COMPONENT CODE: ZZ00

REF NO. AH00502A

PARTS & SERVICE NEWS DATE Apr. 1st, 2000
Page 1 of 20

This PARTS & SERVICE NEWS supercedes the previous issue No. AH00502 dated Feb.
2000 which should be discarded.

SUBJECT: Introduction of the Appearance of the Komatsu Parts & Service News

PURPOSE: Introduction of new Layout of the News

APPLICATION: All Types

FAILURE CODE: ZZ00Z9

DESCRIPTION:

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1. Service Bulletin Number : e.g. REF.-N0.: AH00502A

- 1st letter: A = Parts & Service News

B = Installation Manual

- 2nd letter: Manufacturing subsidiary code H = KOHAG* or KMG**

(both Germany)

* Komatsu Hanomag AG
** Komatsu Mining Germany

- 2 digit numbers: Last two digits of the year 2 0 0 0 = 0 0

- Next 3 numbers: Serial numbers 101 - 499 numbers of KOHAG

501 - 999 numbers of KMG

- Last letter: Revision code (alphabet)

- Example:

A H 0 0 5 02 A

1st Revision
KMG ; Number 2 of the year;
Year 2000
KOHAG or KMG (both Germany)
Parts & Service News

2. Codes

In the past we used 30 sections for the classification of the Service Bulletins.
Now we have a very detailed organization of the information. This will alleviate the
search for information.
Attached you receive a PC -Program on 3 diskettes for working with the Component
Code, the Major Code and the Phenomen Code.

Component *

Major Code Part *

0 0 * Not used at the moment by KMG.

Component Code Phenomen Code

Failure Code

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2.1 FAILURE CODE

The FAILURE CODE consists of 6 digits. The first four digits show the component
that is thought to be the cause of the failure, and the last two digits show the
phenomenon.

. • For all TSI (Technical Service Information) and all Warranty

claim application you have to state the Failure Code

2.2 COMPONENT CODE (4 digits)

The COMPONENT CODE consists of the MAJOR CODE, the COMPONENT and the
PART. KMG use only the MAJOR CODE at the moment. For the COMPONENT and
the Part we enter “0”.
Attached you receive a table with the MAJOR CODES and a picture with the
illustrated index.

2.3 PHENOMENON CODE (2 digits)

The PHENOMEN CODE contains the phenomenon that is the cause of the failure.
Attached you receive a table with the PHENOMENON CODES.

3. How to search for information

About half-yearly we will give you an Excel Chart with all our Service News issued
since January 2000. This chart is arranged after the Component Code.
If you are searching for a Service New you need the Component Code.
There are 3 methods of searching the Component Code:

3.1 Searching from illustrated index

Using the ILLUSTRATED INDEX , search for the 2-digit code for the major
component.
Example: Searching for the code for the arm cylinder packing on a hydraulic
excavator.
Using the hydraulic Excavator Index, locate the arm cylinder and check
that the 2-digit code is H1.

3.2 Searching from MAJOR COMPONENT INDEX

Using the table with the MAJOR COMPONENT INDEX, select the 2-digit code from
the major component name.
Excample: Searching for the code for the arm cylinder packing on a hydraulic
excavator.
Using the MAJOR COMPONENT TABLE, search for code H1 under the
name HYDRAULIC CYLINDER.

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3.3 Searching with the PC- PROGRAM

3.3.1 Installation of the Search program
1. Open your “WINDOWS” program on the PC.

2. Double Click on “My Computer”.

Put the diskette 1 in your diskette drive.
3. Double Click on “3 ½ Diskette (A)”.

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4. Double Click on “setup.exe

A few seconds later there are 3 questions.

Please answer every time with putting “Enter”

5. After request you have to change 2 times the diskette and put “Enter”.
If the installation is finished close all screens with click on the cross above in the
right corner

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Now the installation is ready.

