Komatsu PC2000-11R Hydraulic Excavator Shop Manual SEN06823-01 – PDF DOWNLOAD

Komatsu PC2000-11R Hydraulic Excavator Shop Manual SEN06823-01 – PDF DOWNLOAD

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Komatsu PC2000-11R Hydraulic Excavator Shop Manual SEN06823-01 – PDF DOWNLOAD

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Komatsu PC2000-11R Hydraulic Excavator Shop Manual SEN06823-01 – PDF DOWNLOAD

SERIAL NUMBERS 30019 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• 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.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu PC2000-11R Hydraulic Excavator Shop Manual SEN06823-01 – PDF DOWNLOAD

COVER………………………………………………………………………………………………………………………………….. 1
00 INDEX AND FOREWORD…………………………………………………………………………………………………………………… 3
INDEX……………………………………………………………………………………………………………………………… 4
ABBREVIATION LIST…………………………………………………………………………………………………………………… 23
FOREWORD, SAFETY, BASIC INFORMATION…………………………………………………………………………………………………… 29
HOW TO READ THE SHOP MANUAL………………………………………………………………………………………………………. 29
SAFETY NOTICE FOR OPERATION………………………………………………………………………………………………………. 31
PRECAUTIONS TO PREVENT FIRE………………………………………………………………………………………………………. 39
ACTIONS IF FIRE OCCURS…………………………………………………………………………………………………………… 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS……………………………………………………………………………………….. 42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT……………………………………………………………………………………….. 43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS……………………………………………………………………………… 46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT………………………………………………………………………………………. 52
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT……………………………………………………………………………………… 54
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT……………………………………………………………………………………. 55
PRACTICAL USE OF KOMTRAX…………………………………………………………………………………………………………. 56
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER………………………………………………………………………………………. 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER……………………………………………………………… 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER……………………………………………………………… 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER……………………………………………………………… 59
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…………………………………………………………………………… 61
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR……………………………………………………………………………. 65
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…………………………………………………………………….. 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…………………………………………………………………… 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…………………………………………………………………… 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE………………………………………………………………. 71
DISCONNECT AND CONNECT MOLEX CONNECTOR…………………………………………………………………………………………….. 72
HOW TO READ ELECTRICAL WIRE CODE………………………………………………………………………………………………….. 73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD………………………………………………………………………………………. 77
STANDARD TIGHTENING TORQUE TABLE………………………………………………………………………………………………….. 80
CONVERSION TABLE………………………………………………………………………………………………………………… 87
01 SPECIFICATIONS………………………………………………………………………………………………………………………. 93
CONTENTS…………………………………………………………………………………………………………………………… 94
SPECIFICATIONS……………………………………………………………………………………………………………………… 95
SPECIFICATION DRAWING……………………………………………………………………………………………………………. 95
SPECIFICATION DRAWING: PC2000-11R……………………………………………………………………………………………… 95
WORKING RANGE DRAWINGS…………………………………………………………………………………………………………… 97
WORKING RANGE DRAWINGS: PC2000-11R…………………………………………………………………………………………….. 97
SPECIFICATIONS………………………………………………………………………………………………………………….. 98
SPECIFICATIONS: PC2000-11R……………………………………………………………………………………………………. 98
WEIGHT TABLE……………………………………………………………………………………………………………………. 102
WEIGHT TABLE: PC2000-11R……………………………………………………………………………………………………… 102
FUEL, COOLANT, LUBRICANT…………………………………………………………………………………………………………. 105
USE FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE………………………………………………………………………. 105
10 STRUCTURE AND FUNCTION……………………………………………………………………………………………………………….. 109
CONTENTS…………………………………………………………………………………………………………………………… 110
BOOT-UP SYSTEM……………………………………………………………………………………………………………………… 114
LAYOUT DRAWING OF BOOT-UP SYSTEM………………………………………………………………………………………………….. 114
SYSTEM OPERATING LAMP SYSTEM……………………………………………………………………………………………………… 115
SYSTEM OPERATING LAMP SYSTEM DIAGRAM…………………………………………………………………………………………… 115
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM……………………………………………………………………………………….. 115
BATTERY ISOLATOR………………………………………………………………………………………………………………… 117
LAYOUT DRAWING OF BATTERY ISOLATOR…………………………………………………………………………………………….. 117
FUNCTION OF BATTERY ISOLATOR………………………………………………………………………………………………….. 117
FUNCTION OF STARTING MOTOR ISOLATOR SWITCH……………………………………………………………………………………… 118
ENGINE SYSTEM………………………………………………………………………………………………………………………. 119
LAYOUT DRAWING OF ENGINE SYSTEM…………………………………………………………………………………………………… 119
ENGINE CONTROL SYSTEM……………………………………………………………………………………………………………. 121
SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM………………………………………………………………………………………… 121
OPERATION OF ENGINE CONTROL SYSTEM…………………………………………………………………………………………….. 122
AUTO-DECELERATION SYSTEM…………………………………………………………………………………………………………. 123
AUTO-DECELERATION SYSTEM DIAGRAM………………………………………………………………………………………………. 123
FUNCTION OF AUTO-DECELERATION SYSTEM…………………………………………………………………………………………… 124
OPERATION OF AUTO-DECELERATION SYSTEM………………………………………………………………………………………….. 124
AUTOMATIC LOW IDLE SYSTEM………………………………………………………………………………………………………… 125
AUTOMATIC LOW IDLE SYSTEM DIAGRAM……………………………………………………………………………………………… 125
FUNCTION OF AUTOMATIC LOW IDLE SYSTEM………………………………………………………………………………………….. 125
OPERATION OF AUTOMATIC LOW IDLE SYSTEM…………………………………………………………………………………………. 126
ENGINE AUTOMATIC WARM-UP SYSTEM…………………………………………………………………………………………………… 127
SYSTEM DIAGRAM OF ENGINE AUTOMATIC WARM-UP SYSTEM……………………………………………………………………………….. 127
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM…………………………………………………………………………………….. 127
OVERHEAT PREVENTION SYSTEM……………………………………………………………………………………………………….. 129
OVERHEAT PREVENTION SYSTEM DRAWING…………………………………………………………………………………………….. 129
FUNCTION OF OVERHEAT PREVENTION SYSTEM…………………………………………………………………………………………. 129
TURBOCHARGER PROTECTION SYSTEM……………………………………………………………………………………………………. 131
SYSTEM DIAGRAM OF TURBOCHARGER PROTECTION SYSTEM………………………………………………………………………………… 131
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM……………………………………………………………………………………… 131
COMPONENT PARTS OF ENGINE SYSTEM………………………………………………………………………………………………….. 133
PTO………………………………………………………………………………………………………………………… 133
COOLING SYSTEM……………………………………………………………………………………………………………………… 136
LAYOUT DRAWING OF COOLING SYSTEM………………………………………………………………………………………………….. 136
SPECIFICATIONS OF COOLING SYSTEM………………………………………………………………………………………………. 137
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN………………………………………………………………………………………….. 138
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN……………………………………………………………………………….. 138
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN……………………………………………………………………………. 139
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN………………………………………………………………………………………. 140
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN……………………………………………………………………………. 140
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN………………………………………………………………………… 140
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN……………………………………………………………………………………….. 141
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN…………………………………………………………………………….. 141
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN…………………………………………………………………………. 141
COMPONENT PARTS OF COOLING SYSTEM…………………………………………………………………………………………………. 142
COOLING FAN PUMP…………………………………………………………………………………………………………….. 142
COOLING FAN MOTOR……………………………………………………………………………………………………………. 156
CONTROL SYSTEM……………………………………………………………………………………………………………………… 163
LAYOUT DRAWING OF CONTROL SYSTEM………………………………………………………………………………………………….. 163
MACHINE MONITOR SYSTEM…………………………………………………………………………………………………………… 165
MACHINE MONITOR SYSTEM DIAGRAM………………………………………………………………………………………………… 165
KOMTRAX Plus SYSTEM……………………………………………………………………………………………………………… 167
KOMTRAX Plus SYSTEM DIAGRAM…………………………………………………………………………………………………… 167
FUNCTION OF KOMTRAX Plus SYSTEM……………………………………………………………………………………………….. 167
COMPONENT PARTS OF CONTROL SYSTEM…………………………………………………………………………………………………. 172
MACHINE MONITOR……………………………………………………………………………………………………………… 172
KOMTRAX TERMINAL…………………………………………………………………………………………………………….. 185
KOMTRAX Plus CONTROLLER………………………………………………………………………………………………………. 187
WIRELESS LAN UNIT……………………………………………………………………………………………………………. 191
PUMP CONTROLLER……………………………………………………………………………………………………………… 193
VALVE CONTROLLER 1…………………………………………………………………………………………………………… 197
VALVE CONTROLLER 2…………………………………………………………………………………………………………… 201
RESISTOR FOR PUMP SECONDARY DRIVE……………………………………………………………………………………………… 205
CAN TERMINATING RESISTOR……………………………………………………………………………………………………… 205
ENGINE CONTROLLER……………………………………………………………………………………………………………. 206
FUEL CONTROL DIAL……………………………………………………………………………………………………………. 218
FUEL FEED PUMP………………………………………………………………………………………………………………. 219
FUEL FEED PUMP SWITCH………………………………………………………………………………………………………… 220
HYDRAULIC SYSTEM……………………………………………………………………………………………………………………. 221
LAYOUT DRAWING OF HYDRAULIC SYSTEM………………………………………………………………………………………………… 221
ELECTRONIC OLSS…………………………………………………………………………………………………………………. 224
STRUCTURE OF ELECTRONIC OLSS………………………………………………………………………………………………….. 224
FUNCTION OF ELECTRONIC OLSS…………………………………………………………………………………………………… 225
ENGINE AND PUMP COMBINED CONTROL SYSTEM……………………………………………………………………………………………. 227
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM…………………………………………………………………………………. 227
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM……………………………………………………………………………… 228
COMPONENT PARTS OF HYDRAULIC SYSTEM……………………………………………………………………………………………….. 231
HYDRAULIC TANK………………………………………………………………………………………………………………. 231
MAIN PUMP…………………………………………………………………………………………………………………… 233
CONTROL VALVE……………………………………………………………………………………………………………….. 252
VARIABLE BACK PRESSURE VALVE………………………………………………………………………………………………….. 284
WORK EQUIPMENT SYSTEM……………………………………………………………………………………………………………….. 287
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM……………………………………………………………………………………………. 287
WORK EQUIPMENT SYSTEM DIAGRAM…………………………………………………………………………………………………….. 293
MACHINE PUSH-UP SYSTEM…………………………………………………………………………………………………………… 294
MACHINE PUSH-UP SYSTEM DIAGRAM………………………………………………………………………………………………… 294
FUNCTION OF MACHINE PUSH-UP SYSTEM…………………………………………………………………………………………….. 294
HEAVY LIFT SYSTEM……………………………………………………………………………………………………………….. 296
HEAVY LIFT SYSTEM DIAGRAM…………………………………………………………………………………………………….. 296
FUNCTION OF HEAVY LIFT SYSTEM…………………………………………………………………………………………………. 296
OPERATION OF HEAVY LIFT SYSTEM………………………………………………………………………………………………… 297
BOOM SHOCKLESS CONTROL FUNCTION…………………………………………………………………………………………………… 298
BOOM SHOCKLESS CONTROL FUNCTION SYSTEM DIAGRAM………………………………………………………………………………….. 298
OPERATION OF BOOM SHOCKLESS CONTROL FUNCTION……………………………………………………………………………………. 298
PPC LOCK SYSTEM…………………………………………………………………………………………………………………. 299
PPC LOCK SYSTEM DIAGRAM………………………………………………………………………………………………………. 299
FUNCTION OF PPC LOCK SYSTEM…………………………………………………………………………………………………… 299
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM…………………………………………………………………………………….. 300
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM………………………………………………………………………….. 300
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM………………………………………………………………………. 300
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM……………………………………………………………………… 300
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…………………………………………………………………………………………… 302
WORK EQUIPMENT AND SWING PPC VALVE…………………………………………………………………………………………….. 302
SUCTION SELECTOR VALVE……………………………………………………………………………………………………….. 308
PPC CUT-OFF VALVE……………………………………………………………………………………………………………. 310
SOLENOID VALVE………………………………………………………………………………………………………………. 315
PILOT CIRCUIT ACCUMULATOR…………………………………………………………………………………………………….. 318
SWING SYSTEM……………………………………………………………………………………………………………………….. 319
LAYOUT DRAWING OF SWING SYSTEM……………………………………………………………………………………………………. 319
SWING CONTROL SYSTEM DIAGRAM……………………………………………………………………………………………………… 322
FUNCTION OF SWING CONTROL SYSTEM………………………………………………………………………………………………. 322
SWING PRIORITY SYSTEM DIAGRAM…………………………………………………………………………………………………….. 325
OPERATION OF SWING PRIORITY SYSTEM…………………………………………………………………………………………….. 326
COMPONENT PARTS OF SWING SYSTEM…………………………………………………………………………………………………… 327
SWING MOTOR…………………………………………………………………………………………………………………. 327
SWING MACHINERY……………………………………………………………………………………………………………… 336
SWING CIRCLE………………………………………………………………………………………………………………… 337
TRAVEL SYSTEM………………………………………………………………………………………………………………………. 339
LAYOUT DRAWING OF TRAVEL SYSTEM…………………………………………………………………………………………………… 339
TRAVEL CONTROL SYSTEM DIAGRAM…………………………………………………………………………………………………….. 343
TRAVEL STRAIGHT SYSTEM DIAGRAM……………………………………………………………………………………………………. 344
OPERATION OF TRAVEL STRAIGHT SYSTEM……………………………………………………………………………………………. 345
HIC SYSTEM……………………………………………………………………………………………………………………… 347
LAYOUT DRAWING OF HIC SYSTEM………………………………………………………………………………………………….. 347
HIC SYSTEM DIAGRAM…………………………………………………………………………………………………………… 348
OPERATION OF HIC SYSTEM………………………………………………………………………………………………………. 348
COMPONENT PARTS OF TRAVEL SYSTEM………………………………………………………………………………………………….. 351
TRAVEL MOTOR………………………………………………………………………………………………………………… 351
FINAL DRIVE…………………………………………………………………………………………………………………. 364
TRAVEL PPC VALVE…………………………………………………………………………………………………………….. 365
CENTER SWIVEL JOINT………………………………………………………………………………………………………….. 369
ACCUMULATOR FOR HIC SYSTEM……………………………………………………………………………………………………….. 370
STRUCTURE OF ACCUMULATOR FOR HIC SYSTEM………………………………………………………………………………………… 370
SPECIFICATIONS OF ACCUMULATOR FOR HIC SYSTEM……………………………………………………………………………………. 370
LIFTING SYSTEM……………………………………………………………………………………………………………………… 371
HYDRAULICALLY OPERATED STAIRWAY SYSTEM…………………………………………………………………………………………….. 371
