Professional Documents
Culture Documents
CRAWLER DOZER
1150K
TIER 3
87634755 NA
Replaces 87578807 NA
Issued 01July07
SERVICE CODES
ENGINES
2-1
COOLING SYSTEM
2-2
INTAKE SYSTEM
2-4
EXHAUST SYSTEM
2-5
2-6
2-7
2-8
LUBRICATION SYSTEM
2-10
FUEL SYSTEM
3-1
3-1
3-2
3-2
3-3
ELECTRICAL
4-1
4-1
4-2
4-2
INSTRUMENTATION
4-4
4-4
4-4
ELECTRIC LAMPS
4-5
ELECTRIC MOTORS
4-6
ELECTRICAL ACCESSORIES
4-6
STEERING / UNDERCARRIAGE
5-1
5-1
5-1
5-2
5-3
POWER TRAIN
6-1
PUMP DRIVE
6-2
6-2
6-3
6-3
6-3
6-3
PLANETARIES
6-5
FINAL DRIVES
6-5
6-5
BRAKES
7-1
7-1
BRAKE VALVES
7-1
BRAKE CYLINDERS
7-1
OPERATOR CONTROLS
7-2
HYDRAULIC SYSTEMS
8-1
8-1
HYDRAULIC PUMPS
8-2
8-2
HYDRAULIC VALVES
8-3
8-4
8-6
8-6
8-7
8-7
8-7
9-1
9-1
9-2
ENVIRONMENT CONTROLS
9-4
CAB
9-4
PROTECTIVE STRUCTURES
9-8
9-8
9-9
9-9
9-10
9-11
9-11
9-12
10-1
DECEMBER 2006
23
45
SERVICE PUBLICATIONS
INDEX SYSTEM
2 ENGINES
3 FUEL SYSTEM
4 ELECTRICAL
5 STEERING SYSTEM
6 DRIVE SYSTEM
7 BRAKES
8 HYDRAULIC SYSTEM
9 CHASSIS / STRUCTURE / MOUNTED EQUIPMENT
03
11
LOCATION = FUEL
FUEL TANK
DIESEL ENGINE
03
LOCATION = FUEL
11
C
FUEL TANK, R&I = 2.0 HOURS
FUEL TANK
DIESEL ENGINE
MACHINE
LOCATION
82621
JOB
CODE
1.0
82621 A
1.9
82621 B
BE AWARE!!
CODES LISTED BELOW CAN NEVER BE USED AS MACHINE LOCATIONS.
EXAMPLE: NUMBERS NOT TO USE
20001
30002
40002
40003
80002
200
300 --01 - MAINTENANCE
400
600 --02 - TROUBLESHOOTING
700
800 --03 - REMOVE & INSTALL OR OVERHAUL
900
CODES ENDING IN ____01 MAINTENANCE, ____ 02 TROUBLESHOOTING, AND ____ 03 REMOVE & INSTALL
FOR JOB CODES ONLY. FOR THESE MACHINE LOCATIONS GO INTO THE BOOK
OR OVERHAUL, ARE
SERVICE CODES
SERVICE CODES ARE ENTERED ON A SAR TO IDENTIFY "HOW" OR "WHY" THE PRIME PART FAILED.
ONLY THE APPROVED CODES LISTED ON PAGE 6 MAY BE USED.
JOB CODE
EXAMPLE:
CRAWLERS
1150K
MACHINE
LOCATION
82621
JOB
CODE
1.0
82621 A
1.9
82621 B
JOB TIME
THE CODE MANUALS HAVE BEEN WRITTEN SO THAT MOST SARS CAN BE COMPLETED WITH ONE JOB CODE FOR
EACH PRIME PART. WHEN A JOB TIME IS GIVEN, IT COVERS ALL OPERATIONS NECESSARY TO PERFORM THE JOB
DESCRIBED. THE TIME INCLUDES THE R&I OF ALL PARTS OR COMPONENTS NECESSARY TO GAIN ACCESS TO THE
PART OR COMPONENT DESCRIBED.
JOB TIME (LABOR HOURS) IN THE COLUMN UNDER THE MODELS THE JOB CODE APPLIES TO IS GIVEN IN HOURS
AND TENTHS OF HOURS.
***
OPEN BOX
(NO TIME) MEANS A TIME HAS NOT BEEN DETERMINED FOR THIS MODEL, BUT JOB CODE IS APPLICABLE.
BECAUSE THE MANUALS ARE WRITTEN IN THIS STYLE, THERE IS THE OCCASIONAL SAR THAT WILL COMBINE
(OVERLAP) TWO JOB CODES WHICH INCLUDES THE R&I OF THE SAME PART IN EACH JOB TIME GIVEN.
