colo twWler IMTAIN WAN CONNECTORNOGTRWNS= 10. 11. 12. 13. 14, . Connector type diode . Main failures of connectors and wiring harnesses & INDEX INTRODUCTION ..............0065 1 Types of connector and examples of installment 2 Features of current connectors and locations of use ....... 5 Change from Econoseal to X type ...... cece 6 6 7 Inspecting and repairing of connectors and wiring harnesses ith niacin cecceees 8 . Troubleshooting ( adapter) . cee . 9 . Handling connectors and circuit diagram .. sevteeseeerees 10 Cleaning .. . wee 11 Repairing terminals a . 2 owns AZ Pressure-connection sleeves : eee TA Bypass . ree cee tttetteeetteeeeeeeeeee 1B Connector repair set . we 16 eDLu. cece eeeees © Plug type e@cNn ‘ @ ECONO e MIC ex. © 040 : : . Service tools related to connectors en © Digital Multimeter .... © Connector repair set . © T-adapters matrix tableBM intRobuction As Komatsu products, such as hydraulic excavators, bulldozers, wheel loaders, and dump trucks, introduce more mechatronics, various improvements in performance are achieved, and these become new selling points. The equipment used to achieve the advance into mechatronics includes electronic equipment, such as microcomputers, sensors and actuators and the connectors and wiring harnesses that connect them, The cause of failure in a mechatronics system is less likely to be the main electronic parts, such as the microcomputer. A more common cause is disconnections, defective contact, or defective mating of the connectors and wiring harnesses. It is vital for us service people to realize that it is the connectors and wiring harnesses that are the vital parts that lead directly to serious failures or machine down. For this reason, in field service or shop repairs, inspection and repairs of connectors and wiring harnesses are recently becoming important jobs for us service people, in the same way as replacement of O-rings and hoses is important for the hydraulic system. This manual has been produced to give fundamental knowledge and repair skills, with concentration on connectors. Note: This publication is intended for guidance only and KOMATSU LTD. hereby expressly denies and excludes any representation, warranty of implied warranty for the reuse of connectors.CN-type PC200-5 Air conditioner PC200-5 Coolant temperature sensor ECONO pee. WA350 Boom kickout sensor SWP a ae PC200-5 Governor motor intermediate connectorMIC * X Bese ooo PC200-5 Pump controller MS HD325-2 Transmission actuator 040 —_ —— DLI tee WA350O Rear side of monitor Note: The 040 and DLI male terminals are connected directly to the printboard. Therefore, the terminals for service and repair are only female.PC200-5 Underside of relays PC200-5 Underside of relays PC200-5 Fusible link Changes in main connectors Main use Improvement of releability Water proof ‘ype Open type ‘Outside cab, small number of pins ‘See Section [4] + Screw-in type-=Snap-on type + Soldered type-=Crimped type To prevent defective assembly Outside cab, for controller Inside cab, for controller Inside cab, for monitor Contact pressure increased Note: The new type is adopted from the Dash’s Series, the old type will not be used in future.‘sje geo oulyseur pue geo s,soreodo op)sul :z ‘Buneld pjo6 esn Aide suonpuod eAoge oy |1e Y>!YAR 404 SjeuNUIA asouL, a Booe ‘xeW -oinssaud yeU0d eUILIO| @ YUL “xe ung @ (Ai@Jes ULM parejey sued 104 AOL “XEIN) AL *EIN :2B2I}0A sieuru9} pareid:pj06 Jo vonDojas 104 puepuelg :1 24 ou 5 {ooinos somod punoie) se | 0 can Buibseyo Mieneg | O 6a1 | ¢ 1 |. | ° ot € (oz) | | L8i0N (ay! o¥0 | - | ° ez | ok tiz~8) oe 1 ai0N LAWVI SIN 9 7 O ez | oo wa Lai0N geo soierodo opsut s 2 810N ge0 apisus e-0 ° sued aunsaja‘aulBue punosy w |__|} | Se {geo ss0res2d0 apisino) ° Inwwaval ams luonseuucs aeipawiaryy =O) ° > O | Lan dwnd wu 018 4osuas uo!sstusuesyoul6ue punosy e-s0 eo oz wzwalx {suid jo uopedde voquinu) 4, weoy oF x: ppimqey | waxing ody oa seeuery posodx3 pasodxg pasodxg | " | 10199009, ‘Aane6 Jo uones9|9908 :8 “parjdde aq 1ouUed :yueig “poridde oq UeD: Asn 40 SNOILV9DO1 CNV SHOLOANNOD LNAYYND AO SAYHNLV3AS |(OUTSIDE CAB. Type Housing, terminal, rubber Rubber plug O-ring Housing a Not avaiabe cs i act 1. The sealing material has been changed to silicon rubber, so there is no problem of the O-ring becoming stiff and difficult to insert, such as with Econoseal. 