LAYOUT DRAWING OF HYDRAULICALLY OPERATED STAIRWAY SYSTEM…………………………………………………………………………. 371
HYDRAULICALLY OPERATED STAIRWAY SYSTEM DIAGRAM………………………………………………………………………………….. 372
FUNCTION OF HYDRAULICALLY OPERATED STAIRWAY SYSTEM………………………………………………………………………………. 372
COMPONENT PARTS OF LIFTING SYSTEM…………………………………………………………………………………………………. 373
SWITCH BOX………………………………………………………………………………………………………………….. 373
PROXIMITY SWITCH PART………………………………………………………………………………………………………… 373
CONTROL VALVE ASSEMBLY……………………………………………………………………………………………………….. 374
SERVICE CENTER SYSTEM……………………………………………………………………………………………………………….. 375
LAYOUT DRAWING OF SERVICE CENTER SYSTEM……………………………………………………………………………………………. 375
SERVICE CENTER SYSTEM DIAGRAM…………………………………………………………………………………………………….. 377
FUNCTION OF SERVICE CENTER SYSTEM……………………………………………………………………………………………… 377
COMPONENT PARTS OF SERVICE CENTER SYSTEM…………………………………………………………………………………………… 379
RAISE/LOWER SWITCH…………………………………………………………………………………………………………… 379
PROXIMITY SWITCH PART………………………………………………………………………………………………………… 379
CONTROL VALVE ASSEMBLY……………………………………………………………………………………………………….. 380
LEFT CONSOLE BOX SECTION IN CAB……………………………………………………………………………………………….. 381
SERVICE PANEL PART…………………………………………………………………………………………………………… 381
GREASE LUBRICATION SYSTEM……………………………………………………………………………………………………………. 384
GREASE LUBRICATION SYSTEM DIAGRAM…………………………………………………………………………………………………. 384
FUNCTION OF GREASE LUBRICATION SYSTEM………………………………………………………………………………………….. 386
SPECIFICATIONS OF GREASE LUBRICATION SYSTEM…………………………………………………………………………………….. 387
COMPONENT PARTS OF GREASE LUBRICATION SYSTEM……………………………………………………………………………………….. 388
GREASE PUMP…………………………………………………………………………………………………………………. 388
GREASE GUN………………………………………………………………………………………………………………….. 390
HOSE REEL…………………………………………………………………………………………………………………… 390
INJECTOR DISTRIBUTION VALVE…………………………………………………………………………………………………… 391
UNDERCARRIAGE AND FRAME……………………………………………………………………………………………………………… 394
LAYOUT DRAWING OF UNDERCARRIAGE…………………………………………………………………………………………………… 394
SPECIFICATIONS OF UNDERCARRIAGE……………………………………………………………………………………………….. 394
WORK EQUIPMENT……………………………………………………………………………………………………………………… 395
STRUCTURE OF WORK EQUIPMENT………………………………………………………………………………………………………. 395
FUNCTION OF WORK EQUIPMENT……………………………………………………………………………………………………….. 396
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…………………………………………………………………………………………… 397
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…………………………………………………………………………….. 397
CAB AND ITS ATTACHMENTS……………………………………………………………………………………………………………… 398
CAB……………………………………………………………………………………………………………………………. 398
STRUCTURE OF CAB…………………………………………………………………………………………………………….. 398
WIPER SYSTEM……………………………………………………………………………………………………………………. 399
LAYOUT DRAWING OF WIPER SYSTEM………………………………………………………………………………………………… 399
WIPER SYSTEM DIAGRAM…………………………………………………………………………………………………………. 400
FUNCTION OF WIPER SYSTEM……………………………………………………………………………………………………… 400
CAB MOUNT………………………………………………………………………………………………………………………. 403
STRUCTURE OF CAB MOUNT……………………………………………………………………………………………………….. 403
FUNCTION OF CAB MOUNT………………………………………………………………………………………………………… 403
20 STANDARD VALUE TABLE…………………………………………………………………………………………………………………. 405
CONTENTS…………………………………………………………………………………………………………………………… 406
STANDARD VALUE TABLE FOR ENGINE………………………………………………………………………………………………………. 407
STANDARD VALUE TABLE FOR ENGINE: PC2000-11R………………………………………………………………………………………… 407
STANDARD VALUE TABLE FOR MACHINE……………………………………………………………………………………………………… 411
STANDARD VALUE TABLE FOR MACHINE: PC2000-11R……………………………………………………………………………………….. 411
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE……………………………………………………………………………… 428
30 TESTING AND ADJUSTING………………………………………………………………………………………………………………… 431
CONTENTS…………………………………………………………………………………………………………………………… 432
RELATED INFORMATION ON TESTING AND ADJUSTING…………………………………………………………………………………………… 436
TOOLS FOR TESTING AND ADJUSTING…………………………………………………………………………………………………… 436
ENGINE AND COOLING SYSTEM……………………………………………………………………………………………………………. 444
TEST ENGINE SPEED……………………………………………………………………………………………………………….. 444
TEST ENGINE SPEED……………………………………………………………………………………………………………. 444
TEST BOOST PRESSURE……………………………………………………………………………………………………………… 447
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR…………………………………………………………………………….. 447
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL……………………………………………………………………………….. 448
TEST EXHAUST GAS TEMPERATURE……………………………………………………………………………………………………… 451
TEST EXHAUST GAS TEMPERATURE………………………………………………………………………………………………….. 451
TEST EXHAUST GAS COLOR…………………………………………………………………………………………………………… 452
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER………………………………………………………………………. 452
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER……………………………………………………………………………… 455
TEST AND ADJUST VALVE CLEARANCE…………………………………………………………………………………………………… 458
METHOD FOR TESTING VALVE CLEARANCE…………………………………………………………………………………………….. 458
METHOD FOR ADJUSTING VALVE CLEARANCE…………………………………………………………………………………………… 459
TEST COMPRESSION PRESSURE………………………………………………………………………………………………………… 461
METHOD FOR TESTING COMPRESSION PRESSURE………………………………………………………………………………………… 461
TEST BLOWBY PRESSURE…………………………………………………………………………………………………………….. 465
METHOD FOR TESTING BLOWBY PRESSURE BY TESTING TOOL………………………………………………………………………………. 465
TEST ENGINE OIL PRESSURE…………………………………………………………………………………………………………. 470
TEST ENGINE OIL PRESSURE ON MACHINE MONITOR…………………………………………………………………………………….. 470
TEST ENGINE OIL PRESSURE BY TESTING TOOL……………………………………………………………………………………….. 470
TEST FUEL PRESSURE………………………………………………………………………………………………………………. 472
METHOD FOR TESTING FUEL PRESSURE………………………………………………………………………………………………. 472
TEST FUEL RETURN RATE AND LEAKAGE…………………………………………………………………………………………………. 474
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE…………………………………………………………………………………. 475
BLEED AIR FROM FUEL SYSTEM……………………………………………………………………………………………………….. 480
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM……………………………………………………………………………………….. 481
TEST FUEL CIRCUIT FOR LEAKAGE…………………………………………………………………………………………………….. 483
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…………………………………………………………………………………….. 483
TEST SUPPLY PUMP………………………………………………………………………………………………………………… 485
METHOD FOR TESTING SUPPLY PUMP………………………………………………………………………………………………… 485
HANDLE CYLINDER CUT-OUT MODE OPERATION…………………………………………………………………………………………….. 489
TEST ALTERNATOR…………………………………………………………………………………………………………………. 490
METHOD FOR TESTING ALTERNATOR…………………………………………………………………………………………………. 490
TEST AND ADJUST ALTERNATOR BELT TENSION……………………………………………………………………………………………. 491
METHOD FOR TESTING ALTERNATOR BELT TENSION……………………………………………………………………………………… 491
METHOD FOR ADJUSTING ALTERNATOR BELT TENSION……………………………………………………………………………………. 492
HANDLE NO-INJECTION CRANKING OPERATION…………………………………………………………………………………………….. 493
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION……………………………………………………………………………… 494
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION……………………………………………………………………….. 494
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION……………………………………………………………………… 495
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER………………………………………………………………………………. 496
METHOD FOR WRITING INJECTOR COMPENSATION VALUE………………………………………………………………………………….. 496
POWER TRAIN………………………………………………………………………………………………………………………… 502
TEST SWING CIRCLE BEARING CLEARANCE……………………………………………………………………………………………….. 502
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE……………………………………………………………………………….. 502
RELEASE REMAINING PRESSURE FROM HIC CIRCUIT………………………………………………………………………………………… 503
METHOD FOR RELEASING REMAINING PRESSURE FROM HIC CIRCUIT…………………………………………………………………………. 503
TEST AND CHARGE HIC CIRCUIT ACCUMULATOR NITROGEN GAS PRESSURE………………………………………………………………………… 504
METHOD FOR TESTING HIC CIRCUIT ACCUMULATOR NITROGEN GAS………………………………………………………………………….. 504
METHOD FOR CHARGING HIC CIRCUIT ACCUMULATOR NITROGEN GAS…………………………………………………………………………. 507
BLEED AIR FROM HIC CIRCUIT……………………………………………………………………………………………………….. 510
METHOD FOR BLEEDING AIR FROM HIC CIRCUIT……………………………………………………………………………………….. 510
UNDERCARRIAGE AND FRAME……………………………………………………………………………………………………………… 512
TEST SPROCKET WEAR………………………………………………………………………………………………………………. 512
METHOD FOR TESTING SPROCKET WEAR………………………………………………………………………………………………. 512
TEST AND ADJUST TRACK TENSION…………………………………………………………………………………………………….. 513
METHOD FOR TESTING TRACK TENSION………………………………………………………………………………………………. 513
METHOD FOR ADJUSTING TRACK TENSION…………………………………………………………………………………………….. 513
HYDRAULIC SYSTEM……………………………………………………………………………………………………………………. 516
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM……………………………………………………………………………………. 516
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT……………………………………………………………………. 516
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK………………………………………………………………………. 516
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT……………………………………………………………… 516
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT………………………………………………………………….. 516
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT…………………………………………………………………. 517
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…………………………………………………………….. 518
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS………………………………………………………. 521
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…………………………………………………….. 528
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT…………………………………………………………………………………….. 533
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT………………………………………………………………………………. 533
METHOD FOR ADJUSTING OIL PRESSURE OF CONTROL CIRCUIT…………………………………………………………………………….. 534
TEST PUMP EPC SOLENOID VALVE OUTLET PRESSURE……………………………………………………………………………………….. 535
METHOD FOR TESTING OF PUMP EPC SOLENOID VALVE OUTLET PRESSURE…………………………………………………………………….. 535
METHOD FOR TESTING OF PUMP EPC SOLENOID VALVE ELECTRIC CURRENT……………………………………………………………………. 536
TEST AND ADJUST JET SENSOR DIFFERENTIAL PRESSURE……………………………………………………………………………………. 537
METHOD FOR TESTING JET SENSOR DIFFERENTIAL PRESSURE WITH MACHINE MONITOR…………………………………………………………… 537
METHOD FOR TESTING JET SENSOR DIFFERENTIAL PRESSURE BY TESTING TOOL……………………………………………………………….. 538
METHOD FOR TESTING JET SENSOR DIFFERENTIAL PRESSURE……………………………………………………………………………… 539
METHOD FOR ADJUSTING JET SENSOR DIFFERENTIAL PRESSURE……………………………………………………………………………. 540
TEST OUTLET PRESSURE OF SOLENOID VALVE…………………………………………………………………………………………….. 542
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE…………………………………………………………………………….. 542
OPERATING CONDITION OF SOLENOID VALVE………………………………………………………………………………………….. 544
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE…………………………………………………………………………….. 546
METHOD FOR TESTING OF EPC SOLENOID VALVE OUTLET PRESSURE…………………………………………………………………………. 546
TEST PPC VALVE OUTLET PRESSURE……………………………………………………………………………………………………. 548
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE……………………………………………………………………………………. 549
ADJUST WORK EQUIPMENT AND SWING PPC VALVES…………………………………………………………………………………………. 551
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES………………………………………………………………….. 551
TEST TRAVEL DEVIATION……………………………………………………………………………………………………………. 552
METHOD FOR TESTING TRAVEL DEVIATION……………………………………………………………………………………………. 552
METHOD FOR ADJUSTING TRAVEL DEVIATION………………………………………………………………………………………….. 552
TEST FAN SPEED………………………………………………………………………………………………………………….. 553
METHOD FOR CHECKING OF RADIATOR FAN SPEED………………………………………………………………………………………. 553
METHOD FOR TESTING OF OIL COOLER FAN SPEED……………………………………………………………………………………… 553
TEST OIL PRESSURE IN FAN PUMP CIRCUIT……………………………………………………………………………………………… 554
METHOD OF TESTING RADIATOR FAN PUMP CIRCUIT OIL PRESSURE BY MACHINE MONITOR………………………………………………………… 554
METHOD OF TESTING RADIATOR FAN PUMP CIRCUIT OIL PRESSURE BY TESTING TOOL…………………………………………………………… 554
METHOD OF TESTING OIL COOLER FAN PUMP CIRCUIT OIL PRESSURE BY MACHINE MONITOR………………………………………………………. 555
METHOD OF TESTING OIL COOLER FAN PUMP CIRCUIT OIL PRESSURE BY TESTING TOOL…………………………………………………………. 555
TEST FAN PUMP EPC ELECTRIC CURRENT………………………………………………………………………………………………… 557
METHOD FOR TESTING OF RADIATOR FAN PUMP EPC ELECTRIC CURRENT……………………………………………………………………… 557
METHOD FOR TESTING OF OIL COOLER FAN PUMP EPC ELECTRIC CURRENT……………………………………………………………………. 557
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE……………………………………………………………………………………. 558
METHOD FOR TESTING OF RADIATOR FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE…………………………………………………………. 558
METHOD FOR TESTING OUTLET PRESSURE OF EPC SOLENOID VALVE OF OIL COOLER FAN PUMP…………………………………………………….. 559
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…………………………………………………………………………….. 560
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER……………………………………………. 560
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER………………………………………………………………. 560
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE…………………………………………………………………. 561
TEST OIL LEAKAGE………………………………………………………………………………………………………………… 562
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER……………………………………………………………………………….. 562
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER………………………………………………………………………………… 563
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER……………………………………………………………………………… 563
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR…………………………………………………………………………………. 564
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR………………………………………………………………………………… 564
METHOD FOR TESTING OIL LEAKAGE OF SWIVEL JOINT………………………………………………………………………………….. 565
BLEED AIR FROM HYDRAULIC CIRCUIT………………………………………………………………………………………………….. 567
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT………………………………………………………………………………….. 568
CAB AND ITS ATTACHMENTS……………………………………………………………………………………………………………… 575
METHOD FOR ADJUSTING MIRRORS……………………………………………………………………………………………………… 575
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)……………………………………………………………………………. 575
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)………………………………………………………….. 576