THE
COMPUTER WILL APPROVE AND PAY THE HOURS REQUESTED UNDER A JOB CODE AS LONG AS THE REQUESTED
HOURS DO NOT EXCEED THE GIVEN JOB TIMES AND THE LESSER TIME IS REQUESTED.
EXAMPLE: AN ENGINE SHORT BLOCK IS INSTALLED AND A VALVE GRIND IS NECESSARY ON A CRAWLER.
JOB CODE 20303 B AND 20347 B BOTH INCLUDE R&I THE HEAD. THE REQUEST SHOULD BE FOR:
20.0
18.0 20303 B +
2.0 20347 B =
TOTAL
THE TIME REQUESTED UNDER 20347 B IS ITS GIVEN TIME OF 7.3 HOURS, MINUS THE GIVEN TIME FOR
20345 A R&I HEAD 5.3 HOURS.
REMEMBER, AN OVERHAUL JOB CODE SUCH AS 82621 B INCLUDES EVERYTHING COMPLETELY AND NO
ADDITIONAL JOB CODES ARE NEEDED.
THE TIMES IN THIS "MACHINE LOCATION JOB CODE MANUAL" ARE BASED ON TIME STUDIES AND / OR ACTUAL
WARRANTY CLAIMS SUBMITTED BY DEALERS.
THE TIMES GIVEN WILL NOT INCLUDE ANY OF THE ITEMS LISTED AS NON-REIMBURSABLE IN THE
"WARRANTY POLICY MANUAL" (SECTION 4 IN THE DEALER OPERATING GUIDE).
TROUBLESHOOTING TIME
TROUBLESHOOTING IS A SPECIFIC JOB. TIMES ARE LISTED IN VARIOUS SECTIONS OF THE MANUAL FOR THE HOOKUP OF
THE TEST INSTRUMENTS AND THE PROPER RUNNING OF THE TESTS REQUIRED.
ONLY IN SPECIFIC CASES IS TROUBLESHOOTING INCLUDED AS PART OF THE JOB TIME. FOR EXAMPLE, R&I MAIN RELIEF
VALVE INCLUDES PRESSURE TESTING AND ADJUSTING JUST AS R&I SECONDARY RELIEF VALVE INCLUDES HAND-PUMPING
AND ADJUSTING. IF TROUBLESHOOTING TIME IS INCLUDED, IT WILL BE NOTED IN THE JOB DESCRIPTION.
WELDING TIME
WITH THE FLAT RATE TIMES, WELDING (WHEN PERFORMED BY THE DEALERSHIP) IS ONLY ADDITIONAL TIME TO BE
CONSIDERED. ALL REQUESTS FOR LABOR MUST BE ACCOMPANIED WITH A JOB CODE.
A REQUEST FOR WELDING LABOR IS TO BE MADE BY PICKING THE JOB CODE FOR THE COMPONENT OR PART ON WHICH THE
WELDING WAS PERFORMED AND THEN ADD " W" AS A SECOND ALPHA TO THE JOB CODE.
EXAMPLE:
A MAIN FRAME, R&I JOB CODE IS 90111 A -- WELDING WOULD BE REQUESTED UNDER JOB CODE 90111 AW
AND LABOR CALCULATED BY THE FOLLOWING GUIDELINES :
= OPEN BOX
A JOB CODE MUST ALWAYS BE USED WHEN REQUESTING LABOR; HOWEVER, WHEN NO JOB TIMES ARE GIVEN, USE THE
FOLLOWING GUIDELINES TO CALCULATE:
1. CONSIDER THAT A TRAINED 1ST CLASS MECHANIC PERFORMED THE REPAIRS, IN THE DEALERSHIP'S "CERTIFIED" SHOP.
2. INCLUDE IN THE JOB TIME, CLEANING OF THE AREA TO BE REPAIRED AND THE ACTUAL REPAIR JOB INCLUDING
ASSOCIATED PROBLEMS ENCOUNTERED. TIMES REQUESTED WILL BE CONSIDERED USING THE CURRENT WARRANTY
POLICIES & PROCEDURES.
4. THE JOB TIME IS NOT TO INCLUDE ANY OF THE ITEMS LISTED AS NON-REIMBURSABLE IN THE WARRANTY POLICY MANUAL
(SECTION 4 IN THE DEALER OPERATING GUIDE).
DEFINITIONS
R&I - REMOVE AND INSTALL
INCLUDES REMOVING AN EXISTING PART OR COMPONENT AND INSTALLING THE SAME ONE OR A REPLACEMENT.