You find the search program as following:

1. Put the “Start” button and go with the mouse on “Programs”

2. Then look for “Search Code” and click one time on the Search Code button.

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3. This is the first screen of the “Search Program”

Now you can search by Component Code(enter “2”) or by Component name(enter

“1”).
Follow for that the instructions on the screen.

3.3.2 Searching from the PC – program

Searching for the code for the arm cylinder packing on a hydraulic excavator.
1. Open the search program as above described.
2. Enter number “2”.
3. Now you find “H” as 1st digit for hydraulic cylinder.
4. Click on “H”. You find “1” as the 2nd digit.
5. Click on “Space” and then you will see the table of the PHENOMEN CODE.

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4. Substitution of old Service Bulletins

After revision of an old Service Bulletin it gets a new number with an index
(1st revision).
Below the headline we will make a note which old Service Bulletin has been
substituted.

Appendix

Illustrated Index (Component code)

Major Code List
Phenomen Code List

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Major Code List

0 Related Parts to Engine
00 Machine
01 Engine Related-Parts
03 Cooling System
04 Fuel Tank & Piping System
08 Electric Drive System

1 Torque Converter (T/C), Transmission (T/M), Transfer

10 Main Clutch Group
12 Damper Universal Joint System
13 Torque Connector
14 Direct Transmission
15 Torque-flow 6 Hydro-shift Transmission
16 Transfer
17 Hanger Bearing
18 Power Train Unit
19 Torque Splitter
1A Hydro-Mechanical Transmission (HMT)

2 Steering (S/T), Bevel Gear System, Final Drive (F/D), Swing Machinery
20 Drive Shaft
21 Bevel Gear System
22 Steering Clutch
23 Steering Brake
24 Hydro Static Steering
25 Swing Circle
26 Swing Machinery
27 Final Drive
2A Front Axle
2B Rear Axle
2C Brake
2D Front Wheel Brake
2E Rear Wheel Brake
2F Parking & Center Brake
2G Brake Oil Piping
2H Center Brake Group
2K Skid Loader Drive Group

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Major Code List

3 Undercarriage, Pump Drive Unit, Wheel
30 Track Frame Group
32 Track Shoe
38 Power Takeoff System
39 Pump Drive Unit
3A Wheel, Tire

4 Steering /S/T) Booster, Air System, Revolving Frame

40 Steering Booster
41 Skid-Steering
43 Power Train Control Linkage
44 Work Equipment Control
45 Air System
46 Revolving Frame, Counter Weight
47 Main Frame & Outrigger
48 Lubrication Piping
4A Steering System (Wheel-Type)

5 Guard, Cabin, Suspension System

50 Equalizer Bar System
54 Guard
55 Operator Cab & Ropes
57 Operator Seat
5A Suspension System

6 Hydraulic, Piping, Swivel Joint, Pilot Control System

60 Hydraulic Tank
62 Swivel Joint
63 Pilot Control System
6A Hydraulic Piping (1)
6B Hydraulic Piping (2)

7 Work Equipment
71 Work Equipment for Hydraulic Excavator
75 Blade & Bucket (Crawler)
76 Ripper
77 Work Equipment (Wheel Loader)
79 Dump Body

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Major Code List

7 Work Equipment
7B Scraper Work Equipment
7C Motor Grader Stabilizer Work Equipment
7D Vibration Roller Work Equipment
F Clamshell
7G Breaker
7H Winch
7J Work Equipment (Amphibious-Bull)
7K Crane
7L Work Equipment (Agriculture-Tractor)
7M Backhoe
7N Work Equipment Sprinkler Group
7Q Washing Machine Robot Group
7R Magnet Separator Group
7T Service Crane (Mining-Shovel)

8 Air Conditioner, Heater, Radio

82 Heater System
83 Cooler
85 Radio Control System
87 Air Conditioner
88 Grease Lubrication System
8D Automatic Centralized Lube System

9 Mark, Caution Plate, Tool

98 Name Plate, Tool, Accessory
99 Intermediate

A Engine
A0 Engine Assy.
A1 Engine Cylinder Head
A2 Engine Cylinder Block
A3 Engine Crankshaft
A4 Engine Cam Shaft
A5 Engine Oil Pump
A6 Water Pump Group
A7 Fuel Injector Pump
A8 PT Pump