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (B)……………………………………………………………………………. 577
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (B)………………………………………………………….. 577
PROCEDURE FOR ADJUSTING MACHINE LEFT REAR MIRROR (C)…………………………………………………………………………….. 578
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT REAR MIRROR (C)…………………………………………………………… 579
PROCEDURE FOR ADJUSTING MACHINE RIGHT CENTER MIRROR (D)………………………………………………………………………….. 580
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT CENTER MIRROR (D)………………………………………………………… 581
AUTOMATIC LUBRICATION SYSTEM…………………………………………………………………………………………………………. 584
TESTING AND ADJUSTING AUTOMATIC LUBRICATION SYSTEM………………………………………………………………………………….. 584
METHOD FOR TESTING AUTOMATIC LUBRICATION SYSTEM…………………………………………………………………………………. 584
METHOD FOR ADJUSTING AUTOMATIC LUBRICATION SYSTEM……………………………………………………………………………….. 586
LIFTING SYSTEM……………………………………………………………………………………………………………………… 588
TEST AND ADJUST HYDRAULICALLY OPERATED STAIRWAY PROXIMITY SWITCH……………………………………………………………………… 588
METHOD FOR TESTING CLEARANCE OF HYDRAULICALLY OPERATED STAIRWAY PROXIMITY SWITCH……………………………………………………. 588
METHOD FOR ADJUSTING CLEARANCE OF HYDRAULICALLY OPERATED STAIRWAY PROXIMITY SWITCH………………………………………………….. 589
METHOD FOR TESTING POSITION OF HYDRAULICALLY OPERATED STAIRWAY POSITION DETECTING PLATE……………………………………………… 590
METHOD FOR ADJUSTING POSITION OF HYDRAULICALLY OPERATED STAIRWAY POSITION DETECTING PLATE……………………………………………. 590
SERVICE CENTER SYSTEM……………………………………………………………………………………………………………….. 592
TEST AND ADJUST SERVICE ARM PROXIMITY SWITCH……………………………………………………………………………………….. 592
METHOD FOR TESTING CLEARANCE OF SERVICE ARM PROXIMITY SWITCH……………………………………………………………………… 592
METHOD FOR ADJUSTING CLEARANCE OF SERVICE ARM PROXIMITY SWITCH……………………………………………………………………. 592
ELECTRICAL SYSTEM…………………………………………………………………………………………………………………… 593
SET AND OPERATE MACHINE MONITOR…………………………………………………………………………………………………… 593
OPERATOR MODE……………………………………………………………………………………………………………….. 597
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN………………………………………………………………………. 597
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN…………………………………………………………………………. 597
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)……………………………………………………………………………….. 598
CHECKING FUNCTION OF SERVICE METER…………………………………………………………………………………………….. 598
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD………………………………………………………………………… 598
SERVICE MODE………………………………………………………………………………………………………………… 601
METHOD FOR OPERATING SERVICE MODE……………………………………………………………………………………………… 601
CHECK PRE-DEFINED MONITORING INFORMATION……………………………………………………………………………………….. 604
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION…………………………………………………………………………… 613
ABNORMALITY RECORD MENU………………………………………………………………………………………………………. 628
CHECK MAINTENANCE RECORD……………………………………………………………………………………………………… 632
METHOD FOR OPERATING MAINTENANCE MODE SETTING…………………………………………………………………………………… 634
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING…………………………………………………………………………………. 637
DEFAULT MENU………………………………………………………………………………………………………………… 639
DIAGNOSTIC TESTS MENU………………………………………………………………………………………………………… 647
ADJUSTMENT MENU……………………………………………………………………………………………………………… 650
METHOD FOR PERFORMING NO-INJECTION CRANKING…………………………………………………………………………………….. 669
MACHINE CONFIGURATION MENU……………………………………………………………………………………………………. 671
KOMTRAX SETTINGS MENU………………………………………………………………………………………………………… 674
METHOD FOR DISPLAYING SERVICE MESSAGE………………………………………………………………………………………….. 676
METHOD FOR HANDLING SNAP SHOT…………………………………………………………………………………………………. 677
METHOD FOR STARTING UP KOMTRAX TERMINAL……………………………………………………………………………………………. 679
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER…………………………………………………………………………………………. 684
METHOD FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER………………………………………………………………… 684
SETTING DEFAULT OF WIRELESS LAN MODEM……………………………………………………………………………………………… 687
METHOD FOR SETTING DEFAULT OF WIRELESS LAN MODEM………………………………………………………………………………… 687
METHOD FOR CHECKING OF WIRELESS LAN MODEM COMMUNICATION………………………………………………………………………….. 688
DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA…………………………………………………………………………………………… 690
METHOD FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA……………………………………………………………………………… 690
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED…………………………………………………………………………………….. 693
METHOD FOR ADJUSTING WHEN KOMTRAX Plus CONTROLLER IS REPLACED…………………………………………………………………….. 693
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED…………………………………………………………………………………………. 696
METHOD FOR ADJUSTING WHEN WIRELESS LAN MODEM IS REPLACED…………………………………………………………………………. 696
ADJUST KomVision CAMERA ANGLE…………………………………………………………………………………………………….. 699
METHOD FOR ADJUSTING KomVision CAMERA ANGLE…………………………………………………………………………………….. 699
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER………………………………………………………………………………………… 702
HANDLE BATTERY ISOLATOR AND STARTING MOTOR ISOLATOR…………………………………………………………………………………. 703
TEST DIODES…………………………………………………………………………………………………………………….. 704
METHOD FOR TESTING DIODE USING DIGITAL TESTER…………………………………………………………………………………… 704
METHOD FOR TESTING DIODE USING ANALOG TESTER……………………………………………………………………………………. 704
Pm CLINIC………………………………………………………………………………………………………………………….. 705
Pm CLINIC SERVICE……………………………………………………………………………………………………………….. 705
Pm CLINIC CHECK SHEET: PC2000-11R……………………………………………………………………………………………… 710
PERFORMING QUICK Pm……………………………………………………………………………………………………………… 724
METHOD FOR PERFORMING QUICK Pm………………………………………………………………………………………………… 724
40 TROUBLESHOOTING……………………………………………………………………………………………………………………… 729
CONTENTS…………………………………………………………………………………………………………………………… 730
RELATED INFORMATION ON TROUBLESHOOTING………………………………………………………………………………………………… 741
GENERAL TROUBLESHOOTING POINTS……………………………………………………………………………………………………. 741
SEQUENCE OF EVENTS IN TROUBLESHOOTING……………………………………………………………………………………………… 742
CHECKS BEFORE TROUBLESHOOTING…………………………………………………………………………………………………….. 744
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING………………………………………………………………………………………… 746
WALK-AROUND CHECK……………………………………………………………………………………………………………. 746
TESTING IN ACCORDANCE WITH TESTING PROCEDURE……………………………………………………………………………………….. 748
CHECK FUEL LEVEL AND TYPE…………………………………………………………………………………………………….. 748
CHECK IMPURE INGREDIENT IN FUEL……………………………………………………………………………………………….. 748
CHECK FUEL PREFILTER…………………………………………………………………………………………………………. 749
CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT…………………………………………………………………………………. 749
REPLACE FUEL PREFILTER CARTRIDGE………………………………………………………………………………………………. 750
CHECK FUEL MAIN FILTER……………………………………………………………………………………………………….. 752
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)………………………………………………………………………………….. 754
40 TROUBLESHOOTING…………………………………………………………………………………………………………… 756
CHECK COOLANT LEVEL (RESERVOIR TANK)…………………………………………………………………………………………… 756
CHECK CLOGGING OF AIR CLEANER…………………………………………………………………………………………………. 756
CLEAN OUTER ELEMENT………………………………………………………………………………………………………….. 757
ELEMENTS – REPLACE…………………………………………………………………………………………………………… 759
CHECK HYDRAULIC OIL LEVEL…………………………………………………………………………………………………….. 759
CHECK HYDRAULIC OIL STRAINER………………………………………………………………………………………………….. 761
CHECK HYDRAULIC FILTER……………………………………………………………………………………………………….. 762
CHECK OIL LEVEL IN SWING MACHINERY CASE………………………………………………………………………………………… 763
CHECK OIL LEVEL IN PTO CASE…………………………………………………………………………………………………… 764
CHECK PTO LUBRICATION FILTER STRAINER………………………………………………………………………………………….. 765
CHECK OIL LEVEL IN FINAL DRIVE CASE……………………………………………………………………………………………. 765
BLEED AIR FROM FUEL SYSTEM……………………………………………………………………………………………………. 766
BLEED AIR FROM HYDRAULIC SYSTEM……………………………………………………………………………………………….. 766
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod……………………………………………………………………………………. 766
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM………………………………………………………………………………… 771
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR………………………………………………………………………………. 771
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER…………………………………………………………………………….. 771
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER………………………………………………………………………………. 771
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX Plus CONTROLLER……………………………………………………………………….. 772
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER………………………………………………………………………….. 772
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK……………………………………………………………….. 772
PROCEDURE FOR TESTING AND TROUBLESHOOTING………………………………………………………………………………………….. 777
SYMPTOM AND TROUBLESHOOTING NUMBERS……………………………………………………………………………………………….. 780
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE……………………………………………………………………………………… 785
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM…………………………………………………….. 787
CONNECTOR LIST AND LAYOUT………………………………………………………………………………………………………… 790
CONNECTOR CONTACT IDENTIFICATION………………………………………………………………………………………………….. 815
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE……………………………………………………………………………………………. 857
FUSE LOCATION TABLE……………………………………………………………………………………………………………… 863
FAILURE CODE TABLE………………………………………………………………………………………………………………. 870
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)………………………………………………………………………………………. 888
FAILURE CODE [7@HAZL]……………………………………………………………………………………………………………. 888
FAILURE CODE [7@HBZL]……………………………………………………………………………………………………………. 890
FAILURE CODE [7@HCZL]……………………………………………………………………………………………………………. 891
FAILURE CODE [7@HDZL]……………………………………………………………………………………………………………. 892
FAILURE CODE [8800ZG]……………………………………………………………………………………………………………. 893
FAILURE CODE [989L00]……………………………………………………………………………………………………………. 894
FAILURE CODE [989M00]……………………………………………………………………………………………………………. 895
FAILURE CODE [989N00]……………………………………………………………………………………………………………. 896
FAILURE CODE [A900FR]……………………………………………………………………………………………………………. 897
FAILURE CODE [A900N6]……………………………………………………………………………………………………………. 898
FAILURE CODE [A900NY]……………………………………………………………………………………………………………. 899
FAILURE CODE [AA10NX]……………………………………………………………………………………………………………. 900
FAILURE CODE [AA1FNX]……………………………………………………………………………………………………………. 901
FAILURE CODE [AB00KE]……………………………………………………………………………………………………………. 902
FAILURE CODE [B@BAZG]……………………………………………………………………………………………………………. 904
FAILURE CODE [B@BAZK]……………………………………………………………………………………………………………. 905
FAILURE CODE [B@BCNS]……………………………………………………………………………………………………………. 906
FAILURE CODE [B@BCQA]……………………………………………………………………………………………………………. 907
FAILURE CODE [B@BCZK]……………………………………………………………………………………………………………. 909
FAILURE CODE [B@CBNS]……………………………………………………………………………………………………………. 911
FAILURE CODE [B@HAMB]……………………………………………………………………………………………………………. 913
FAILURE CODE [B@HANS]……………………………………………………………………………………………………………. 914
FAILURE CODE [B@HAZK]……………………………………………………………………………………………………………. 915
FAILURE CODE [CA115]…………………………………………………………………………………………………………….. 916
FAILURE CODE [CA122]…………………………………………………………………………………………………………….. 920
FAILURE CODE [CA123]…………………………………………………………………………………………………………….. 922
FAILURE CODE [CA131]…………………………………………………………………………………………………………….. 924
FAILURE CODE [CA132]…………………………………………………………………………………………………………….. 926
FAILURE CODE [CA135]…………………………………………………………………………………………………………….. 928
FAILURE CODE [CA141]…………………………………………………………………………………………………………….. 930
FAILURE CODE [CA144]…………………………………………………………………………………………………………….. 932
FAILURE CODE [CA145]…………………………………………………………………………………………………………….. 934
FAILURE CODE [CA153]…………………………………………………………………………………………………………….. 936
FAILURE CODE [CA154]…………………………………………………………………………………………………………….. 939
FAILURE CODE [CA212]…………………………………………………………………………………………………………….. 941
FAILURE CODE [CA213]…………………………………………………………………………………………………………….. 943
FAILURE CODE [CA221]…………………………………………………………………………………………………………….. 945
FAILURE CODE [CA222]…………………………………………………………………………………………………………….. 947
FAILURE CODE [CA234]…………………………………………………………………………………………………………….. 949
FAILURE CODE [CA238]…………………………………………………………………………………………………………….. 950
FAILURE CODE [CA239]…………………………………………………………………………………………………………….. 952
FAILURE CODE [CA271]…………………………………………………………………………………………………………….. 954
FAILURE CODE [CA272]…………………………………………………………………………………………………………….. 956
FAILURE CODE [CA273]…………………………………………………………………………………………………………….. 957
FAILURE CODE [CA274]…………………………………………………………………………………………………………….. 959
FAILURE CODE [CA322]…………………………………………………………………………………………………………….. 960
FAILURE CODE [CA323]…………………………………………………………………………………………………………….. 962
FAILURE CODE [CA324]…………………………………………………………………………………………………………….. 964
FAILURE CODE [CA325]…………………………………………………………………………………………………………….. 966
FAILURE CODE [CA331]…………………………………………………………………………………………………………….. 968
FAILURE CODE [CA332]…………………………………………………………………………………………………………….. 970
FAILURE CODE [CA343]…………………………………………………………………………………………………………….. 972
FAILURE CODE [CA351]…………………………………………………………………………………………………………….. 976
FAILURE CODE [CA352]…………………………………………………………………………………………………………….. 979
FAILURE CODE [CA386]…………………………………………………………………………………………………………….. 981
FAILURE CODE [CA441]…………………………………………………………………………………………………………….. 983
FAILURE CODE [CA442]…………………………………………………………………………………………………………….. 986
FAILURE CODE [CA449]…………………………………………………………………………………………………………….. 989
FAILURE CODE [CA451]…………………………………………………………………………………………………………….. 990
FAILURE CODE [CA452]…………………………………………………………………………………………………………….. 992
FAILURE CODE [CA515]…………………………………………………………………………………………………………….. 994
FAILURE CODE [CA516]…………………………………………………………………………………………………………….. 995
FAILURE CODE [CA553]…………………………………………………………………………………………………………….. 996
FAILURE CODE [CA559]…………………………………………………………………………………………………………….. 997
FAILURE CODE [CA689]……………………………………………………………………………………………………………..1003
FAILURE CODE [CA691]……………………………………………………………………………………………………………..1005
FAILURE CODE [CA692]……………………………………………………………………………………………………………..1007
FAILURE CODE [CA697]……………………………………………………………………………………………………………..1009
FAILURE CODE [CA698]……………………………………………………………………………………………………………..1010
FAILURE CODE [CA731]……………………………………………………………………………………………………………..1011
FAILURE CODE [CA778]……………………………………………………………………………………………………………..1015
FAILURE CODE [CA1117]…………………………………………………………………………………………………………….1018