INCLUDES THE R&I OF ALL PARTS OR COMPONENTS NECESSARY TO GAIN ACCESS TO THE PART OR
COMPONENT DESCRIBED.
REPLACE - INCLUDES REMOVAL OF AN EXISTING PART AND INSTALLING A NEW OR DIFFERENT PART.
EXAMPLE: FILTER ELEMENTS
OVERHAUL - INCLUDES:
- R&I OF THE COMPONENT
- COMPLETE DISASSEMBLY
- INSPECTION FOR WEAR OR DAMAGE
- CLEANING OF ALL PARTS
- REASSEMBLY, CHECKING ALL TOLERANCES
- REPLACING ALL RELATED FILTER ELEMENTS
- RENEWING ALL OILS & LUBRICANTS
- REPLACING ALL SEALS, GASKETS, O-RINGS, ETC.
- PROPER RUN-IN WHEN NECESSARY
- REQUIRED ADJUSTMENTS
EXAMPLE:
CRAWLERS
1150K
MACHINE
LOCATION
JOB
CODE
82621
1.0
82621 A
1.9
82621 B
SERVICE CODES
APPROVED FOR CARES SYSTEM
ADHESION/BONDING -005
ADJUSTMENT (WHY) - 010
APPEARANCE (DESCRIBE) - 015
CHATTERS/NOISY - 065
CHIPPED/NICKED - 070
CLAMPING-POOR/NONE - 075
COLLAPSED - 080
CONNECTION-POOR - 085
CONTAMINATED (DESCRIBE) - 090
CRACKED (DESCRIBE) - 095
CREEPING OR LEAKING DOWN - 100
CUT/TORN - 105
GLAZED/GRABBING - 150
GROOVED - 155
HIGH FUEL CONSUMPTION - 160
HIGH OIL CONSUMPTION - 165
INTERFERENCE/RUBBING - 170
JUMPS OUT OF GEAR - 175
KINKED/PINCHED - 180
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
DIESEL ENGINES
NOTE: ALL ENGINE REPAIR JOB CODES INCLUDE
RUN-IN PROCEDURES, ADJUSTMENTS,
CLEANING & PAINTING IF NECESSARY.
REFER TO INTRODUCTION PAGE 3 JOB TIME.
MAINTENANCE
FILTER ELEMENT, REPLACE
- ENGINE OIL
0.3
20401 A
0.4
20401 B
0.3
20402 A
0.4
20402 B
INJECTION SYSTEM TEST - FUEL LINE & COMMON RAIL FUEL FLOW TEST
FOR ALL CYLINDERS
1.5
20402 C
0.4
20402 D
0.3
20402 E
0.8
20402 F
- AIR CLEANER
TROUBLESHOOTING
2-1
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
14.0
20403 A
25.1
20403 B
35.9
20403 C
0.1
20411 A
0.4
20411 B
0.5
20411 C
3.0
20411 D
COOLING SYSTEM
RADIATOR CAP & HOSES
20411
20411 E
DRAIN HOSE / CAP PLUG OR SHUT OFF VALVE COOLING SYSTEM, R&I
0.4
20411 F
0.4
20411 G
2-2
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
20413
2.0
20413 A
1.0
20415 A
0.4
20415 B
0.4
20415 C
1.9
20415 D
2.0
20415 E
0.7
20417 A
THERMOSTAT, R&I
(INCLUDES REPLACING GASKETS)
0.7
20419 A
0.7
20419 B
0.8
20419 C
FANS, BELTS
20415
20417
20419
2-3
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
INTAKE SYSTEM
AIR CLEANER & PRE-CLEANER
20421
0.3
20421 A
0.2
20421 B
0.1
20421 C
0.8
20421 D
0.5
20421 E
0.3
20423 A
0.5
20423 B
TURBOCHARGER, R&I
1.4
20425 A
TURBOCHARGER, OVERHAUL
(INCLUDES JOB CODE 20425 A)
2.9
20425 B
0.9
20425 C
0.3
20425 D
20423
TURBOCHARGER
20425
2-4
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
INTAKE MANIFOLDS
JOB CODE
20427
1.2
20427 A
0.7
20427 B
0.3
20431 A
MUFFLER, R&I
0.3
20431 B
0.5
20431 C
2.3
20433 A
20429
EXHAUST SYSTEM
EXHAUST MUFFLERS & EXTENSIONS
20431
20433
2-5
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
20441
0.3
20441 A
1.0
20443 A
3.5
20443 B
1.2
20443 C
3.5
20443 D
6.0
20445 A
7.0
20445 B
20443
- ALL CYLINDERS
CYLINDER HEADS
,
,(
20445