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Major Code List

A Engine
A9 Turbocharger
AA Air Cleaner
AB Alternator
AJ Air Compressor Group

D Electric System, Sensor, Meter

D0 Electrical System
D1 Relay group
D2 Timer
D3 Diode Group
D4 Fuse & Breaker Group
D5 Wiring Harness Group
D6 Battery Group
D7 Electrical System Miscellaneous
DA Electronic Controller Group
DB Electronic Controller (2)
DD Switch Group
DE Electrical Swivel Joint
DF Electrical Lever & Dial
DG Temperature Sensor Group
DH Pressure Sensor Group
DJ Level Sensor Group
DK Angle Sensor Group
DL Rotation Speed Sensor Group
DM Regulator Group
DN Limit Switch Group
DP Monitor Panel Group
DS Meter & Gauge Group
DT Indicator Group
DU Lamp Group
DV Buzzer Group
DW Solenoid Valve Group
DX Solenoid Valve, Servo Group
DY Motor, Electric Direct Current
DZ Resistor

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Major Code List

G Engine Generator Set, Engine Compressor Set
G0 Engine Generator Group
GC Engine Compressor Group
GM Marine Engine

H Hydraulic Cylinder
H1 Hydraulic Cylinder

J Hydraulic Pump
J1 Hydraulic gear Pump

K Hydraulic Piston Pump

K1 Hydraulic Piston Pump

L Hydraulic Motor
L1 Swing Motor
L5 Travel Motor
L6 Hydro Static Steering Motor
L7 Hydro-Mechanical Transmission (HMT) Motor Group
L8 Work Equipment Hydraulic Motor
L9 Winch & other Hydraulic Motor
LA Cooling Fan Hydraulic Motor
LB Work Equipment Oil Cooling Fan Motor

M Hydro-Static Transmission (HST) Pump, Motor

M0 HST Unit
M1 HST Pump
M4 HST Motor
M.5 HST Brake Valve

P Hydraulic Control Valve

P0 Work Equipment Control Valve
P1 Boom Control Valve
P2 Arm Control Valve
P3 Bucket Control Valve
P4 Swing Control Valve
P5 Travel Control Valve

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Major Code List

P Hydraulic Control Valve
P7 Blade Control Valve
P8 Ripper Control Valve
P9 Bottom Dump Control Valve
PA Lift Arm Control Valve
PC Hoist Control Valve
PD Service Valve
PE Motor Scraper Control Valve
PF Motor Grader Control Valve
PJ Control and Filter Plate Group
PK Anti-Cavitation Valve
PX Attachment Valve Group

Q Pilot Pressure Control, Pilot Operation Control

Q1 Pilot Pressure Control Valve, Pilot Operation Control Valve system
Q2 Electric Pressure Control Valve
Q3 Multi-Pattern valve
Q5 Pilot Pressure Control Check Valve
Q6 Rotary Servo Valve
Q7 Shuttle Valve
Q8 Check Valve
Q9 Open center Load Sensing System (OLSS) Relief Valve
QA Electric Proportional Control (EPC) Valve Group
QD Block Assy.

R Steering valve, Flow Divider Valve

R1 Steering Clutch Valve
R2 Steering & Demand Valve
R3 Flow Divider Valve
R4 Electric Pilot Control Valve Group
RX Hydraulic Control Valve

Z Other
ZY Claim Objection Report
ZZ Others

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Phenomen Code List (Machine)

A Leak
AA Leak Oil
AB Oil-Up
AC Leak Fuel
AD Leak Grease
AE Leak Water
AF Leak Anti-Freeze
AG Leak Fluid
AH Leak Gas
AJ Leak Exhaust Gas
AK Excessive Blow-By Gas
AL Leak Air
AM Decreased Capacity
A1 Decrease