FAILURE CODE [CA1135]…………………………………………………………………………………………………………….1021
FAILURE CODE [CA1257]…………………………………………………………………………………………………………….1024
FAILURE CODE [CA1843]…………………………………………………………………………………………………………….1025
FAILURE CODE [CA1844]…………………………………………………………………………………………………………….1027
FAILURE CODE [CA1942]…………………………………………………………………………………………………………….1029
FAILURE CODE [CA2185]…………………………………………………………………………………………………………….1031
FAILURE CODE [CA2186]…………………………………………………………………………………………………………….1033
FAILURE CODE [CA2249]…………………………………………………………………………………………………………….1035
FAILURE CODE [CA2555]…………………………………………………………………………………………………………….1040
FAILURE CODE [CA2556]…………………………………………………………………………………………………………….1042
FAILURE CODE [CA2765]…………………………………………………………………………………………………………….1044
FAILURE CODE [CA4952]…………………………………………………………………………………………………………….1045
FAILURE CODE [CB115]……………………………………………………………………………………………………………..1047
FAILURE CODE [CB122]……………………………………………………………………………………………………………..1051
FAILURE CODE [CB123]……………………………………………………………………………………………………………..1053
FAILURE CODE [CB153]……………………………………………………………………………………………………………..1055
FAILURE CODE [CB154]……………………………………………………………………………………………………………..1058
FAILURE CODE [CB238]……………………………………………………………………………………………………………..1061
FAILURE CODE [CB239]……………………………………………………………………………………………………………..1063
FAILURE CODE [CB271]……………………………………………………………………………………………………………..1065
FAILURE CODE [CB272]……………………………………………………………………………………………………………..1067
FAILURE CODE [CB273]……………………………………………………………………………………………………………..1068
FAILURE CODE [CB274]……………………………………………………………………………………………………………..1070
FAILURE CODE [CB343]……………………………………………………………………………………………………………..1071
FAILURE CODE [CB351]……………………………………………………………………………………………………………..1074
FAILURE CODE [CB352]……………………………………………………………………………………………………………..1077
FAILURE CODE [CB386]……………………………………………………………………………………………………………..1079
FAILURE CODE [CB441]……………………………………………………………………………………………………………..1081
FAILURE CODE [CB442]……………………………………………………………………………………………………………..1084
FAILURE CODE [CB449]……………………………………………………………………………………………………………..1087
FAILURE CODE [CB451]……………………………………………………………………………………………………………..1088
FAILURE CODE [CB452]……………………………………………………………………………………………………………..1090
FAILURE CODE [CB515]……………………………………………………………………………………………………………..1092
FAILURE CODE [CB516]……………………………………………………………………………………………………………..1093
FAILURE CODE [CB553]……………………………………………………………………………………………………………..1094
FAILURE CODE [CB559]……………………………………………………………………………………………………………..1095
FAILURE CODE [CB689]……………………………………………………………………………………………………………..1100
FAILURE CODE [CB691]……………………………………………………………………………………………………………..1102
FAILURE CODE [CB692]……………………………………………………………………………………………………………..1104
FAILURE CODE [CB697]……………………………………………………………………………………………………………..1106
FAILURE CODE [CB698]……………………………………………………………………………………………………………..1107
FAILURE CODE [CB731]……………………………………………………………………………………………………………..1108
FAILURE CODE [CB778]……………………………………………………………………………………………………………..1112
FAILURE CODE [CB1117]…………………………………………………………………………………………………………….1115
FAILURE CODE [CB1257]…………………………………………………………………………………………………………….1118
FAILURE CODE [CB1548]…………………………………………………………………………………………………………….1119
FAILURE CODE [CB1549]…………………………………………………………………………………………………………….1121
FAILURE CODE [CB1551]…………………………………………………………………………………………………………….1123
FAILURE CODE [CB1552]…………………………………………………………………………………………………………….1125
FAILURE CODE [CB1553]…………………………………………………………………………………………………………….1127
FAILURE CODE [CB1622]…………………………………………………………………………………………………………….1129
FAILURE CODE [CB2249]…………………………………………………………………………………………………………….1131
FAILURE CODE [CB2765]…………………………………………………………………………………………………………….1136
FAILURE CODE [CB4952]…………………………………………………………………………………………………………….1137
FAILURE CODE [D110KB]…………………………………………………………………………………………………………….1139
FAILURE CODE [D163KB]…………………………………………………………………………………………………………….1141
FAILURE CODE [D195KA]…………………………………………………………………………………………………………….1143
FAILURE CODE [D195KB]…………………………………………………………………………………………………………….1146
FAILURE CODE [D19JKZ]…………………………………………………………………………………………………………….1148
FAILURE CODE [D1E7KA]…………………………………………………………………………………………………………….1150
FAILURE CODE [D1E7KB]…………………………………………………………………………………………………………….1152
FAILURE CODE [D1E7KY]…………………………………………………………………………………………………………….1153
FAILURE CODE [D1E9KB]…………………………………………………………………………………………………………….1154
FAILURE CODE [D1EAKB]…………………………………………………………………………………………………………….1157
FAILURE CODE [D1EBKB]…………………………………………………………………………………………………………….1159
FAILURE CODE [D1ECKB]…………………………………………………………………………………………………………….1162
FAILURE CODE [D1F0KA]…………………………………………………………………………………………………………….1164
FAILURE CODE [D1F0KB]…………………………………………………………………………………………………………….1166
FAILURE CODE [D1F0KY]…………………………………………………………………………………………………………….1167
FAILURE CODE [D862KA]…………………………………………………………………………………………………………….1168
FAILURE CODE [D8AQKR]…………………………………………………………………………………………………………….1170
FAILURE CODE [DA20MC]…………………………………………………………………………………………………………….1175
FAILURE CODE [DA22KK]…………………………………………………………………………………………………………….1176
FAILURE CODE [DA25KP]…………………………………………………………………………………………………………….1179
FAILURE CODE [DA26KP]…………………………………………………………………………………………………………….1181
FAILURE CODE [DA29KQ]…………………………………………………………………………………………………………….1183
FAILURE CODE [DA2LKA]…………………………………………………………………………………………………………….1185
FAILURE CODE [DA2LKB]…………………………………………………………………………………………………………….1188
FAILURE CODE [DA2QKR]…………………………………………………………………………………………………………….1190
FAILURE CODE [DA2RKR]…………………………………………………………………………………………………………….1196
FAILURE CODE [DAF0KM]…………………………………………………………………………………………………………….1201
FAILURE CODE [DAF0MB]…………………………………………………………………………………………………………….1202
FAILURE CODE [DAF0MC]…………………………………………………………………………………………………………….1203
FAILURE CODE [DAF7KB]…………………………………………………………………………………………………………….1204
FAILURE CODE [DAF8KB]…………………………………………………………………………………………………………….1206
FAILURE CODE [DAF9KQ]…………………………………………………………………………………………………………….1209
FAILURE CODE [DAFGMC]…………………………………………………………………………………………………………….1210
FAILURE CODE [DAFLKA]…………………………………………………………………………………………………………….1211
FAILURE CODE [DAFLKB]…………………………………………………………………………………………………………….1214
FAILURE CODE [DAFQKR]…………………………………………………………………………………………………………….1216
FAILURE CODE [DAFSMC]…………………………………………………………………………………………………………….1221
FAILURE CODE [DAZQKR]…………………………………………………………………………………………………………….1223
FAILURE CODE [DB2QKR]…………………………………………………………………………………………………………….1227
FAILURE CODE [DB2RKR]…………………………………………………………………………………………………………….1236
FAILURE CODE [DBP0KM]…………………………………………………………………………………………………………….1244
FAILURE CODE [DBP0KT]…………………………………………………………………………………………………………….1245
FAILURE CODE [DBP0MC]…………………………………………………………………………………………………………….1246
FAILURE CODE [DBP0NR]…………………………………………………………………………………………………………….1247
FAILURE CODE [DBP5KP]…………………………………………………………………………………………………………….1248
FAILURE CODE [DBPLKA]…………………………………………………………………………………………………………….1251
FAILURE CODE [DBPLKB]…………………………………………………………………………………………………………….1254
FAILURE CODE [DBPQKR]…………………………………………………………………………………………………………….1256
FAILURE CODE [DBPUKR]…………………………………………………………………………………………………………….1261
FAILURE CODE [DBPVKR]…………………………………………………………………………………………………………….1271
FAILURE CODE [DBV0MC]…………………………………………………………………………………………………………….1281
FAILURE CODE [DBV1KK]…………………………………………………………………………………………………………….1282
FAILURE CODE [DBV5KB]…………………………………………………………………………………………………………….1284
FAILURE CODE [DBV6KB]…………………………………………………………………………………………………………….1286
FAILURE CODE [DBV8KB]…………………………………………………………………………………………………………….1288
FAILURE CODE [DBVLKA]…………………………………………………………………………………………………………….1293
FAILURE CODE [DBVLKB]…………………………………………………………………………………………………………….1296
FAILURE CODE [DBVQKR]…………………………………………………………………………………………………………….1298
FAILURE CODE [DBVRKR]…………………………………………………………………………………………………………….1302
FAILURE CODE [DBVVKR]…………………………………………………………………………………………………………….1306
FAILURE CODE [DBVWKR]…………………………………………………………………………………………………………….1307
FAILURE CODE [DBWQKR]…………………………………………………………………………………………………………….1308
FAILURE CODE [DBWRKR]…………………………………………………………………………………………………………….1314
FAILURE CODE [DBX0MC]…………………………………………………………………………………………………………….1320
FAILURE CODE [DBX2KK]…………………………………………………………………………………………………………….1321
FAILURE CODE [DBX5KP]…………………………………………………………………………………………………………….1323
FAILURE CODE [DBX6KP]…………………………………………………………………………………………………………….1325
FAILURE CODE [DBX9KQ]…………………………………………………………………………………………………………….1327
FAILURE CODE [DBXLKA]…………………………………………………………………………………………………………….1329
FAILURE CODE [DBXLKB]…………………………………………………………………………………………………………….1332
FAILURE CODE [DBXQKR]…………………………………………………………………………………………………………….1334
FAILURE CODE [DBXRKR]…………………………………………………………………………………………………………….1340
FAILURE CODE [DBY0MC]…………………………………………………………………………………………………………….1346
FAILURE CODE [DBY2KK]…………………………………………………………………………………………………………….1347
FAILURE CODE [DBY5KP]…………………………………………………………………………………………………………….1349
FAILURE CODE [DBY6KP]…………………………………………………………………………………………………………….1351
FAILURE CODE [DBY9KQ]…………………………………………………………………………………………………………….1353
FAILURE CODE [DBYLKA]…………………………………………………………………………………………………………….1355
FAILURE CODE [DBYLKB]…………………………………………………………………………………………………………….1358
FAILURE CODE [DDNRKA]…………………………………………………………………………………………………………….1360
FAILURE CODE [DDNRKY]…………………………………………………………………………………………………………….1362
FAILURE CODE [DDNS00]…………………………………………………………………………………………………………….1364
FAILURE CODE [DDXAL4]…………………………………………………………………………………………………………….1366
FAILURE CODE [DGE5KB]…………………………………………………………………………………………………………….1368
FAILURE CODE [DGH2KA]…………………………………………………………………………………………………………….1370
FAILURE CODE [DGH2KB]…………………………………………………………………………………………………………….1372
FAILURE CODE [DGT3KB]…………………………………………………………………………………………………………….1374
FAILURE CODE [DGT5KA]…………………………………………………………………………………………………………….1376
FAILURE CODE [DGT5KB]…………………………………………………………………………………………………………….1378
FAILURE CODE [DGT6KA]…………………………………………………………………………………………………………….1380
FAILURE CODE [DGT6KB]…………………………………………………………………………………………………………….1382
FAILURE CODE [DGTUKY]…………………………………………………………………………………………………………….1384
FAILURE CODE [DGTUKZ]…………………………………………………………………………………………………………….1386
FAILURE CODE [DGTVKY]…………………………………………………………………………………………………………….1388
FAILURE CODE [DGTVKZ]…………………………………………………………………………………………………………….1390
FAILURE CODE [DGTWKY]…………………………………………………………………………………………………………….1392
FAILURE CODE [DGTWKZ]…………………………………………………………………………………………………………….1394
FAILURE CODE [DGTXKY]…………………………………………………………………………………………………………….1396
FAILURE CODE [DGTXKZ]…………………………………………………………………………………………………………….1398
FAILURE CODE [DH25MA]…………………………………………………………………………………………………………….1400
FAILURE CODE [DH26MA]…………………………………………………………………………………………………………….1402
FAILURE CODE [DH27MA]…………………………………………………………………………………………………………….1404
FAILURE CODE [DH28MA]…………………………………………………………………………………………………………….1406
FAILURE CODE [DHA4KA]…………………………………………………………………………………………………………….1408
FAILURE CODE [DHA5KA]…………………………………………………………………………………………………………….1410
FAILURE CODE [DHPEMA]…………………………………………………………………………………………………………….1411
FAILURE CODE [DHPFMA]…………………………………………………………………………………………………………….1413
FAILURE CODE [DHPGMA]…………………………………………………………………………………………………………….1415
FAILURE CODE [DHPSMA]…………………………………………………………………………………………………………….1417
FAILURE CODE [DHPHMA]…………………………………………………………………………………………………………….1419
FAILURE CODE [DHPTMA]…………………………………………………………………………………………………………….1421
FAILURE CODE [DHPUMA]…………………………………………………………………………………………………………….1423
FAILURE CODE [DHS3MA]…………………………………………………………………………………………………………….1425
FAILURE CODE [DHS4MA]…………………………………………………………………………………………………………….1428
FAILURE CODE [DHS8MA]…………………………………………………………………………………………………………….1431
FAILURE CODE [DHS9MA]…………………………………………………………………………………………………………….1434
FAILURE CODE [DHSAMA]…………………………………………………………………………………………………………….1437
FAILURE CODE [DHSBMA]…………………………………………………………………………………………………………….1440
FAILURE CODE [DHSCMA]…………………………………………………………………………………………………………….1443
FAILURE CODE [DHSDMA]…………………………………………………………………………………………………………….1446
FAILURE CODE [DHSFMA]…………………………………………………………………………………………………………….1449
FAILURE CODE [DHSGMA]…………………………………………………………………………………………………………….1452
FAILURE CODE [DHSHMA]…………………………………………………………………………………………………………….1455
FAILURE CODE [DHSJMA]…………………………………………………………………………………………………………….1458
FAILURE CODE [DKR0MA]…………………………………………………………………………………………………………….1461
FAILURE CODE [DKR1MA]…………………………………………………………………………………………………………….1464
FAILURE CODE [DKR2KA]…………………………………………………………………………………………………………….1467
FAILURE CODE [DKR2KB]…………………………………………………………………………………………………………….1468
FAILURE CODE [DKR2NX]…………………………………………………………………………………………………………….1469
FAILURE CODE [DKR3KA]…………………………………………………………………………………………………………….1470
FAILURE CODE [DKR3KB]…………………………………………………………………………………………………………….1471
FAILURE CODE [DKR3NX]…………………………………………………………………………………………………………….1472
FAILURE CODE [DKR4KA]…………………………………………………………………………………………………………….1474
FAILURE CODE [DKR4KB]…………………………………………………………………………………………………………….1475
FAILURE CODE [DKR4NX]…………………………………………………………………………………………………………….1476
FAILURE CODE [DKR5MA]…………………………………………………………………………………………………………….1478
FAILURE CODE [DKR6MA]…………………………………………………………………………………………………………….1481
FAILURE CODE [[DKTKKX]……………………………………………………………………………………………………………1484
FAILURE CODE [DKTMKX]…………………………………………………………………………………………………………….1486
FAILURE CODE [DKULKA]…………………………………………………………………………………………………………….1488
FAILURE CODE [DKULKB]…………………………………………………………………………………………………………….1490
FAILURE CODE [DKULKY]…………………………………………………………………………………………………………….1492
FAILURE CODE [DKVEL8]…………………………………………………………………………………………………………….1494
FAILURE CODE [DKVEMA]…………………………………………………………………………………………………………….1496
FAILURE CODE [DKVFL8]…………………………………………………………………………………………………………….1498
FAILURE CODE [DKVFMA]…………………………………………………………………………………………………………….1500
FAILURE CODE [DKVGL8]…………………………………………………………………………………………………………….1502
FAILURE CODE [DKVGMA]…………………………………………………………………………………………………………….1504
FAILURE CODE [DKVHL8]…………………………………………………………………………………………………………….1506
FAILURE CODE [DKVHMA]…………………………………………………………………………………………………………….1508
FAILURE CODE [DKVJL8]…………………………………………………………………………………………………………….1510
FAILURE CODE [DKVJMA]…………………………………………………………………………………………………………….1512
FAILURE CODE [DLM3KA]…………………………………………………………………………………………………………….1514
FAILURE CODE [DLM3KB]…………………………………………………………………………………………………………….1516