- CLEANING HEAD
- REPLACING GASKETS
- ADJUSTING VALVES
CYLINDER HEAD, REPLACE, (INCLUDES)
- TRANSFER OF PARTS
- JOB CODE 20445 A
20445 C
2-6
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
20447
6.8
20447 A
8.3
20447 B
8.5
20447 C
20447 D
20451
- ALL PISTONS
PISTON, R&I (INCLUDES)
- CHECKING PISTON & CYLINDER TOLERANCES
- FITTING PISTON PIN
- ONE
- ALL
CYLINDER BORE, OVER SIZE (INCLUDES)
- FITTING & ASSEMBLING OVER SIZE PISTON
- ONE
17.9
20451 A
19.9
20451 B
17.9
20451 C
20.7
20451 D
20451 E
20451 F
- ALL
2-7
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
20455
8.2
20455 A
10.0
20455 B
17.9
20455 C
19.7
20455 D
0.8
20461 A
1.5
20461 B
0.3
20461 C
9.5
20461 D
0.3
20461 E
10.2
20463 A
7.6
20463 B
- ALL
CONNECTING ROD ASSEMBLY, R&I
- ONE
- ALL
TIMING GEARS
20461
20463
2-8
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
20465
15.6
20465 A
LIFTERS, R&I
17.2
20465 B
7.5
20467 A
12.3
20467 B
31.5
20468 A
20467
20468
20468 B
20469
FLYWHEEL, R&I
7.0
20469 A
7.5
20469 B
7.3
20469 C
2-9
ENGINES
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
LUBRICATION SYSTEM
OIL PAN & DIPSTICK
20471
0.1
20471 A
0.4
20471 B
0.4
20471 C
0.3
20471 D
2.5
20471 E
3.0
20473 A
2.2
20473 B
20473
OIL PUMP DRIVE GEAR, R&I - ON CRANKSHAFT (INCLUDES JOB CODE 20461 D)
20473 C
20475
1.2
20475 A
1.0
20475 B
0.4
20477 A
0.4
20477 B
EXTERNAL LUBRICATION
TUBES & HOSES
20477
2-10
FUEL SYSTEM
JOB CODE
30401 A
1.2
30402 A
0.1
30411 A
0.4
30411 B
2.0
30411 C
0.4
30413 A
0.4
30413 B
0.9
30413 C
0.3
30413 D
0.3
30413 E
0.3
30413 F
0.2
30413 G
0.9
30413 H
TROUBLESHOOTING
FUEL INJECTION PUMP, CHECK & ADJUST TIMING
30411
30413
3-1
FUEL SYSTEM
JOB CODE
30421
0.9
30421 A
0.2
30421 B
2.5
30431 A
4.1
30431 B
0.3
30431 C
0.3
30433 A
0.6
30433 B
- #2 CYLINDER
0.6
30433 C
- #3 CYLINDER
0.6
30433 D
- #4 CYLINDER
0.6
30433 E
- #5 CYLINDER
0.7
30433 F
- #6 CYLINDER
0.7
30433 G
- ALL CYLINDERS
2.0
30433 H
1.3
30433 I
0.3
30433 J
30431
30433
3-2
FUEL SYSTEM
FUEL INJECTORS
JOB CODE
30435
- ALL
1.2
30435 A
2.7
30435 B
0.5
30443 A
0.7
30443 B
30443
(INCLUDES BUSHINGS)
3-3
NOTES
ELECTRICAL
1150 K TIER III CRAWLER DOZER
1150 K
MACHINE
LOCATION
JOB CODE
ELECTRICAL
TROUBLESHOOTING
BATTERY, CHECK & TEST - ALL
(HYDROMETER & LOAD TEST)
0.5
40002 A
0.8
40002 B
1.0
40002 C
1.0
40002 D
1.0
40002 E
0.3
40002 F
1.4
40110 A
0.5
40110 B
0.3
40110 C
2.0
40120 A
1.5
40120 B
1.5
40120 C
1.5
40120 D
40110
MAIN WIRING
40120
4-1
ELECTRICAL
1150 K TIER III CRAWLER DOZER
1150 K
MACHINE
LOCATION
LAMP WIRING
JOB CODE
40160
0.8
40160 A
1.0
40160 B
1.0
40170 A
2.0
40170 B
2.5
40170 C
- AIR CONDITIONING
2.0
40170 D
0.1
40510 A
0.1
40510 B
FUSE, R&I
0.1
40520 A
0.8
40520 B
0.4
40530 A
0.4
41512 A
40170
40510
FUSES
40520
RESISTORS
40530
RESISTOR, R&I
41512
4-2
ELECTRICAL
1150 K TIER III CRAWLER DOZER
1150 K
MACHINE
LOCATION
FUEL SHUTOFF
JOB CODE
41513
0.2
41513 A
0.5
41515 A
0.5
41515 B
0.6
41515 C
0.5
41515 D