B Enter, Mix
BA Enter Oil
BB Mixed with Oil
BC Enter Fuel
BD Mixed with Fuel
BE Enter Water
BF Mixed with Water
BG Enter Anti-Freeze
BH Enter Rain Water
BJ Mixed with Air
BK Enter Dirt
BL Enter Dust
BM Enter Sand
BN Enter Foreign Material
BP Mixed with foreign Material
B1 Increase

C Worn
CA Worn
CB Worn Abnormally
CC Worn prematurely
CD Worn unevenly
CE Worn out

Code Table
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Phenomen Code List (Machine)

D Rust, Deterioration
DA Deterioration
DB Aging
DC Hardening
DD Corrosion
DE Initial Stage of Rust
DF Sluggish Movement of Rust
DG Rust in Red Color
DH Life Span
DJ Periodic

E Deform
EA Deformed
EB Distorted
EC Bent
ED Twisted
EE Boved
EF Elongated
EG Misaligned
EH Crushed
EJ Uneven

F Damage
FA Damaged
FB Dented
FC Scored
FD Flaked
FE Split
FF Broken
FG Internal Breakage
FH Metal Powder found
FJ Chipped
FK Metal Particles found
FL Cut
FM Fractured
FN Broken in Hole
FP Melted

Code Table
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Phenomen Code List (Machine)

F Damage
FQ Burned out
FR Seized
FS Sticking
FT Punctured

G Abnormal Noise / Vibration

GA Abnormal Noise
GB Vibration
GC Play
GD Excessive Noise
GE Excessive Play, Gap
GF Shaking (Excessive Play)
GG Excessive Undesired Sound
GH Noisy
GJ Excessive Vibration
GK Radial Run-out
GL Face Run-out
GM Hunting

H Crack
HA Cracked
HB Weld Portion Cracked
HC Base Metal Cracked
HD Chaped

K Electric Failure
KA Wire-Harness Cut
KB Wiring Harness Cut
KC Defective Light
KD Bulb Broken
KE Insufficient charge
KF No Charge
KG Over Charge
KH Discharge
KJ Lack of Capacity
K1 Keeps Sounding
K2 Does Not Sound

Code Table
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Phenomen Code List (Machine)

M Defective Function
MA Malfunction
MB Deterioration
MC Actuation Defective
MD Sliding Defective
ME Impossible to Release
MF Impossible to Operate
MG Abnormal Operating Force
MH Heavy
MJ Light
MK Hard
ML Stiff
MM Dors Not Extract
MN Does Not Insert
MP Come Out
MQ Falling Off
MR Disconnected
MS Loosen
MT Does Not Tighten
MU Distortion
MU Interference
MW Slips
MX Not returning properly
MY Returns
MZ Does Not return
M1 Catching
M2 Foreign material Bitten

N Operating Failure
NA Does Not Start
NB Does Not Travel
NC Does Not Rotate
ND Does Not Turn
NE Impossible to Switch
NF Bad Exhaust Smoke Color
NG Poor Performance
NH Interlock Malfunction
NJ Malfunction in Up/Down

Code Table
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Phenomen Code List (Machine)

N Operating Failure
NK Does Not Go Up
NL Does Not Come Down
NM Slow
NN Excessive Hydraulic Drift
NP Can Not Lift
NQ Lack of Power
NR Abnormal Generation of Heat
NS Overheating
NT Heat Up
NU Hot
NV Does Not Become Warm
NW Does Not Become Cold
NX Clogged
NY Lack of Grease

P Defective Adjustment
PA Improper Contact
PB Improper Adjustment
PC Improper Clearance
PD Excessive Clearance
PE Poor maintenance
PF Poor Painting
PG Defective Welding
PH Defective Installation
PJ Wrong Part’s Installed
PK Mis-wiring
PL Porus (Casting Defect)
PM Machining defective
PN Mis-assembly of Parts
PP Omitted Parts
PQ Shortage
PR Foreign Material Found

Z Others
ZA Defect
ZB Excessive Dirt
ZC Failure
Z9 Others

Code Table
KM-Bagger Allgem