FAILURE CODE [DLM3MB]…………………………………………………………………………………………………………….1518
FAILURE CODE [DLM8KA]…………………………………………………………………………………………………………….1522
FAILURE CODE [DLM8KB]…………………………………………………………………………………………………………….1523
FAILURE CODE [DLM8MB]…………………………………………………………………………………………………………….1524
FAILURE CODE [DMU6KB]…………………………………………………………………………………………………………….1525
FAILURE CODE [DPQ1LD]…………………………………………………………………………………………………………….1527
FAILURE CODE [DPQ4KB]…………………………………………………………………………………………………………….1528
FAILURE CODE [DPQ4KT]…………………………………………………………………………………………………………….1529
FAILURE CODE [DR10KA]…………………………………………………………………………………………………………….1530
FAILURE CODE [DR20KA]…………………………………………………………………………………………………………….1532
FAILURE CODE [DR21KX]…………………………………………………………………………………………………………….1534
FAILURE CODE [DR30KA]…………………………………………………………………………………………………………….1536
FAILURE CODE [DR31KX]…………………………………………………………………………………………………………….1538
FAILURE CODE [DR40KA]…………………………………………………………………………………………………………….1540
FAILURE CODE [DR50KA]…………………………………………………………………………………………………………….1542
FAILURE CODE [DR60KA]…………………………………………………………………………………………………………….1544
FAILURE CODE [DR90KA]…………………………………………………………………………………………………………….1546
FAILURE CODE [DV20KB]…………………………………………………………………………………………………………….1548
FAILURE CODE [DW41KA]…………………………………………………………………………………………………………….1550
FAILURE CODE [DW41KB]…………………………………………………………………………………………………………….1552
FAILURE CODE [DW41KY]…………………………………………………………………………………………………………….1554
FAILURE CODE [DW45KA]…………………………………………………………………………………………………………….1556
FAILURE CODE [DW45KB]…………………………………………………………………………………………………………….1558
FAILURE CODE [DW45KY]…………………………………………………………………………………………………………….1560
FAILURE CODE [DW4CKY]…………………………………………………………………………………………………………….1562
FAILURE CODE [DW7BKA]…………………………………………………………………………………………………………….1565
FAILURE CODE [DW7BKB]…………………………………………………………………………………………………………….1567
FAILURE CODE [DW7BKY]…………………………………………………………………………………………………………….1569
FAILURE CODE [DW7HKA]…………………………………………………………………………………………………………….1570
FAILURE CODE [DW7HKB]…………………………………………………………………………………………………………….1572
FAILURE CODE [DW7HKY]…………………………………………………………………………………………………………….1574
FAILURE CODE [DW91KA]…………………………………………………………………………………………………………….1576
FAILURE CODE [DW91KB]…………………………………………………………………………………………………………….1578
FAILURE CODE [DW91KY]…………………………………………………………………………………………………………….1580
FAILURE CODE [DWA5KA]…………………………………………………………………………………………………………….1582
FAILURE CODE [DWA5KB]…………………………………………………………………………………………………………….1584
FAILURE CODE [DWA5KY]…………………………………………………………………………………………………………….1586
FAILURE CODE [DWACKA]…………………………………………………………………………………………………………….1587
FAILURE CODE [DWACKB]…………………………………………………………………………………………………………….1589
FAILURE CODE [DWACKY]…………………………………………………………………………………………………………….1591
FAILURE CODE [DWK0KA]…………………………………………………………………………………………………………….1592
FAILURE CODE [DWK0KB]…………………………………………………………………………………………………………….1594
FAILURE CODE [DWK0KY]…………………………………………………………………………………………………………….1596
FAILURE CODE [DWK2KA]…………………………………………………………………………………………………………….1598
FAILURE CODE [DWK2KB]…………………………………………………………………………………………………………….1600
FAILURE CODE [DWK2KY]…………………………………………………………………………………………………………….1602
FAILURE CODE [DWM1KA]…………………………………………………………………………………………………………….1604
FAILURE CODE [DWM1KB]…………………………………………………………………………………………………………….1606
FAILURE CODE [DWM1KY]…………………………………………………………………………………………………………….1608
FAILURE CODE [DWN5KA]…………………………………………………………………………………………………………….1610
FAILURE CODE [DWN5KB]…………………………………………………………………………………………………………….1611
FAILURE CODE [DWNCKA]…………………………………………………………………………………………………………….1612
FAILURE CODE [DWNCKB]…………………………………………………………………………………………………………….1613
FAILURE CODE [DWNPKA]…………………………………………………………………………………………………………….1614
FAILURE CODE [DWNPKB]…………………………………………………………………………………………………………….1616
FAILURE CODE [DWNPKY]…………………………………………………………………………………………………………….1618
FAILURE CODE [DWNQKA]…………………………………………………………………………………………………………….1619
FAILURE CODE [DWNQKB]…………………………………………………………………………………………………………….1621
FAILURE CODE [DWNQKY]…………………………………………………………………………………………………………….1623
FAILURE CODE [DWNRKA]…………………………………………………………………………………………………………….1624
FAILURE CODE [DWNRKB]…………………………………………………………………………………………………………….1626
FAILURE CODE [DWNRKY]…………………………………………………………………………………………………………….1628
FAILURE CODE [DXAAKA]…………………………………………………………………………………………………………….1630
FAILURE CODE [DXAAKB]…………………………………………………………………………………………………………….1632
FAILURE CODE [DXABKA]…………………………………………………………………………………………………………….1634
FAILURE CODE [DXABKB]…………………………………………………………………………………………………………….1636
FAILURE CODE [DXACKA]…………………………………………………………………………………………………………….1638
FAILURE CODE [DXACKB]…………………………………………………………………………………………………………….1640
FAILURE CODE [DXADKA]…………………………………………………………………………………………………………….1642
FAILURE CODE [DXADKB]…………………………………………………………………………………………………………….1644
FAILURE CODE [DXR6KA]…………………………………………………………………………………………………………….1646
FAILURE CODE [DXR6KB]…………………………………………………………………………………………………………….1647
FAILURE CODE [DXR6KY]…………………………………………………………………………………………………………….1648
FAILURE CODE [DXR9KA]…………………………………………………………………………………………………………….1649
FAILURE CODE [DXR9KB]…………………………………………………………………………………………………………….1650
FAILURE CODE [DXR9KY]…………………………………………………………………………………………………………….1651
FAILURE CODE [DXRAKA]…………………………………………………………………………………………………………….1652
FAILURE CODE [DXRAKB]…………………………………………………………………………………………………………….1653
FAILURE CODE [DXRAKY]…………………………………………………………………………………………………………….1654
FAILURE CODE [DXRCKA]…………………………………………………………………………………………………………….1655
FAILURE CODE [DXRCKB]…………………………………………………………………………………………………………….1656
FAILURE CODE [DXRCKY]…………………………………………………………………………………………………………….1657
FAILURE CODE [DXRDKA]…………………………………………………………………………………………………………….1658
FAILURE CODE [DXRDKB]…………………………………………………………………………………………………………….1659
FAILURE CODE [DXRDKY]…………………………………………………………………………………………………………….1660
FAILURE CODE [DXRFKA]…………………………………………………………………………………………………………….1661
FAILURE CODE [DXRFKB]…………………………………………………………………………………………………………….1662
FAILURE CODE [DXRFKY]…………………………………………………………………………………………………………….1663
FAILURE CODE [DXRJKA]…………………………………………………………………………………………………………….1664
FAILURE CODE [DXRJKB]…………………………………………………………………………………………………………….1665
FAILURE CODE [DXRJKY]…………………………………………………………………………………………………………….1666
FAILURE CODE [DY20MA]…………………………………………………………………………………………………………….1667
FAILURE CODE [DY2CKA]…………………………………………………………………………………………………………….1670
FAILURE CODE [DY2CKB]…………………………………………………………………………………………………………….1672
FAILURE CODE [DY2CKY]…………………………………………………………………………………………………………….1676
FAILURE CODE [DY2FMA]…………………………………………………………………………………………………………….1678
FAILURE CODE [F7FQKR]…………………………………………………………………………………………………………….1681
FAILURE CODE [F7G0MC]…………………………………………………………………………………………………………….1683
FAILURE CODE [F@B3NR]…………………………………………………………………………………………………………….1684
FAILURE CODE [F@B3NS]…………………………………………………………………………………………………………….1686
FAILURE CODE [F@B4NR]…………………………………………………………………………………………………………….1688
FAILURE CODE [F@B4NS]…………………………………………………………………………………………………………….1690
FAILURE CODE [F@B5NR]…………………………………………………………………………………………………………….1692
FAILURE CODE [F@B5NS]…………………………………………………………………………………………………………….1694
FAILURE CODE [F@B6NR]…………………………………………………………………………………………………………….1696
FAILURE CODE [F@B6NS]…………………………………………………………………………………………………………….1698
FAILURE CODE [LA10ZL]…………………………………………………………………………………………………………….1700
FAILURE CODE [LA20ZL]…………………………………………………………………………………………………………….1701
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…………………………………………………………………………………………..1702
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)……………………………………………………………………………………1702
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK………………………………………………………………………………………….1709
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK……………………………………………………………………………………….1712
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP………………………………………………………………….1714
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING……………………………………………………..1716
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW………………………1719
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW…………………1720
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING……………………………………………………….1721
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING………………………………………………………..1722
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…………………………………………………………..1723
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…………………………………………………………………….1724
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING………………………………………………………………………1725
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING………………………………………………………..1726
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING………………………………………………………………1727
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…………………………………………………………1728
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM…………………………………………………………………………1729
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL…………………………………………………………………………….1731
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM……………………………………………………..1732
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE…………………………………………………1733
E-20 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED…………………………………………………………………………..1734
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM………………………………………………………1735
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE……………………………………………………..1737
E-23 FUNCTION SWITCH DOES NOT OPERATE………………………………………………………………………………………………1738
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)…………………………………………………………………………1739
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF……………………………….1740
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER………………………………………………………………………….1741
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED………………………………………………..1742
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED…………………………………………………..1743
E-29 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…………………………………………………………..1744
E-30 SERVICE MODE CANNOT BE SELECTED……………………………………………………………………………………………….1745
E-31 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE…………………………………………………………………..1746
E-32 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK……………………………………………………………………1749
E-33 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING……………………………………………………..1751
E-34 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE……………………………………….1753
E-35 HORN DOES NOT SOUND………………………………………………………………………………………………………….1755
E-36 HORN DOES NOT STOP SOUNDING…………………………………………………………………………………………………..1758
E-37 ALARM DOES NOT SOUND DURING TRAVEL…………………………………………………………………………………………….1760
E-38 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED……………………………………………………………………………1762
E-39 ALARM BUZZER CANNOT BE CANCELED……………………………………………………………………………………………….1763
E-40 NONE OF ROOM LAMP, HEADLAMP, OR WORKING LAMP DOES NOT LIGHT UP……………………………………………………………………1764
E-41 HEADLAMP OR WORKING LAMP DOES NOT LIGHT UP……………………………………………………………………………………..1767
E-42 ROOM LAMP DOES NOT LIGHT UP…………………………………………………………………………………………………..1771
E-43 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF…………………………………………………………..1773
E-44 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (UPPER WIPER SPECIFICATION)……………………………………………………1774
E-45 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED (LOWER WIPER SPECIFICATION)……………………………………………………1777
E-46 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY……………………………………………………………………………1780
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE……………………………………………………………..1784
E-48 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION………………………………………………………………1785
E-49 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………….1786
E-50 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…………………………………………………………..1787
E-51 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…………………………………………………………..1788
E-52 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION………………………………………………………………..1789
E-53 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………….1790
E-54 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………1791
E-55 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION……………………………………………………………1792
E-56 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY……………………………………………………………………………………….1793
E-57 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED…………………………………………………………………………………….1794
E-58 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE………………………………………………………………………………………1796
E-59 STEP LIGHT DOES NOT LIGHT UP………………………………………………………………………………………………….1797
E-60 STEP LIGHT DOES NOT GO OUT……………………………………………………………………………………………………1800
E-61 BOOM SHOCKLESS FUNCTION CANNOT BE CANCELED……………………………………………………………………………………..1802
E-62 BOOM SHOCKLESS FUNCTION DOES NOT WORK………………………………………………………………………………………….1804
E-63 AIR CONDITIONER CONTROL PANEL DOES NOT TURN ON………………………………………………………………………………….1805
E-64 WIND DOES NOT COME OUT FROM THE AIR CONDITIONER…………………………………………………………………………………1807
E-65 AIR CONDITIONER IS WEAK IN COLD(ELECTRIC CAPACITOR DOES NOT MOVE OR ONLY HI ROTATION MOVES)………………………………………….1809
E-66 AIR CONDITIONER DOES NOT GET COLD(COMPRESSOR DOES NOT MOVE)………………………………………………………………………1811
E-67 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS………………………………………………………………………..1814
E-68 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY………………………………………………………………………………1818
E-69 KomVision MONITOR CANNOT BE TOUCH……………………………………………………………………………………………..1825
E-70 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL…………………………………………………………………………….1828
E-71 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR………………………………………………………………..1831
E-72 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION…………………………………………………………….1833
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…………………………………………………………………………….1834
H-1 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK………………………………………………………………………………..1834
H-2 ALL WORK EQUIPMENT, TRAVEL, SWING SPEED OR POWER IS LOW…………………………………………………………………………..1835
H-3 ENGINE SPEED DROPS SIGNIFICANTLY OR ENGINE STALLS………………………………………………………………………………..1837
H-4 UNUSUAL NOISE IS HEARD FROM AROUND WORK EQUIPMENT PUMP……………………………………………………………………………1838
H-5 BOOM SPEED OR POWER IS LOW IN NORMAL MODE……………………………………………………………………………………….1839
H-6 BOOM RAISE SPEED OR POWER IS LOW IN HEAVY LIFT MODE………………………………………………………………………………1840