0.2
41531 A
0.5
41540 A
1.0
41540 B
0.6
41540 C
0.5
41540 D
0.5
41540 E
0.3
41540 F
41515
CAB RELAYS
41531
ELECTRICAL CONTROLS
41540
- LEFT
4-3
ELECTRICAL
1150 K TIER III CRAWLER DOZER
1150 K
MACHINE
LOCATION
JOB CODE
INSTRUMENTATION
GAUGES, INDICATOR LAMPS & SENDERS
42010
0.4
42010 A
0.5
42010 B
0.5
42010 C
0.5
42010 D
0.4
42010 E
2.0
42010 F
0.5
42010 G
0.3
42040 A
0.8
42510 A
1.6
42510 B
2.8
42510 C
0.4
42550 A
1.0
42550 B
0.5
42550 C
(ONE)
INSTRUMENT PANEL
42040
42510
BATTERIES
42550
- BOTH
BATTERY SUPPORT BRACKET, R&I
(INCLUDES JOB CODE 42550 B)
4-4
ELECTRICAL
1150 K TIER III CRAWLER DOZER
1150 K
MACHINE
LOCATION
JOB CODE
ELECTRICAL CHARGING
COMPONENTS
ALTERNATOR
43010
ALTERNATOR, R&I
0.8
43010 A
1.8
43010 B
0.3
43010 C
0.4
43030 A
0.3
43550 A
0.3
43550 B
0.3
43550 C
0.4
43560 A
0.3
43560 B
0.2
43560 C
43030
ELECTRIC LAMPS
WORK LAMPS
43550
CONSOLE LAMPS
(DOME, PANEL)
43560
4-5
ELECTRICAL
1150 K TIER III CRAWLER DOZER
1150 K
MACHINE
LOCATION
JOB CODE
ELECTRIC MOTORS
HEATER / AIR CONDITIONER
44010
2.0
44010 A
2.0
44010 B
1.4
44010 C
0.5
44010 D
0.5
44010 E
0.7
44010 F
AC CONTROLLER
0.5
44010 G
0.7
44020 A
- REAR
0.6
44020 B
- DOOR
0.6
44020 C
0.3
44020 D
0.3
44020 E
SWITCH, R&I
0.4
44020 F
0.3
44510 A
0.5
44510 B
HORN, R&I
0.3
44510 C
0.3
44510 D
WIPER MOTOR
44020
ELECTRICAL ACCESSORIES
BACKUP ALARM / HORN
44510
4-6
ELECTRICAL
1150 K TIER III CRAWLER DOZER
1150 K
MACHINE
LOCATION
JOB CODE
44550
0.7
44550 A
0.4
44550 B
1.0
44550 C
0.5
44570 A
SPEAKER, R&I
0.3
44570 B
ANTENNA, R&I
0.1
44570 C
2.0
44570 D
0.5
44570 E
0.3
44580 A
44570
44580
4-7
NOTES
JOB CODE
CRAWLER UNDERCARRIAGE
MAINTENANCE
1.8
55001 A
5.9
55011 A
8.0
55011 B
0.8
55013 A
- CENTER
1.1
55013 B
- REAR
1.1
55013 C
0.4
55013 D
0.8
55013 E
1.0
55021 A
1.0
55023 A
2.7
55023 B
0.3
55023 C
55011
55013
RECOIL MECHANISM /
TRACK ADJUSTERS / IDLERS
TRACK RECOIL MECHANISM
55021
TRACK ADJUSTERS
55023
5-1
JOB CODE
55025
1.3
55025 A
2.6
55025 B
3.2
55025 C
0.5
55031 A
1.1
55031 B
CARRIER ROLLER, REPLACE SEAL, BUSHING & SHAFT, & FILL WITH
LUBRICANT (INCLUDES JOB CODE 55031 A)
1.3
55031 C
0.5
55031 D
1.1
55033 A
2.1
55033 B
1.8
55033 C
3.0
55033 D
2.4
55033 E
3.5
55033 F
55031
TRACK ROLLERS
55033
5-2
JOB CODE
55035
1.5
55035 A
- TWO
(INCLUDES INSTALLING SHIMS - ALIGNMENT)
3.0
55035 B
0.8
55041 A
1.7
55041 B
2.1
55041 C
6.6
55041 D
PIN & BUSHING KIT, R&I -SEALED TRACK(INCLUDES JOB CODE 55041 B)
12.9
55041 E
PIN & BUSHING KIT, R&I - LUBED TRACK (INCLUDES JOB CODE 55041 B)
19.3
55041 F
PIN & BUSHING KIT, R&I - EXTENDED LIFE TRACK (INCLUDES JOB CODE 55041 B)
19.3
55041 G
0.5
55045 A
- ONE SIDE
5.5
55045 B
- BOTH SIDES
10.8
55045 C
55041
TRACK SHOES
55045
5-3
NOTES
POWER TRAIN
JOB CODE
POWER TRAIN
MAINTENANCE
DRAIN & FILL
- FINAL DRIVE OIL (ONE)
0.4
60001 A
0.5
60002 A
0.5
60002 B
1.5
60002 C
1.5
60002 D
0.5
60002 E
TROUBLESHOOTING
NOTE: ALL POWER TRAIN TROUBLESHOOTING
CODES INCLUDE 20302 A.