2. When mating the male and female housing, itis possible to check by the click sound that they are properly engaged. In other words, always push in until the click sound is heard. 3. To prevent defective contact, a flat type terminal is used, and the contact pressure has been increased. This makes the connector also stiffer to insert or remove. [By CONNEC The connector for the connector type diode is a CN type with 2 pins; the pins at the diode end are male. Inthe electrical circuit diagram, itis displayed as in the following example: CN-D10 1 D110 tag is attached to the wire. This has been fixed f in KES to deal with the new connectors.WIRING HARNESSES 1) Defective contact of connector (defective contact of male, female) © Improper mating of the connector male (plug) and female (receptacle) © Misalignment of male and female because of deformation © Corrosion, oxidization of the contact surface 2) Defective crimping of connector The connector male and female pins are contacted bya crimped terminal. Ifthe crimping is defective, or an excessively large force is brought, to bear on the wiring, the contact may be insufficient or the wire may break. 3) Disconnection in wiring If excessive force is brought to bear, such as in the following cases, the crimped part of the connector may come apart or the wire may break © The wires are held to pull the connectors apart © The equipment is lifted with a crane with the wiring still connected © A heavy object hits against the wires Even if no damage to the covering of the wire can be seen from outside, the wire may be broken inside 4) Entry of water into the connector when sprayed with high pressure water © The connectors used on Komatsu machines are designed to prevent the entry of water (drip- proof structure], but if high pressure water is directed directly onto the connector, water may enter, depending on the direction of the water jet. © The structure is designed to prevent the entry of water, so when water once gets in, itis difficult todrain. If water gets into the connector, a short circuit will be formed between the pins by the water. 5) Oil or dust stuck to the connector © If oil or grease is stuck to the connector, and a film of oil is formed on the contact surface of the male and female pins, the oil will not let the electricity pass, so there will be defective contact, © foil or grease is stuck to the connector, clean it off with a dry cloth, and spray it with a contact cleaner lubricant. © If the connector becomes extremely dirty, the pins may be deformed or drops of water may get Defective mating ~ Defective crimping % © If water gets into the connector, dry the connector or take some other suitable action before passing current through the connector. + Avoid high pressure water washing around mechatronic devices as much as possible, cause a short circuit or defective contact, * When wiping the contact portion of the connector, do not use any excessive force~ CONNECTORS AND WIRING HARNESSES Disconnect connector clamp holder See p.9 + Remove from the + Remove from the See p.10 Check the voltage, resistance, and] TOOL __: T-adapter, Digital multimeter pera to determine which pin of |_| __ Materials uit diagram connector is defective. — “oe ers Sitice Machine : Connector location, tag number connector and wire to check. See p.16~ 22 Cleaning fluid Repair |— Dryer Contact cleaner lubricant Connector | Wire +* When badly | affected ‘© Defective crimping of terminal Disconnection, ane ae ‘© Disconnection near terminal short circuit Oil, dust | | ENV °F | | oxicization of contact surface X, 040, SWP or multiple pin See p.12 See p.11 ta See p.15 Clean, or wipe with well-dried clean cloth if there is no cleaning Pull out terminal foe a solution. Dry with dryer Cut, strip Bypass Contact cleaner i lubricant one + When wire becomes | See p.14 shorter cts} os] imeAs the basic operation in troubleshooting of the mechatronics system, carry out the following checks and measurements at the connectors using a T- adapter and digital multimeter. © Measurement of voltage ‘© Measurement of resistance © Check of continuity Fila For this purpose, T-adapters are available for each = connector. If T-adapters are used, even with multiple- ele pin connectors, there is no need to make troublesome o—— searches for the pin position, so this is an cruise indispensable service tool Checker Note 1: With the CN connector, it is possible to carry out the check by contacting a meter directly against the terminal, so no T-adapter is set. Note 2; Two wiring harnesses (white and red) come from the checker, but connect the T-adapter as follows. © For 12 pins and below, connect to white only © For 13 pins to 21 pins, connect to both white and red 1. Measuring voltage Both the male and female of the T-adapter are connected to the chassis wiring harness to form a T, and measurement is made with a meter. 