H-7 BOOM LOWER SPEED OR POWER IS LOW IN MACHINE PUSH UP MODE………………………………………………………………………….1841
H-8 ARM SPEED OR POWER IS LOW……………………………………………………………………………………………………..1842
H-9 BUCKET SPEED OR POWER IS LOW…………………………………………………………………………………………………..1843
H-10 BOOM DOES NOT OPERATE………………………………………………………………………………………………………..1844
H-11 ARM DOES NOT OPERATE…………………………………………………………………………………………………………1845
H-12 BUCKET DOES NOT OPERATE………………………………………………………………………………………………………1846
H-13 HYDRAULIC DRIFT OF BOOM IS LARGE………………………………………………………………………………………………1847
H-14 HYDRAULIC DRIFT OF ARM IS LARGE……………………………………………………………………………………………….1848
H-15 HYDRAULIC DRIFT OF BUCKET IS LARGE…………………………………………………………………………………………….1849
H-16 TIME LAG OF BOOM IS LARGE…………………………………………………………………………………………………….1850
H-17 TIME LAG OF ARM IS LARGE……………………………………………………………………………………………………..1851
H-18 TIME LAG OF BUCKET IS LARGE…………………………………………………………………………………………………..1852
H-19 BOOM SHOCKLESS FUNCTION DOES NOT WORK OR CANNOT BE RELEASED………………………………………………………………………1853
H-20 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS IN THE SAME DIRECTION WHEN TRAVELING FORWARD AND REVERSE)……….1854
H-21 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS (IT TURNS IN THE DIFFERENT DIRECTIONS WHEN TRAVELING FORWARD AND REVERSE)….1856
H-22 ONLY WHEN OPERATING THE TRAVEL LEVER FULLY, TRAVEL DEVIATION IS LARGE AT START OF TRAVELING………………………………………….1857
H-23 REGARDLESS OF THE STROKE OF THE TRAVEL LEVER, TRAVEL DEVIATION IS LARGE AT START OF TRAVELING………………………………………..1858
H-24 TRAVEL DEVIATION IS LARGE AT COMBINED OPERATION…………………………………………………………………………………1859
H-25 TRAVEL SPEED OR POWER IS LOW………………………………………………………………………………………………….1860
H-26 ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE DOES NOT TRAVEL EITHER FORWARD OR REVERSE)……………………………………………..1861
H-27 ONLY THE ONE SIDE TRACK CAN OPERATE (MACHINE CAN TRAVEL ONLY FORWARD OR REVERSE)……………………………………………………1862
H-28 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST…………………………………………………………………1863
H-29 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT………………………………………………………………………..1864
H-30 SWINGS ONLY IN ONE DIRECTION………………………………………………………………………………………………….1865
H-31 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)……………………………………………………….1866
H-32 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION…………………………………………………1867
H-33 IN COMBINED OPERATION OF WORK EQUIPMENT, SWING SPEED OR POWER IS LOW………………………………………………………………1868
H-34 WHILE COMBINED OPERATION WITH BOOM SWING SPEED IS LOW OR SWING ACCELERATION PERFORMANCE IS POOR………………………………………1869
H-35 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)…………………………………………………..1870
H-36 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)…………………………………1871
H-37 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING (BOTH RIGHT AND LEFT)…………………………………………………………..1872
H-38 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING………………………………………………………………………………1873
H-39 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING (BOTH RIGHT AND LEFT)………………………………………………1874
H-40 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING IN ONLY ONE DIRECTION………………………………………………1875
H-41 SWING DRIFT ON A SLOPE IS LARGE……………………………………………………………………………………………….1876
H-42 FAN SPEED IS ABNORMAL (SUCH AS EXCESSIVE NOISE OR VIBRATION OF FAN, OR OVERHEATING)…………………………………………………1877
TROUBLESHOOTING OF ENGINE (S-MODE)…………………………………………………………………………………………………….1878
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)………………………………………………………………………………1878
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO………………………………………………………………………………1879
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT………………………………………………………………………………………….1880
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING:ENGINE CRANKS BUT DOES NOT START)…………………………………………….1881
ENGINE STARTABILITY IS POOR……………………………………………………………………………………………………….1882
ENGINE DOES NOT PICK UP SMOOTHLY…………………………………………………………………………………………………..1884
ENGINE STOPS DURING OPERATION……………………………………………………………………………………………………..1886
ENGINE RUNS ROUGH OR IS UNSTABLE…………………………………………………………………………………………………..1888
ENGINE LACKS POWER……………………………………………………………………………………………………………….1889
ENGINE OIL CONSUMPTION IS EXCESSIVE………………………………………………………………………………………………..1891
OIL BECOMES CONTAMINATED QUICKLY…………………………………………………………………………………………………..1892
FUEL CONSUMPTION IS EXCESSIVE……………………………………………………………………………………………………..1893
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT…………………………………………………………………………………1894
OIL PRESSURE DROPS……………………………………………………………………………………………………………….1895
FUEL MIXES INTO ENGINE OIL………………………………………………………………………………………………………..1897
WATER MIXES INTO ENGINE OIL (MILKY)………………………………………………………………………………………………..1898
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)…………………………………………………………………………………….1899
UNUSUAL NOISE IS HEARD……………………………………………………………………………………………………………1900
VIBRATION IS EXCESSIVE……………………………………………………………………………………………………………1901
AIR CANNOT BE BLED FROM FUEL CIRCUIT……………………………………………………………………………………………….1902
50 DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………………1903
CONTENTS……………………………………………………………………………………………………………………………1904
ABBREVIATION LIST……………………………………………………………………………………………………………………1909
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………1915
HOW TO READ THIS MANUAL…………………………………………………………………………………………………………..1915
COATING MATERIALS LIST……………………………………………………………………………………………………………1917
SPECIAL TOOLS LIST……………………………………………………………………………………………………………….1921
SKETCHES OF SPECIAL TOOLS…………………………………………………………………………………………………………1939
ENGINE AND COOLING SYSTEM…………………………………………………………………………………………………………….1942
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (RIGHT BANK)…………………………………………………………………………………1942
REMOVE SUPPLY PUMP ASSEMBLY (RIGHT BANK)………………………………………………………………………………………..1942
INSTALL SUPPLY PUMP ASSEMBLY (RIGHT BANK)……………………………………………………………………………………….1955
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY (LEFT BANK)………………………………………………………………………………….1976
REMOVE SUPPLY PUMP ASSEMBLY (LEFT BANK)…………………………………………………………………………………………1976
INSTALL SUPPLY PUMP ASSEMBLY (LEFT BANK)………………………………………………………………………………………..1985
REMOVE AND INSTALL INJECTOR ASSEMBLY (RIGHT BANK)……………………………………………………………………………………2000
REMOVE INJECTOR ASSEMBLY (RIGHT BANK)…………………………………………………………………………………………..2000
INSTALL INJECTOR ASSEMBLY (RIGHT BANK)………………………………………………………………………………………….2015
REMOVE AND INSTALL INJECTOR ASSEMBLY (LEFT BANK)…………………………………………………………………………………….2032
REMOVE INJECTOR ASSEMBLY (LEFT BANK)……………………………………………………………………………………………2032
INSTALL INJECTOR ASSEMBLY (LEFT BANK)…………………………………………………………………………………………..2047
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY (RIGHT BANK)……………………………………………………………………………….2064
REMOVE CYLINDER HEAD ASSEMBLY (RIGHT BANK)………………………………………………………………………………………2064
INSTALL CYLINDER HEAD ASSEMBLY (RIGHT BANK)……………………………………………………………………………………..2096
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY (LEFT BANK)………………………………………………………………………………..2137
REMOVE CYLINDER HEAD ASSEMBLY (LEFT BANK)……………………………………………………………………………………….2137
INSTALL CYLINDER HEAD ASSEMBLY (LEFT BANK)………………………………………………………………………………………2172
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY………………………………………………………………………………………….2222
REMOVE STARTING MOTOR ASSEMBLY…………………………………………………………………………………………………2222
INSTALL STARTING MOTOR ASSEMBLY………………………………………………………………………………………………..2225
REMOVE AND INSTALL ALTERNATOR BELT…………………………………………………………………………………………………2228
REMOVE ALTERNATOR BELT………………………………………………………………………………………………………..2228
INSTALL ALTERNATOR BELT……………………………………………………………………………………………………….2230
REMOVE AND INSTALL ALTERNATOR ASSEMBLY……………………………………………………………………………………………..2234
REMOVE ALTERNATOR ASSEMBLY…………………………………………………………………………………………………….2234
INSTALL ALTERNATOR ASSEMBLY……………………………………………………………………………………………………2237
REMOVE AND INSTALL RADIATOR ASSEMBLY……………………………………………………………………………………………….2244
METHOD FOR REMOVING RADIATOR ASSEMBLY…………………………………………………………………………………………..2244
METHOD FOR INSTALLING RADIATOR ASSEMBLY…………………………………………………………………………………………2249
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY…………………………………………………………………………………….2255
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY………………………………………………………………………………..2255
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY………………………………………………………………………………2258
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…………………………………………………………………………………………….2262
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY………………………………………………………………………………………..2262
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY………………………………………………………………………………………2267
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY……………………………………………………………………………………….2273
REMOVE COOLING FAN MOTOR ASSEMBLY………………………………………………………………………………………………2273
METHOD FOR INSTALLING COOLING FAN MOTOR ASSEMBLY…………………………………………………………………………………2299
REMOVE AND INSTALL POWER MODULE PACKAGING ASSEMBLY…………………………………………………………………………………..2324
REMOVE POWER MODULE PACKAGING ASSEMBLY………………………………………………………………………………………….2324
METHOD FOR INSTALLING POWER MODULE PACKAGING ASSEMBLY…………………………………………………………………………….2339
REMOVE AND INSTALL ENGINE, PTO, AND HYDRAULIC PUMP ASSEMBLY…………………………………………………………………………..2354
REMOVE ENGINE, PTO, AND HYDRAULIC PUMP ASSEMBLY………………………………………………………………………………….2355
INSTALL ENGINE, PTO, AND HYDRAULIC PUMP ASSEMBLY…………………………………………………………………………………2388
REMOVE AND INSTALL ENGINE FRONT OIL SEAL……………………………………………………………………………………………2422
REMOVE ENGINE FRONT OIL SEAL…………………………………………………………………………………………………..2422
INSTALL ENGINE FRONT OIL SEAL………………………………………………………………………………………………….2430
REMOVE AND INSTALL ENGINE REAR OIL SEAL…………………………………………………………………………………………….2438
REMOVE ENGINE REAR OIL SEAL……………………………………………………………………………………………………2438
INSTALL ENGINE REAR OIL SEAL…………………………………………………………………………………………………..2440
REMOVE AND INSTALL FUEL COOLER ASSEMBLY…………………………………………………………………………………………….2444
METHOD FOR REMOVING FUEL COOLER ASSEMBLY………………………………………………………………………………………..2444
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY………………………………………………………………………………………2446
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY…………………………………………………………………………………………….2448
REMOVE ENGINE HOOD ASSEMBLY……………………………………………………………………………………………………2448
INSTALL ENGINE HOOD ASSEMBLY…………………………………………………………………………………………………..2453
REMOVE AND INSTALL FUEL TANK ASSEMBLY………………………………………………………………………………………………2459
METHOD FOR REMOVING FUEL TANK ASSEMBLY………………………………………………………………………………………….2459
METHOD FOR INSTALLING FUEL TANK ASSEMBLY………………………………………………………………………………………..2462
REMOVE AND INSTALL MUFFLER ASSEMBLY………………………………………………………………………………………………..2466
REMOVE MUFFLER ASSEMBLY……………………………………………………………………………………………………….2466
INSTALL MUFFLER ASSEMBLY………………………………………………………………………………………………………2475
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY……………………………………………………………………………………………2485
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY……………………………………………………………………………………….2485
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY……………………………………………………………………………………..2487
REMOVE AND INSTALL TURBOCHARGER ASSEMBLY (RIGHT BANK)………………………………………………………………………………..2488
REMOVE TURBOCHARGER ASSEMBLY (RIGHT BANK)……………………………………………………………………………………….2488
INSTALL TURBOCHARGER ASSEMBLY (RIGHT BANK)………………………………………………………………………………………2500
REMOVE AND INSTALL TURBOCHARGER ASSEMBLY (LEFT BANK)…………………………………………………………………………………2513
REMOVE TURBOCHARGER ASSEMBLY (LEFT BANK)………………………………………………………………………………………..2513
INSTALL TURBOCHARGER ASSEMBLY (LEFT BANK)……………………………………………………………………………………….2525
REMOVE AND INSTALL AIR CLEANER ASSEMBLY…………………………………………………………………………………………….2540
REMOVE AIR CLEANER ASSEMBLY……………………………………………………………………………………………………2540
INSTALL AIR CLEANER ASSEMBLY…………………………………………………………………………………………………..2543
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY……………………………………………………………………………….2547
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…………………………………………………………………………..2547
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…………………………………………………………………………2550
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY………………………………………………………………………………..2553
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY……………………………………………………………………………2553
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY………………………………………………………………………….2556
POWER TRAIN…………………………………………………………………………………………………………………………2559
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY………………………………………………………………………………………………2559
METHOD FOR DISASSEMBLING PTO ASSEMBLY…………………………………………………………………………………………..2559
METHOD FOR ASSEMBLING PTO ASSEMBLY……………………………………………………………………………………………..2564
REMOVE AND INSTALL PTO ASSEMBLY……………………………………………………………………………………………………2568
METHOD FOR REMOVING PTO ASSEMBLY……………………………………………………………………………………………….2568
METHOD FOR INSTALLING PTO ASSEMBLY……………………………………………………………………………………………..2569
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY……………………………………………………………………………..2570
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…………………………………………………………………………………….2570
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY……………………………………………………………………………………2574
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY……………………………………………………………………………………….2578
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY……………………………………………………………………………………2579
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY………………………………………………………………………………………2585
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY…………………………………………………………………………..2594
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY………………………………………………………………………………….2595
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY…………………………………………………………………….2603
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY……………………………………………………………………………………2609
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY………………………………………………………………………………..2609
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY…………………………………………………………………………………..2615
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY……………………………………………………………………………………………2622
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY……………………………………………………………………………………….2622
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY……………………………………………………………………………………..2622