6-1
POWER TRAIN
JOB CODE
6.5
60003 A
60003 B
60003 C
3.0
60003 D
60003 E
3.0
60003 F
3.7
60003 G
3.5
60003 H
5.7
60003 J
2.0
61031 A
2.6
61031 B
PUMP DRIVE
PUMP DRIVE
61031
HYDRAULIC (HYDROSTATIC)
TRANSMISSION RESERVOIRS &
FILTERS
NOTE: FOR REPAIRS ON HYDRAULIC RESERVOIR REFER TO MACHINE
LOCATION IN 82611.
6-2
POWER TRAIN
FILTERS
JOB CODE
62713
0.8
62713 A
1.0
62741 A
1.0
62751 A
0.7
62751 B
62721
62731
62741
62751
6-3
POWER TRAIN
CONTROL CIRCUIT
DIAGNOSTIC LINES
JOB CODE
62754
0.5
62754 A
0.5
62754 B
0.5
62754 C
0.5
62754 D
0.3
62754 E
0.2
62754 F
0.7
62755 A
0.5
62755 B
0.5
62755 C
0.5
62755 D
0.7
62759 A
0.7
62759 B
0.7
62759 C
0.7
62759 D
0.5
62759 E
0.5
62759 F
0.5
62759 G
RETURN LINES
62755
MOTOR LINES
62759
- LOWER
FRONT PUMP TO RIGHT HAND MOTOR LINE, R&I
- UPPER
- LOWER
6-4
POWER TRAIN
JOB CODE
PLANETARIES
PLANETARY SHAFTS, BEARINGS &
BUSHINGS
63121
PLANETARY GEARS
63123
PLANETARY HOUSING
63127
FINAL DRIVES
SHAFTS, BEARINGS & BUSHINGS
63131
63133
63135
65010
0.3
65010 A
0.5
65010 B
6-5
NOTES
BRAKES
JOB CODE
BRAKES
MAINTENANCE
0.5
70001 A
0.3
71041 A
0.3
71041 B
0.3
71041 C
0.3
71041 D
0.3
71041 E
0.8
71053 A
4.5
71061 A
4.5
71073 A
71041
BRAKE VALVES
CONTROL VALVES
71053
BRAKE CYLINDERS
BRAKE CYLINDERS
71061
BRAKE DISCS
71073
7-1
BRAKES
BRAKE HOUSINGS
(FINAL DRIVE HOUSING)
JOB CODE
71075
3.4
71075 A
- BOTH SIDES
5.9
71075 B
1.1
71081 A
0.3
71081 B
1.0
71085 A
OPERATOR CONTROLS
PEDALS & LEVERS
71081
71085
7-2
HYDRAULICS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
HYDRAULIC SYSTEM
MAINTENANCE
DRAIN & FILL
- HYDRAULIC OIL RESERVOIR
0.5
80001 A
0.3
80001 B
1.5
80001 C
0.4
80002 A
0.6
80002 B
0.7
80002 C
1.1
80002 D
2.4
80002 E
0.1
82611 A
0.3
82611 B
0.7
82611 C
2.0
82611 D
0.8
82613 A
0.8
82613 B
1.5
82613 C
TROUBLESHOOTING
- 'B' PORT
FLOW & PRESSURE TEST
COMPLETE EQUIPMENT HYDRAULIC SYSTEM
(INCLUDES JOB CODES 80002 A, B, C, & D)
82611
HYDRAULIC FILTERS
82613
8-1
HYDRAULICS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
82615
0.3
82615 A
1.0
82621 A
1.9
82621 B
1.3
82621 C
2.2
82621 D
0.7
82629 A
1.2
82631 A
0.6
82631 B
0.6
82633 A
1.2
82633 B
HYDRAULIC PUMPS
NOTE: REFER TO MACHINE LOCATION & JOB CODES IN 60003
FOR HYDROSTATIC TRANSMISSION PUMPS.