2. Measuring resistance, checking con- ity Connect to the side tobe measured (either male or female), and measure. + When checking for continuity, it is important to shake the harness, and to check carefully that there is no condition that will sometimes cause defective contact. If a T is formed, the side with the low resistance value is given. Normally, this check should be carried out with the power source turned OFF. Note: For details of the part numbers of the T-adapters, see p. 24 or the SERVICE TOOL GUIDE.1. Check tag number (Example on PC200-5) Check that the connector of the coolant level sensor is a 2-pin X type and has a tag with a P8 number. Check the colors of the wires at the same \o time asscn | aie Baest Gi — hee Green wiwhite stripe fe Black od 2. Remove the connector from the connector holder. Remove the connector from clamp firstly, if there is a clamp. If the connector is disconnected without removing it from the holder, excessive force will be brought to bear, and the part indicated by the arrow will be broken. 3. Disconnection of connector Hold the male and female housings firmly with the left and right hands, keep the notch pushed in, and pull apart. + Check the terminals to judge male and female. The housing is the opposite CN-P8(X2) WEI ie f (~ ae} + osuas yenay auej009 Female Male 4, Joining connectors Always insert until the clicking sound of the lock is made. After this, pull the housing to check that it does not come out, then insert it on the holder. Always return any clamps that were removed to their original positions. If the wire is hanging loose, this may cause problems. AV Telnet Connector No. \ [This number is display on the machine and in troubleshooting) Basic codeIf defective contact occurs because there is slight corrosion or oxidization of the contact surface, or entry of water inside the connector, or the connector is dirty with oil or dust, take the following action. 1. Clean Remove the dirt with a cleaning fluid. If no cleaning fluid is available, wipe with a dry cloth % Do not wash with water or clean with steam. * There are many types of cleaning fluids available on the market, so read the instructions provided. 2. Drying When blowing with compressed air, moisture contained in the air will be deposited, so blow with a dryer. Use a dryer to dry particularly the places where = water has got in. 3. Contact cleaner lubricant Blow with contact cleaner lubricant. Note: Contact cleaner lubricant provides the following effects. © Prevention of salt corrosion © Prevention of corrosion, extension of life © Lubrication * For details of the method of use, read the instructions provided. + Problems can often be fixed simply by cleaning the connectors, so it is an important process.al The following is an explanation of a series of common technical points using CN type terminals. 1. How to use the cutter %* Match the number stamped on the cutter with the nominal number of the electrical wire. Ifthe size is not correct, the core of the wire may be damaged or twisted, so care is needed Note: The nominal number is shown in the wiring diagram in the shop manual Direction of cutter Correct Direction of cutter Incorrect * If has slipped at the tapered portion and made the covering and bare wire out of line. 2. Stripping covering % Pull straight + After stripping © Never do not twist ! @ Never do not band ! 