UNDERCARRIAGE AND FRAME………………………………………………………………………………………………………………2624
REMOVE AND INSTALL IDLER ASSEMBLY………………………………………………………………………………………………….2624
METHOD FOR REMOVING IDLER ASSEMBLY……………………………………………………………………………………………..2624
METHOD FOR INSTALLING IDLER ASSEMBLY……………………………………………………………………………………………2625
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY……………………………………………………………………………………………2626
METHOD FOR REMOVING TRACK ROLLER ASSEMBLY……………………………………………………………………………………….2626
METHOD FOR INSTALLING TRACK ROLLER ASSEMBLY……………………………………………………………………………………..2627
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY………………………………………………………………………………………….2629
METHOD FOR REMOVING CARRIER ROLLER ASSEMBLY……………………………………………………………………………………..2629
METHOD FOR INSTALLING CARRIER ROLLER ASSEMBLY……………………………………………………………………………………2630
SEPARATION AND CONNECTION OF TRACK ASSEMBLY…………………………………………………………………………………………2632
METHOD FOR SEPARATING TRACK ASSEMBLY……………………………………………………………………………………………2632
METHOD FOR INSTALLING TRACK ASSEMBLY……………………………………………………………………………………………2633
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY…………………………………………………………………………………………….2635
METHOD FOR DISASSEMBLING IDLER ASSEMBLY…………………………………………………………………………………………2635
METHOD FOR ASSEMBLING IDLER ASSEMBLY……………………………………………………………………………………………2637
DISASSEMBLE AND ASSEMBLE AIDLER ADJUSTMENT CYLINDER ASSEMBLY………………………………………………………………………….2640
METHOD FOR DISASSEMBLING AIDLER ADJUSTMENT CYLINDER ASSEMBLY………………………………………………………………………2640
METHOD FOR ASSEMBLING AIDLER ADJUSTMENT CYLINDER ASSEMBLY…………………………………………………………………………2641
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY………………………………………………………………………………………2643
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY…………………………………………………………………………………..2643
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY……………………………………………………………………………………..2644
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY……………………………………………………………………………………..2646
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY…………………………………………………………………………………2646
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY……………………………………………………………………………………2647
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY…………………………………………………………………………………………2650
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY…………………………………………………………………………………….2650
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY…………………………………………………………………………………..2654
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY…………………………………………………………………………………………..2658
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY………………………………………………………………………………………2658
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY…………………………………………………………………………………….2660
HYDRAULIC SYSTEM…………………………………………………………………………………………………………………….2663
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY……………………………………………………………………………………..2663
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY…………………………………………………………………………………2663
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY……………………………………………………………………………….2665
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY………………………………………………………………………………..2669
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY…………………………………………………………………………….2670
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY……………………………………………………………………………….2671
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY………………………………………………………………………………………….2672
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY……………………………………………………………………………………..2672
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY……………………………………………………………………………………2680
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY………………………………………………………………………………………….2688
REMOVE HYDRAULIC PUMP ASSEMBLY…………………………………………………………………………………………………2689
INSTALL HYDRAULIC PUMP ASSEMBLY………………………………………………………………………………………………..2708
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY…………………………………………………………………………………………..2728
REMOVE CONTROL VALVE ASSEMBLY………………………………………………………………………………………………….2729
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY…………………………………………………………………………………….2742
REMOVE AND INSTALL SWING MOTOR ASSEMBLY…………………………………………………………………………………………….2758
REMOVE SWING MOTOR ASSEMBLY……………………………………………………………………………………………………2758
METHOD FOR INSTALLING SWING MOTOR ASSEMBLY………………………………………………………………………………………2764
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY……………………………………………………………………………2770
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY………………………………………………………………………..2770
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY…………………………………………………………………………..2770
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY…………………………………………………………………………………..2773
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY……………………………………………………………………………….2773
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY………………………………………………………………………………….2774
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY………………………………………………………………………………………..2777
METHOD FOR DISASSEMBLING GREASE GUN ASSEMBLY…………………………………………………………………………………….2777
METHOD FOR ASSEMBLING GREASE GUN ASSEMBLY……………………………………………………………………………………….2777
WORK EQUIPMENT………………………………………………………………………………………………………………………2778
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY…………………………………………………………………………………………2778
METHOD FOR REMOVING BUCKET CYLINDER ASSEMBLY…………………………………………………………………………………….2779
METHOD FOR INSTALLING BUCKET CYLINDER ASSEMBLY…………………………………………………………………………………..2781
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY……………………………………………………………………………………………2783
METHOD FOR REMOVING ARM CYLINDER ASSEMBLY……………………………………………………………………………………….2783
METHOD FOR INSTALLING ARM CYLINDER ASSEMBLY……………………………………………………………………………………..2785
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY…………………………………………………………………………………………..2788
METHOD FOR REMOVING BOOM CYLINDER ASSEMBLY………………………………………………………………………………………2788
METHOD FOR INSTALLING BOOM CYLINDER ASSEMBLY…………………………………………………………………………………….2791
REMOVE AND INSTALL BUCKET ASSEMBLY…………………………………………………………………………………………………2794
METHOD FOR REMOVING BUCKET ASSEMBLY…………………………………………………………………………………………….2794
METHOD FOR INSTALLING BUCKET ASSEMBLY…………………………………………………………………………………………..2796
REMOVE AND INSTALL ARM ASSEMBLY……………………………………………………………………………………………………2799
REMOVE ARM ASSEMBLY…………………………………………………………………………………………………………..2799
METHOD FOR INSTALLING ARM ASSEMBLY……………………………………………………………………………………………..2805
REMOVE AND INSTALL BOOM ASSEMBLY…………………………………………………………………………………………………..2810
METHOD FOR REMOVING BOOM ASSEMBLY………………………………………………………………………………………………2810
METHOD FOR INSTALLING BOOM ASSEMBLY…………………………………………………………………………………………….2813
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY…………………………………………………………………………….2817
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY…………………………………………………………………………2818
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY……………………………………………………………………………2821
CAB AND ITS ATTACHMENTS………………………………………………………………………………………………………………2826
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY………………………………………………………………………………………….2826
REMOVE OPERATOR CAB ASSEMBLY…………………………………………………………………………………………………..2827
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY……………………………………………………………………………………..2834
REMOVE AND INSTALL CAB BASE……………………………………………………………………………………………………….2841
METHOD FOR REMOVING CAB BASE…………………………………………………………………………………………………..2841
METHOD FOR INSTALLING CAB BASE…………………………………………………………………………………………………2845
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)………………………………………………………………………………..2850
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)……………………………………………………………………………2851
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)………………………………………………………………………….2852
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ASSEMBLING TYPE)…………………………………………………………………………….2859
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ASSEMBLING TYPE)………………………………………………………………………..2859
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ASSEMBLING TYPE)………………………………………………………………………2861
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…………………………………………………………………………………….2863
REMOVE AIR CONDITIONER UNIT ASSEMBLY……………………………………………………………………………………………2863
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY………………………………………………………………………………2878
REMOVE AND INSTALL OPERATOR’S SEAT…………………………………………………………………………………………………2891
METHOD FOR REMOVING OPERATOR’S SEAT…………………………………………………………………………………………….2891
METHOD FOR INSTALLING OPERATOR’S SEAT…………………………………………………………………………………………..2894
REMOVE AND INSTALL SEAT BELT………………………………………………………………………………………………………2897
METHOD FOR REMOVING SEAT BELT………………………………………………………………………………………………….2897
METHOD FOR INSTALLING SEAT BELT………………………………………………………………………………………………..2898
REMOVE AND INSTALL FRONT WIPER ASSEMBLY…………………………………………………………………………………………….2900
METHOD FOR REMOVING FRONT WIPER ASSEMBLY………………………………………………………………………………………..2900
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY………………………………………………………………………………………2904
ELECTRICAL SYSTEM……………………………………………………………………………………………………………………2908
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY (RIGHT BANK)……………………………………………………………………………2908
REMOVE ENGINE CONTROLLER ASSEMBLY (RIGHT BANK)…………………………………………………………………………………..2908
INSTALL ENGINE CONTROLLER ASSEMBLY (RIGHT BANK)………………………………………………………………………………….2910
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY (LEFT BANK)…………………………………………………………………………….2912
REMOVE ENGINE CONTROLLER ASSEMBLY (LEFT BANK)……………………………………………………………………………………2912
INSTALL ENGINE CONTROLLER ASSEMBLY (LEFT BANK)…………………………………………………………………………………..2913
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY…………………………………………………………………………………………2916
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY…………………………………………………………………………………….2916
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY…………………………………………………………………………………..2917
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY…………………………………………………………………………………….2919
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY………………………………………………………………………………..2919
METHOD FOR INSTALLING KomVision CONTROLLER………………………………………………………………………………………2920
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…………………………………………………………………………………………2922
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…………………………………………………………………………………….2922
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…………………………………………………………………………………..2925
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR………………………………………………………………………………2929
REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR……………………………………………………………………………………..2929
INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR…………………………………………………………………………………….2930
REMOVE AND INSTALL CRANKCASE PRESSURE SENSOR………………………………………………………………………………………..2931
REMOVE CRANKCASE PRESSURE SENSOR……………………………………………………………………………………………….2931
INSTALL CRANKCASE PRESSURE SENSOR………………………………………………………………………………………………2932
REMOVE AND INSTALL KomVision CAMERA………………………………………………………………………………………………..2934
METHOD FOR REMOVING KomVision CAMERA……………………………………………………………………………………………2934
METHOD FOR INSTALLING KomVision CAMERA………………………………………………………………………………………….2938
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY………………………………………………………………………………….2942
METHOD FOR REMOVING KOMTRAX Plus CONTROLLER ASSEMBLY……………………………………………………………………………..2942
METHOD FOR INSTALLING KOMTRAX Plus CONTROLLER ASSEMBLY……………………………………………………………………………2943
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY……………………………………………………………………………………….2945
METHOD FOR REMOVING WIRELESS LAN UNIT ASSEMBLY…………………………………………………………………………………..2945
METHOD FOR NSTALLING WIRELESS LAN UNIT ASSEMBLY………………………………………………………………………………….2947
60 MAINTENANCE STANDARD………………………………………………………………………………………………………………….2949
CONTENTS……………………………………………………………………………………………………………………………2950
ENGINE AND COOLING SYSTEM…………………………………………………………………………………………………………….2951
MAINTENANCE STANDARD OF ENGINE MOUNT……………………………………………………………………………………………….2951
MAINTENANCE STANDARD FOR PTO………………………………………………………………………………………………………2952
MAINTENANCE STANDARD OF COOLING FAN PUMP……………………………………………………………………………………………2954
MAINTENANCE STANDARD OF EPC VALVE OF COOLING FAN PUMP…………………………………………………………………………….2957
MAINTENANCE STANDARD OF COOLING FAN MOTOR…………………………………………………………………………………………..2958
POWER TRAIN…………………………………………………………………………………………………………………………2961
MAINTENANCE STANDARD OF SWING CIRCLE……………………………………………………………………………………………….2961
MAINTENANCE STANDARD OF SWING MACHINERY…………………………………………………………………………………………….2962
MAINTENANCE STANDARD OF FINAL DRIVE………………………………………………………………………………………………..2964
MAINTENANCE STANDARD OF SPROCKET…………………………………………………………………………………………………..2966
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING……………………………………………………………………..2967
UNDERCARRIAGE AND FRAME………………………………………………………………………………………………………………2968
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION………………………………………………………………………………..2968
MAINTENANCE STANDARD OF IDLER……………………………………………………………………………………………………..2971
MAINTENANCE STANDARD OF TRACK ROLLER……………………………………………………………………………………………….2973
MAINTENANCE STANDARD OF CARRIER ROLLER……………………………………………………………………………………………..2974
MAINTENANCE STANDARD OF TRACK SHOE…………………………………………………………………………………………………2976
MAINTENANCE STANDARD OF DOUBLE SHOE………………………………………………………………………………………………..2979
MAINTENANCE STANDARD OF TRIPLE SHOE………………………………………………………………………………………………..2980
HYDRAULIC SYSTEM…………………………………………………………………………………………………………………….2981
MAINTENANCE STANDARD OF MAIN PUMP………………………………………………………………………………………………….2981
MAINTENANCE STANDARD OF MAIN PUMP SERVO VALVE……………………………………………………………………………………2985
MAINTENANCE STANDARD OF SWING MOTOR………………………………………………………………………………………………..2987
MAINTENANCE STANDARD OF TRAVEL MOTOR……………………………………………………………………………………………….2990
MAINTENANCE STANDARD OF CONTROL VALVE………………………………………………………………………………………………2994
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE…………………………………………………………………………………3028
MAINTENANCE STANDARD OF PPC CUT-OFF VALVE…………………………………………………………………………………………..3029
MAINTENANCE STANDARD OF SUCTION SELECTOR VALVE………………………………………………………………………………………3033
MAINTENANCE STANDARD OF PPC CUT-OFF VALVE…………………………………………………………………………………………..3035