82621
82629
HYDRAULIC LINES
(BETWEEN RESERVOIR & VALVE)
PUMP INLET CIRCUIT LINES
82631
82633
8-2
HYDRAULICS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
82635
0.4
82635 A
1.0
82635 B
1.0
82635 C
1.0
82637 A
1.0
82637 B
0.8
82637 C
0.7
82641 A
1.0
82641 B
0.5
82643 A
0.6
82643 B
1.2
82643 C
2.6
82643 D
3.4
82643 E
5.1
82643 F
3.0
82643 G
COOLING LINES
82637
HYDRAULIC VALVES
MAIN RELIEF VALVE
82641
- ALL SECTIONS
CONTROL VALVE, REPLACE (ONE SECTION)
(INCLUDES JOB CODE 82643 D)
8-3
82643
HYDRAULICS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
82645
1.2
82645 A
- 'B' PORT
(INCLUDES JOB CODE 80002 D)
1.2
82645 B
1.0
82647 A
0.5
82651 A
0.6
82651 B
0.8
82651 C
0.8
82651 D
0.8
82651 E
0.4
82651 F
0.3
82651 G
0.5
82653 A
0.6
82653 B
0.8
82653 C
0.8
82653 D
82647
82651
- 'B' PORT
LINE - CONTROL VALVE, R&I
- 'A' PORT
- 'B' PORT
82653
- 'B' PORT
LINE - CONTROL VALVE, R&I
- 'A' PORT
- 'B' PORT
8-4
HYDRAULICS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
0.5
82653 E
0.5
82653 F
0.4
82653 G
0.3
82653 H
0.5
82655 A
0.6
82655 B
0.9
82655 C
0.8
82655 D
0.7
82655 E
0.5
82655 F
0.4
82656 A
0.3
82656 B
0.5
82656 C
0.5
82656 D
1.4
82656 E
2.2
82656 F
82655
- 'B' PORT
LINE - CONTROL VALVE, R&I
- 'A' PORT
- 'B' PORT
82656
8-5
HYDRAULICS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
82659
0.4
82659 A
0.4
82659 B
0.6
82661 A
1.6
82661 B
1.8
82661 C
0.8
82663 A
1.8
82663 B
2.0
82663 C
0.6
82665 A
1.6
82665 B
1.8
82665 C
3.5
82681 A
- 'B' PORT
82661
82663
82665
82681
8-6
HYDRAULICS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
82691
CABLES / LINKAGE
82693
85051
0.5
85051 A
0.7
85051 B
0.6
85051 C
0.7
85051 D
0.3
85051 E
0.3
85051 F
0.5
85061 A
1.2
85061 B
1.6
85061 C
- 'B' PORT
LINE - CONTROL VALVE, R&I
- 'A' PORT
- 'B' PORT
85061
8-7
NOTES
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
CHASSIS / STRUCTURE
MOUNTED EQUIPMENT
MAINTENANCE
NOTE: 90001, 90002 & 90003 ARE NOT MACHINE LOCATION
NUMBERS. GO TO SPECIFIC LOCATION.
