while its temperature is high • The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are easily discharged from the circuit. Perform the replacement while oil temperature is high. •...
  • Page 37 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- 00 INDEX AND FOREWORD INGS PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and as- sembly" of the components, observe the following precautions. Precautions for removal and disassembling work •...
  • Page 38 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- INGS 00 INDEX AND FOREWORD Introduction of parts for the disconnection of the taper seal type hoses and tubes Hose side Pipe joint side Nominal No. Plug (1) Nut (2) 07376-50210 07222-00210 07376-50315 07222-00312 07376-50422 07222-00414...
  • Page 39 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- 00 INDEX AND FOREWORD INGS Shoe bolt pitch Hose side Tube side Nomi (mm) O-ring (4) Bolt (5) Washer (6) Split flange Sleeve head Flange (1) 58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032 66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232...
  • Page 40 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- INGS 00 INDEX AND FOREWORD Introduction of parts for the removal of taper pipe thread type joint Plug (1) Nominal Nominal No. thread size Square head type (A) Hexagonal socket head (B) 07042-00108 07043-00108 07042-00211 07043-00211...
  • Page 41 When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser- voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 42 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP- INGS 00 INDEX AND FOREWORD Fuel system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion. If there is any looseness, damage, or fuel leak, retighten or repair the part. Check the exhaust equipment and its installation portion for looseness and damage.
  • Page 43 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at im- proving the quality of repairs.
  • Page 44 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD Disconnection in wiring If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the sol- dering, or break the wiring harness.
  • Page 45 If a filter oth- er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
  • Page 46 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT The machines equipped with Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure.
  • Page 47 00 INDEX AND FOREWORD PRACTICAL USE OF KOMTRAX PRACTICAL USE OF KOMTRAX Various information which KOMTRAX system transmits by using the radio communication is useful for KOM- TRAX operator to provide various services for the customers. When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.
  • Page 48 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER REMARK • Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank. • Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.
  • Page 49 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition. REMARK When the hose fitting is pulled back, the rubber cap moves approximately 3.5 mm toward the hose, but it is not a prob- lem.
  • Page 50 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD Connection Hold the tightening adapter part, and push body (2) straight un- til sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end. METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER Disconnection Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact...

  • Page 51: Connecting Connectors

    PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- 00 INDEX AND FOREWORD NECTORS PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC- TORS Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, always hold the con- necting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel.
  • Page 52 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- NECTORS 00 INDEX AND FOREWORD • Check that there is no deformation, defective contact, corrosion, or damage on the connector pins. • Check that there is no damage or crack on the external surfaces of the connectors. NOTICE •...
  • Page 53 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- 00 INDEX AND FOREWORD NECTORS Disconnect the connector and wipe off the water with a dry cloth. NOTICE If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defec- tive contact, remove oil and water in the air before starting air blow.
  • Page 54 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON- NECTORS 00 INDEX AND FOREWORD NOTICE • Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine. •...
  • Page 55 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH 00 INDEX AND FOREWORD CONNECTOR METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC- Method for disconnecting Deutsch connector While pressing locks (a) and (b) from each side respectively, pull out female connector (2). Method for connecting Deutsch connector Push in female connector (2) horizontally, and insert it straight until it clicks.
  • Page 56 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00 INDEX AND FOREWORD METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA- TOME-2) Slide lock (L1) to the right. While pressing lock (L2), pull out connector (1) toward you. REMARK If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward...
  • Page 57 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK 00 INDEX AND FOREWORD TYPE CONNECTOR While pressing lock (L2), pull out connector (1). REMARK Lock (L2) is located behind connector (1) in the figure. Method for connecting slide lock type connector (FRAMATOME-24) Insert it straight until it clicks.
  • Page 58 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00 INDEX AND FOREWORD METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL Method for disconnecting connector with lock to pull Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.
  • Page 59 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR 00 INDEX AND FOREWORD WITH LOCK TO PUSH METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH Method for disconnecting connector with lock to push (BOSCH-3) While pressing lock (C), pull out connector (3) in the direction of the arrow. •...
  • Page 60 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 INDEX AND FOREWORD Method for disconnecting connector with lock to push (AMP-3) While pressing lock (E), pull out connector (5) in the direction of the arrow. Method for connecting connector with lock to push (AMP-3) Insert it straight until it clicks.
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