MAINTENANCE STANDARD OF SUCTION SELECTOR VALVE………………………………………………………………………………………3039
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE……………………………………………………………………………3041
MAINTENANCE STANDARD OF TRAVEL PPC VALVE……………………………………………………………………………………………3044
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT…………………………………………………………………………………………3047
WORK EQUIPMENT………………………………………………………………………………………………………………………3048
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE………………………………………………………………………………………3048
DIMENSION OF ARM……………………………………………………………………………………………………………..3052
DIMENSIONS OF BUCKET………………………………………………………………………………………………………….3054
MAINTENANCE STANDARD OF BOOM CYLINDER………………………………………………………………………………………………3057
MAINTENANCE STANDARD OF ARM CYLINDER……………………………………………………………………………………………….3058
MAINTENANCE STANDARD OF BUCKET CYLINDER…………………………………………………………………………………………….3059
80 APPENDIX…………………………………………………………………………………………………………………………….3061
CONTENTS……………………………………………………………………………………………………………………………3062
AIR CONDITIONER SYSTEM……………………………………………………………………………………………………………….3065
PRECAUTIONS FOR REFRIGERANT……………………………………………………………………………………………………….3065
AIR CONDITIONER COMPONENT…………………………………………………………………………………………………………3066
AIR CONDITIONER COMPONENT…………………………………………………………………………………………………………3068
SPECIFICATIONS OF AIR CONDITIONER………………………………………………………………………………………………….3070
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE……………………………………………………………………………………3071
OUTLINE OF REFRIGERATION CYCLE…………………………………………………………………………………………………….3072
COMPONENT PARTS OF AIR CONDITIONER SYSTEM………………………………………………………………………………………………3074
AIR CONDITIONER UNIT……………………………………………………………………………………………………………..3074
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT……………………………………………………………………………………3074
FUNCTION OF AIR CONDITIONER UNIT……………………………………………………………………………………………….3076
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT………………………………………………………………………….3077
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………3078
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………3078
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………3078
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………….3079
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT……………………………………………………………………..3079
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…………………………………………………………………………3079
FUNCTION OF DUAL PRESSURE SWITCH……………………………………………………………………………………………….3080
AIR CONDITIONER CONTROLLER………………………………………………………………………………………………………..3081
STRUCTURE OF AIR CONDITIONER CONTROLLER…………………………………………………………………………………………3081
COMPRESSOR………………………………………………………………………………………………………………………3082
STRUCTURE OF COMPRESSOR……………………………………………………………………………………………………….3082
SPECIFICATIONS OF COMPRESSOR…………………………………………………………………………………………………..3082
FUNCTION OF COMPRESSOR………………………………………………………………………………………………………..3082
CONDENSER……………………………………………………………………………………………………………………….3083
STRUCTURE OF CONDENSER………………………………………………………………………………………………………..3083
SPECIFICATIONS OF CONDENSER……………………………………………………………………………………………………3083
FUNCTION OF CONDENSER…………………………………………………………………………………………………………3083
RECEIVER DRIER…………………………………………………………………………………………………………………..3084
STRUCTURE OF RECEIVER DRIER……………………………………………………………………………………………………3084
SPECIFICATIONS OF RECEIVER DRIER……………………………………………………………………………………………….3084
FUNCTION OF RECEIVER DRIER…………………………………………………………………………………………………….3084
SENSORS FOR AIR CONDITIONER SYSTEM…………………………………………………………………………………………………3085
FUNCTION OF SUNLIGHT SENSOR……………………………………………………………………………………………………3085
STRUCTURE OF AMBIENT TEMPERATURE SENSOR…………………………………………………………………………………………3085
FUNCTION OF AMBIENT TEMPERATURE SENSOR………………………………………………………………………………………….3085
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER………………………………………………………………..3086
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER……………………………………………………………………..3088
AIR CONDITIONER SYSTEM DIAGRAM………………………………………………………………………………………………………..3090
AIR CONDITIONER CONTROL PANEL……………………………………………………………………………………………………..3091
EXPLANATION OF AIR CONDITIONER EQUIPMENT………………………………………………………………………………………..3091
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER……………………………………………………………………………….3092
FUNCTION OF AIR CONDITIONER CONTROLLER………………………………………………………………………………………….3093
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS………………………………………………………………3094
TESTING AIR LEAKAGE (DUCT)……………………………………………………………………………………………………………3098
METHOD FOR TESTING AIR LEAKAGE (DUCT)………………………………………………………………………………………………3098
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION……………………………………………………………………………………3099
TEST VENT (MODE) CHANGEOVER…………………………………………………………………………………………………………..3101
METHOD FOR TESTING VENT (MODE) CHANGEOVER…………………………………………………………………………………………..3101
TESTING FRESH/RECIRC AIR CHANGEOVER……………………………………………………………………………………………………3105
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER………………………………………………………………………………………3105
TEST SUNLIGHT SENSOR…………………………………………………………………………………………………………………3106
METHOD FOR TESTING SUNLIGHT SENSOR…………………………………………………………………………………………………3106
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT…………………………………………………………………………………………….3107
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT…………………………………………………………………………….3107
TEST RELAYS…………………………………………………………………………………………………………………………3109
METHOD FOR TESTING RELAYS…………………………………………………………………………………………………………3109
AIR CONDITIONER TROUBLESHOOTING CHART 1………………………………………………………………………………………………..3110
AIR CONDITIONER TROUBLESHOOTING CHART 2………………………………………………………………………………………………..3111
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE………………………………………………………………………………………….3114
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)……………………………………………………………..3116
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)………………………………………………………………3118
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)………………………………………………………3121
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER……………………………………………………………………………………..3123
TROUBLESHOOTING USING GAUGE PRESSURE…………………………………………………………………………………………………..3125
CONNECTION OF SERVICE TOOL……………………………………………………………………………………………………………3128
METHOD FOR CONNECTING SERVICE TOOL…………………………………………………………………………………………………3128
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS……………………………………………………..3130
HANDLE COMPRESSOR OIL………………………………………………………………………………………………………………..3132
KomVision SYSTEM…………………………………………………………………………………………………………………….3134
STRUCTURE AND OPERATION OF KomVision SYSTEM…………………………………………………………………………………………….3135
PRECAUTIONS FOR KomVision SYSTEM…………………………………………………………………………………………………..3135
LAYOUT DRAWING OF KomVision SYSTEM…………………………………………………………………………………………………3136
LAYOUT DRAWING OF KomVision SWITCHES AND MONITORS………………………………………………………………………………..3136
KomVision SYSTEM DIAGRAM………………………………………………………………………………………………………3137
FUNCTION OF KomVision SYSTEM…………………………………………………………………………………………………..3137
COMPONENT PARTS OF KomVision SYSTEM………………………………………………………………………………………………..3139
KomVision CONTROLLER………………………………………………………………………………………………………….3139
KomVision MONITOR…………………………………………………………………………………………………………….3144
KomVision CAMERA……………………………………………………………………………………………………………..3149
TESTING AND ADJUSTING KomVision SYSTEM…………………………………………………………………………………………………3150
SET AND OPERATE KomVision MONITOR………………………………………………………………………………………………….3150
SETTING DEFAULT OF KomVision SYSTEM…………………………………………………………………………………………….3150
TOUCH PANEL OPERATION…………………………………………………………………………………………………………3151
OPERATOR MODE AND MAINTENANCE MODE OF KomVision MONITOR…………………………………………………………………………..3151
METHOD FOR OPERATING KomVision MAINTENANCE MODE………………………………………………………………………………….3152
METHOD FOR OPERATING MAIN SETTINGS……………………………………………………………………………………………..3154
METHOD FOR CHECKING SYSTEM STATE……………………………………………………………………………………………….3161
METHOD FOR CONFIRMING ERROR LOG………………………………………………………………………………………………..3162
HOW TO PERFORM CHCKDSK………………………………………………………………………………………………………..3163
METHOD FOR INITIALIZING KomVision CONTROLLER…………………………………………………………………………………….3164
CAMERA CALIBRATION……………………………………………………………………………………………………………….3165
7 CAMERA CALIBRATION……………………………………………………………………………………………………………..3166
CALIBRATION SHEET…………………………………………………………………………………………………………….3166
METHOD FOR OPERATING 7 CAMERA CALIBRATION……………………………………………………………………………………….3177
1 CAMERA CALIBRATION……………………………………………………………………………………………………………..3191
METHOD FOR USING 1 CAMERA CALIBRATION…………………………………………………………………………………………..3191
TROUBLESHOOTING OF KomVision SYSTEM……………………………………………………………………………………………………3196
RELATED INFORMATION ON TROUBLESHOOTING…………………………………………………………………………………………………3197
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…………………………………………………………………………………3197
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER…………………………………………………………………………..3197
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK………………………………………………………………..3197
PROCEDURE FOR TESTING AND TROUBLESHOOTING…………………………………………………………………………………………..3202
SYMPTOM AND TROUBLESHOOTING NUMBERS………………………………………………………………………………………………..3206
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE………………………………………………………………………………………3207
CONNECTORS LIST AND LAYOUT………………………………………………………………………………………………………..3209
FAILURE CODES TABLE………………………………………………………………………………………………………………….3225
FAILURE CODE [DBP0KM]…………………………………………………………………………………………………………….3226
FAILURE CODE [DBP0KT]…………………………………………………………………………………………………………….3227
FAILURE CODE [DBP0MC]…………………………………………………………………………………………………………….3228
FAILURE CODE [DBP0NR]…………………………………………………………………………………………………………….3229
FAILURE CODE [DBP5KP]…………………………………………………………………………………………………………….3230
FAILURE CODE [DBPLKA]…………………………………………………………………………………………………………….3233
FAILURE CODE [DBPLKB]…………………………………………………………………………………………………………….3236
FAILURE CODE [DBPQKR]…………………………………………………………………………………………………………….3238
FAILURE CODE [DBPRKR]…………………………………………………………………………………………………………….3243
FAILURE CODE [DBPUKR]…………………………………………………………………………………………………………….3249
FAILURE CODE [DBPVKR]…………………………………………………………………………………………………………….3259
FAILURE CODE [DBPWKR]…………………………………………………………………………………………………………….3269
FAILURE CODE [DBPXKR]…………………………………………………………………………………………………………….3271
FAILURE CODE [DPQ1LD]…………………………………………………………………………………………………………….3274
FAILURE CODE [DPQ4KB]…………………………………………………………………………………………………………….3275
FAILURE CODE [DR10KA]…………………………………………………………………………………………………………….3276
FAILURE CODE [DR20KA]…………………………………………………………………………………………………………….3278
FAILURE CODE [DR30KA]…………………………………………………………………………………………………………….3280
FAILURE CODE [DR40KA]…………………………………………………………………………………………………………….3282
FAILURE CODE [DR50KA]…………………………………………………………………………………………………………….3284
FAILURE CODE [DR60KA]…………………………………………………………………………………………………………….3286
FAILURE CODE [DR90KA]…………………………………………………………………………………………………………….3288
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…………………………………………………………………………………………..3290
E-67 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS………………………………………………………………………..3290
E-68 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY………………………………………………………………………………3294
E-69 KomVision MONITOR CANNOT BE TOUCH……………………………………………………………………………………………..3301
E-70 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL…………………………………………………………………………….3304
E-71 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR………………………………………………………………..3307
E-72 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION…………………………………………………………….3309
90 CIRCUIT DIAGRAMS……………………………………………………………………………………………………………………..3311
CONTENTS……………………………………………………………………………………………………………………………3312
ABBREVIATION LIST……………………………………………………………………………………………………………………3313
HYDRAULIC CIRCUIT DIAGRAM…………………………………………………………………………………………………………….3319
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…………………………………………………………………………………………..3319
HYDRAULIC CIRCUIT DIAGRAM…………………………………………………………………………………………………………3323
ELECTRICAL CIRCUIT DIAGRAM……………………………………………………………………………………………………………3325
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM………………………………………………………………………………………….3325
ELECTRICAL CIRCUIT DIAGRAM (1/29)………………………………………………………………………………………………….3329
ELECTRICAL CIRCUIT DIAGRAM (2/29)………………………………………………………………………………………………….3331
ELECTRICAL CIRCUIT DIAGRAM (3/29)………………………………………………………………………………………………….3333
ELECTRICAL CIRCUIT DIAGRAM (4/29)………………………………………………………………………………………………….3335
ELECTRICAL CIRCUIT DIAGRAM (5/29)………………………………………………………………………………………………….3337
ELECTRICAL CIRCUIT DIAGRAM (6/29)………………………………………………………………………………………………….3339
ELECTRICAL CIRCUIT DIAGRAM (7/29)………………………………………………………………………………………………….3341
ELECTRICAL CIRCUIT DIAGRAM (8/29)………………………………………………………………………………………………….3343
ELECTRICAL CIRCUIT DIAGRAM (9/29)………………………………………………………………………………………………….3345
ELECTRICAL CIRCUIT DIAGRAM (10/29)…………………………………………………………………………………………………3347
ELECTRICAL CIRCUIT DIAGRAM (11/29)…………………………………………………………………………………………………3349
ELECTRICAL CIRCUIT DIAGRAM (12/29)…………………………………………………………………………………………………3351
ELECTRICAL CIRCUIT DIAGRAM (13/29)…………………………………………………………………………………………………3353
ELECTRICAL CIRCUIT DIAGRAM (14/29)…………………………………………………………………………………………………3355
ELECTRICAL CIRCUIT DIAGRAM (15/29)…………………………………………………………………………………………………3357
ELECTRICAL CIRCUIT DIAGRAM (16/29)…………………………………………………………………………………………………3359
ELECTRICAL CIRCUIT DIAGRAM (17/29)…………………………………………………………………………………………………3361
ELECTRICAL CIRCUIT DIAGRAM (18/29)…………………………………………………………………………………………………3363
ELECTRICAL CIRCUIT DIAGRAM (19/29)…………………………………………………………………………………………………3365
ELECTRICAL CIRCUIT DIAGRAM (20/29)…………………………………………………………………………………………………3367
ELECTRICAL CIRCUIT DIAGRAM (21/29)…………………………………………………………………………………………………3369
ELECTRICAL CIRCUIT DIAGRAM (22/29)…………………………………………………………………………………………………3371
ELECTRICAL CIRCUIT DIAGRAM (23/29)…………………………………………………………………………………………………3373
ELECTRICAL CIRCUIT DIAGRAM (24/29)…………………………………………………………………………………………………3375
ELECTRICAL CIRCUIT DIAGRAM (25/29)…………………………………………………………………………………………………3377
ELECTRICAL CIRCUIT DIAGRAM (26/29)…………………………………………………………………………………………………3379
ELECTRICAL CIRCUIT DIAGRAM (27/29)…………………………………………………………………………………………………3381
ELECTRICAL CIRCUIT DIAGRAM (28/29)…………………………………………………………………………………………………3383
ELECTRICAL CIRCUIT DIAGRAM (29/29)…………………………………………………………………………………………………3385
INDEX…………………………………………………………………………………………………………………………………..3387