1.2
90001 A
1.0
90002 A
3.6
90003 A
3.4
90003 B
TROUBLESHOOTING
TEST AIR CONDITIONING SYSTEM USING
LEAK DETECTOR & MANIFOLD GAUGES
90111
90111 A
90115
7.5
90115 A
1.2
90115 B
1.2
90115 C
0.5
90115 D
1.0
90115 E
0.8
90115 F
1.5
90115 G
- REAR
TANDEM PUMP MOUNT, R&I
- ONE
- ALL
9-1
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
90117
COUNTERWEIGHT, R&I
1.4
90117 A
DRAWBAR, R&I
0.4
90117 B
0.4
90117 C
- REAR
0.3
90117 D
0.4
90131 A
0.4
90131 B
0.5
90131 C
0.2
90131 D
0.1
90131 E
0.3
90131 F
0.3
90131 G
0.4
90131 H
0.3
90131 J
0.1
90131 K
PROTECTIVE COVERINGS
APPEARANCE / CONVENIENCE
HOOD & SIDE PANELS
90131
9-2
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
90132
0.4
90132 A
0.2
90132 B
0.6
90132 C
0.3
90132 D
0.4
90135 A
0.4
90135 B
0.3
90135 C
0.4
90135 D
0.3
90135 E
0.3
90136 A
0.2
90136 B
0.3
90136 C
90135
90136
90137
PAINTING
90137 A
REPLACE DECALS
90137 B
9-3
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
ENVIRONMENT CONTROLS
SOUND CONTROL
90141
90141 A
90142
1.6
90142 A
1.7
90142 B
2.0
90142 C
0.2
90142 D
0.4
90142 E
1.4
90142 F
0.2
90142 G
CAB TILT
0.4
90311 A
0.8
90311 B
2.8
90311 C
CAB
CAB FRAME & HARDWARE
90311
9-4
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
90313
0.3
90313 A
0.5
90313 B
0.2
90313 C
0.2
90313 D
2.0
90313 E
WINDOW, R&I
- DOOR
1.0
90313 F
- WINDSHIELD
1.0
90313 G
- REAR CORNER
1.0
90313 H
- REAR
1.0
90313 J
0.5
90313 K
0.2
90313 L
0.3
90313 M
0.2
90313 N
0.3
90313 P
0.1
90313 Q
0.4
90313 R
0.1
90313 S
0.3
90313 T
9-5
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
90315
0.8
90315 A
1.8
90315 B
1.0
90315 C
1.0
90315 D
0.6
90315 E
1.0
90315 F
1.0
90315 G
0.5
90315 H
0.8
90317 A
0.7
90317 B
0.7
90317 C
0.7
90317 D
0.7
90317 E
0.7
90317 F
0.9
90317 G
1.0
90317 H
1.2
90317 J
- ENGINE
9-6
90317
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
0.7
90317 K
1.9
90317 L
0.6
90317 M
1.2
90317 N
1.5
90317 P
0.4
90317 Q
0.7
90317 R
0.3
90317 S
- SIDES
0.5
90317 T
- FRONT OR REAR
0.5
90317 U
1.5
90317 V
0.4
90318 A
0.4
90318 B
HEADLINER, R&I
1.0
90319 A
0.4
90319 B
OPERATORS CONSOLE /
INSTRUMENT PANEL HOUSING
90318
- RIGHT SIDE
90319
9-7
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
PROTECTIVE STRUCTURES
ROLL OVER PROTECTION - ROPS
90321
0.8
90321 A
0.3
90321 B
0.3
90321 C
2.5
90321 D
0.5
90331 A
1.5
90331 B
1.0
90331 C
- SEAT
1.0
90331 D
0.2
90331 E
SUPPORT, R&I
(INCLUDES CONSOLE REMOVAL)
0.9
90331 F
0.8
90331 G
3.0
90331 H
2.0
90331 J
0.4
90331 K
0.8
90331 L
0.7
90331 M
- REAR
90331
9-8
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
1.2
90331 N
1.4
90331 P
0.6
90331 Q
0.3
90333 A
3.4
92611 A
1.0
92611 B
0.5
92611 C
0.3
92621 A
1.0
92621 B
0.3
92621 C
0.3
92623 A
1.0
92623 B
0.3
92623 C
1.1
92623 D
SEAT BELTS
90333
92611
- END
92621
9-9
92623
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
92625
0.3
92625 A
0.7
92625 B
0.3
92625 C
1.1
92625 D
0.4
92625 E
1.0
92627 A
2.0
92627 B
2.5
92627 C
0.4
92629 A
1.1
92629 B
4.5
92633 A
0.2
92639 A
0.3
92639 B
92627
92629
92633
92639
9-10
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
95011
0.3
95011 A
0.8
95011 B
0.5
95011 C
1.3
95011 D
0.3
95021 A
0.8
95021 B
0.3
95021 C
1.1
95021 D
0.3
95021 E
0.8
95021 F
0.3
95021 G
0.7
95021 H
0.4
95021 J
1.4
95021 K
- ALL
SHANKS FOR RIPPER TEETH, R&I
- ONE
- ALL
95021
- ALL
PINS FOR LOWER LINK, R&I
- ONE
- ALL
PINS OR ROD FOR MOUNTING SHANKS, R&I
- ONE
- ALL
- LOWER
9-11
CHASSIS
1150 K TIER III CRAWLER DOZER
1150K
MACHINE
LOCATION
JOB CODE
95031
2.5
95031 A
1.4
95031 B
1.8
95033 A
2.8
95033 B
95033
- BOTH
9-12
Labor hour adjustment requests for a specific Job Code can be submitted to the
Territory Service Manager. All related documentation MUST BE INCLUDED, i.e.,
copies of work orders, time sheets, etc.
10-1