3. Checking looks and length of stripped portion Length of wire barrel (L) +1.0 mm +0.5 mm. External appearance (1) Broken or damaged wire cannot be used, (2) The ends of cut wire must be aligned. (3) The bare wires must be aligned Ifthe bare wires are not aligned, they must not be twisted to align them. (4) The cover must be cut cleanly.4. Setting terminal 5. Inserting and crimping wire * Set carefully, considering the confirmation Insert the wire and crimp it items and size in 7. + If the tool is not tightened until the wire is Grip it slightly and it will stop at that position. completely crimped, the tool will not open. + After crimping, pull the wire strongly to check 6. Finishing Examples of good finishing (green wire) and poor finishing (red wires) Example of poor finishing 1. The cover is crimped (defective stripping 1 2 3 length) 2, The crimped tip is offset (defective setting in the tool) 3. The wire is protruding 7. Check items after crimping If the crimping is defective, start again from beginning. (1) The wires can be seen from the top (2) The cover material is protruding (03 ~0.8 mm) (05mm~ ) “IP (4) There must be no bending, rolling or twisting of (3) Always fit a bellmouth the crimped portion (within 3° of center line of wire) (reference: min. 0.5 mm) Front bellmouthy —) j= -~) -= Rear bellmouth Upward bending VE] ra} Twisting Downward bending ot @ Rolling @ M7 ve)When repairing terminals, the old terminal portion is cut off, and for this reason, the wire becomes shorter, so there is danger that it may be pulled. In such cases, add a pressure-connection sleeve to make the wire with the crimped terminal longer. 1. After stripping the cover as explained in the previous section, insert the wire into the sleeve and crimp it. * When inserting, insert it smoothly without catching, Never twist the wires where they have been stripped. 2. Finishing Hold both sides and pull strongly to check that the # wires do not come out. 3. Overall condition of connectors The repaired portion becomes shorter, so consider, the length to ensure that no excessive force is pulling on the wires 4. Confirmation 1) Check the continuity between the repaired terminals (pin numbers). 2) Check that there is no short circuit between the repaired pin number and any other pin,When repairing X type, SWP type, or 040, or multiple-pin connectors, do not repair the terminals. Cut off only the defective portion and make a bypass. For X type and 040, it is impossible to carry out manual repair of the terminal. The repair set contains a terminal and wire that has already been set using an automatic crimping machine, so use this and connect it with pressure-connection sleeves. 1. Bypass connector The photograph shows X-type. Onlya2-pin bypass is provided in the set, so use a blind plug for one side. (Same way for ECONOSEAL) 2. Connect with pressure-connection sleeves (to the portion marked with an arrow) After completion of repair, carry out a continuity test, and secure with a nylon tie. + When making additional circuit, it is also possible to use the same method. Note: Orange is the color for the service wire. This color is used so that it is possible to see later that service (repair) has been carried out. For this reason, orange wires are not used in the original design.Note: For details of part numbers, etc., see p.23 or the SERVICE TOOL GUIDE. Kit CONNECTORS: No. Type 2 bu }3 cN —— 5 ECONO 6 mic 7 8 x, 040 Part Name REPAIR KIT-TOOL REPAIR KIT-CONNECTOR REPAIR KIT-CONNECTOR REPAIR KIT-CONNECTOR REPAIR KIT CONNECTOR REPAIR KIT CONNECTOR REPAIR KIT: CONNECTOR REPAIR KIT-CONNECTOR Set Sera 10 1.05 23 13 12 1.55 Remarks {main uses, structure) Three types of crimping tools and a bag to hold them (For crimping and stripping covers from electric wiring) Plung type connectors (KES parts), teri nals for DLI connectors, bodies, drawing tools, and plastic storage case Teminals for CN (KES parts, lock type) connectors, bodies, drawing tools, and plastic storage case Round teminals (crimping teminals held by sorews, 28 types, applicable wire: 0.5 ~ 15), and plastic storage case Teminals for Econoseal (KES parts) con rectors, bodies, inserting, drawing tools, and plastic storage case, Teminals for MIC connectors, bodies, drawing tools, and plastic storage case Crimping connectors with insulation cov- ers (3 types), clamp bands, viny! tape, and plastic strage case New X (made by Yazaki), 040 (made by AMP) housings used on new models, teminals with cable, metal-plated MIC teminals, and plastic storage case1. Pulling out z Use a special tool to pull the connector out. * Insert the tool horizontally, and keep the locking lance of the terminal pushed down while pulling the wire out. ae 2. Crimping Step 1 3. Completion of crimping 4. Crimping Step 25. Completion of crimping %* See 11 6) to check the crimping condition. + Pull and check that it does not come out. 6. Insertion in connector Fit to the locking lance and insert until it makes a click sound. Plug type The three wires show the following (from the bottom): © After completion of crimping © Male and female inserted © After completion of assembly1. Pulling out terminal 3 Use a special tool to pull out the terminal a % Put a special tool in contact with the locking ‘al lance at the housing side, then twist lightly and pull out the wire. %* Be careful not to damage the locking lance at the se oe housing side when pulling out the wire. 2. Stripping the cover After cutting the terminal, strip the cover off. ® Pull straight. 