COMPONENT CODE DD

KOHAG NO. AH12004

PARTS & SERVICE DATE 2012-01-22

NEWS Page 1 of 6

SUBJECT: Boom and bucket proximity switch

APPLICATION: Machine Serial no.

WA380-6 H60051 and up
WA430-6 H60051 - H60265
WA430-6E0 H60266 and up
WA470-6 H50051 - H50879
WA470-6 H52001 - H52029
WA470-6LC H50880 and up
WA480-6 H60051 - H60469
WA480-6LC H60470 and up

FAILURE CODE: DDB7ZC

DESCRIPTION: Boom or bucket proximity switch without function

LIST OF PARTS:

part no. part name purpose of part qt'y remarks

56B-06-15610 Switch 1
Replacement One sensor for each function
(42U-06-15170) (Switch) (1)
793-H70-0330 Cable 1
Tool Test equipment
() () ()
793-H70-0340 Checker 1
Tool Test equipment
() () ()

Komatsu Hanomag GmbH

Printed in Germany
AH12004 Page 2 of 6

1. Symptom of failure and contents of modification

1.1. Symptom of failure

Frequent error message or no function of boom or bucket switch.

Externally, there are no cause visible.

1.2. Cause of the failure

In many cases, deviations in the attitude of the switch presumed.

Less often is the cause of failure the sensor itself.

1.3. Content of modification

If any failure occur in reference to the boom or bucket proximity switch, please refer to the
following procedure before you start to change the switch.

Background of this measure is that at many claimed sensors could no failure detected after
investigation at the supplier and KOHAG.

2. Inspection of justification and electrical function

2.1. Precautions before starting the inspection and modification

- Before beginning check and / or rework procedure ensure that the machine is in a
safe condition.
- Ensure the machine is located on flat level ground. Place chocks behind each wheel to
prevent the machine from moving.
- Lower the work equipment to the ground and turn off the engine.

Komatsu Hanomag GmbH

Printed in Germany
AH12004 Page 3 of 6

2.2. Inspection of justification

- Adjustment of bucket proximity switch

1. Deflector
2. Safety bracket to fix and guard the proximity switch.
3. Space between Deflector and safety bracket (Target: 1 - 3mm).
4. Switch
5. Space between switch and deflector (Target: max. 4mm).
Make sure that the end of the proximity switch is always behind the safety bracket.

- Adjustment of boom proximity switch

1. 3.

2.

1. Switch
2. Deflector
3. Space between boom switch and deflector (Target: 4 ± 1mm).

Komatsu Hanomag GmbH

Printed in Germany
AH12004 Page 4 of 6

2.3. Control of electrical function

If the boom or bucket switch still without function after inspection and correction of
the adjustment, proceed with help of the test equipment like it shown below.

Test device:

Cable
793-H70-0330

Checker
793-H70-0340

2.3.1. Control of boom or bucket switch with test device

1. Make sure that the defector is not in front of the switch.

2. Disconnect the sensor connector and connect it together with the test device
(793-H70-0330 and 793-H70-0340) like it shown at the picture.
3. Hold a piece of metal in front of the switch.
4. If the green LED is lightening at the test device and the buzzer made a sound, the
switch signal is OK and no failure is inexistent.
5. If the green LED is lightening without a piece of metal, the switch has
permanently passage and must be replaced.
6. If no LED lightening and no signal from the buzzer, the switch has a defect in
general and must be replaced.

Komatsu Hanomag GmbH

Printed in Germany
AH12004 Page 5 of 6

2.3.2. Control of boom or bucket switch without test device

Switch 42U-06-15170

Switch 56B-06-15610

Test procedure for both switches:

Pin 1: 24V
Pin 3: ground
Pin 2: Connect a standard 24V test lamp between Pin1 and Pin2.
In the moment when you put a piece of metal in front of the switch, the test lamp
has to switch on. If not, the switch has a defect and must be changed.

Please note that independent which sensor is involved (42U-06-15170 or 56B-06-15610), in

case of necessary exchange you have to use the sensor 56B-06-15610.

Komatsu Hanomag GmbH

Printed in Germany
AH12004 Page 6 of 6

3. Claim report
In case of necessary exchange of the switch, please write the problem description in the
claim more detailed like it written below, which will help to analyze the cause.

1. Switch damages at the head (adjustment problems).

2. Switch damages from outside (for example: stone, ...)
3. LED of Switch is defect, but the sensor works normal
4. Switch has permanently passage
5. Cable is damaged
6. Others (with description of the failure).

Please expect a Damage Parts Request of claimed sensors.

Komatsu Hanomag GmbH

Printed in Germany