3. Crimping terminal 4, FinishingPulling out terminal 2. Crimping terminal Put the tool in contact with the locking lance at_ + Donot crimp the stabilizer (marked with arrow) the housing side, then twist lightly and pull out used to prevent the terminal from rotating the wire + Be careful not to damage the locking lance at the housing side when pulling out the wire. %* Check that the wires are parallel % Align the match marks (arrow in photograph) + Fit blind plugs in places where no wire is used.1. Pulling out terminal Use a special tool to pull out the terminal. % Be careful not to damage the locking lance at the housing side when pulling out the wire. 2. Crimping terminal First, crimp the bare wire portion 3. Crimping cover portion Next, crimp the cover portion. 4. Insert in the housing to complete the operation.1. Thi SWP. + There is no crimping work for the terminal, so using a sleeve for a connection is always necessary. The X type can be used for repair of any type connector, such as ECONOSEAL, etc. used when repairing X type or 2. For 1-pin The kit contains only a 2-pin connector, so when using it for a 1-pin system, always fit a blind plug. % This operation is indispensable for the use of outside cab as water-proof type. [049] 1. Pulling out terminal Use a paper clip and pull out. 2. Finishing The terminal cannot be repaired, so use the wire and terminal in the set and connect with a pressure-connection sleeve.+ DIGITAL MULTIMETER Parts No. : 79A — 264 — 0210 (See the photograph on the P.9.) + CONNECTOR REPAIR SET (See the photograph on the P. 16) ada jy BE 8s / se <2 89/82 Kit CONNECTORS: Remarks: No. Type: Part Name o/s (main uses, structure) zs/e/#/# | ol F/ E ) +1 / +2 / xg) _ | Three types oferimping tools anda bag to + (Pepeexetonl| ream xrr-Too. 11 = ag hal em For erimping snd stibsng | covers from alactrie wiring DL | Plung type connectors (KES parts), temi- 2 | 790-222-2800 REPAIR KIT-CONNECTOR 1-1 | 1.0. for DLI connectors, bodies, drawing tools, and plastic storage case CN | Teminais for CN (KES parts, lock type) 3 | 790-222-3100 | REPAIR KIT-CONNECTOR 1-1 =| 1108 Connectors, bodies, drawing tools, and plastic storage case Round teminals (crimping teminals held 4 | 790222-2200 | REPAIR KIT-CONNECTOR 1 1 | 2.3 |_—byscrows 28iypes, aplcble wire: 08 15), and plastic storage case ECONO Teminais for Econoseal (KES parts) con- 5 | 790-222-2000 REPAIR KIT-CONNECTOR 1 «11.3. nectors, bodies, inserting, drawing tools |_ and plastic storage case mic Teminals for MIC connectors, bodies, , + = | 42 : Crimping connectors with insulation cow 7 790-222-3200 REPAIR KI-CONNECTOR = 1— 1 | 1.13 er5(Stypes), clamp bands, vinyl tape, and | plastic strage case 7 ry |New mae by Yaa 89 made by | usings used on new modes, 8 Rete) REPAIR'KIT-CONNECTOR ~ * ~ 155 | teminals with cable, metal-plated MIC teminals, and plastic storage case Carrying case for holding above kits 18 8 790-299-1100 CASE i | @ 1 | 22 | Gnysietsin one case) (w485x0345xH133mm) "1: The new Set 2 consists of the present Set 1 with the addition of repair parts for connectors used on new models, "2: The carrying case, which is newly available as an option, has been made available to overcome the inconvenience of carrying kits 1 108 separately without any holder. This case has the Komatsu mark on it. The figure in ( ) indicates the number of cases that are needed to hold all the kits. *3: The terminals with cable (already crimped) in kit 8 have been prepared by a specialist company to ensure the crimp quality. {itis impossible to crimping with the set tools or commercially available tools.) + No.9 CASE is available as an option, so itis not included in the part number for Set 1 or Set 2.CESS of ae)