Bur 87634755NA - J.C.M. 1150K Tier 3 (ENG)

JOB CODE MANUAL
CRAWLER DOZER
1150K
TIER 3
87634755 NA
Replaces 87578807 NA
North American English

Part Number 87634755 NA
Printed in U.S.A. Bur
Issued 01July07
1150K TIER III

CRAWLER DOZER
INDEX
INTRODUCTION
SERVICE CODES
ENGINES
2-1
COOLING SYSTEM
2-2
INTAKE SYSTEM
2-4
EXHAUST SYSTEM
2-5
CYLINDER HEADS & VALVES
2-6
SLEEVES, PISTONS & RODS
2-7
CRANKSHAFT, CAMSHAFT & TIMING TRAIN
2-8
LUBRICATION SYSTEM
2-10
FUEL SYSTEM
3-1
FUEL TANK, LINES & TRANSFER PUMP
3-1
FUEL FILTER SYSTEM
3-2
FUEL INJECTION SYSTEM
3-2
FUEL SYSTEM CONTROLS
3-3
ELECTRICAL
4-1
WIRING & HARNESSES
4-1
CIRCUIT BREAKERS / FUSES & RELAYS
4-2
SWITCHES & CONTROLS
4-2
INSTRUMENTATION
4-4
ELECTRICAL STARTER & BATTERY
4-4
ELECTRICAL CHARGING COMPONENTS
4-4
ELECTRIC LAMPS
4-5
ELECTRIC MOTORS
4-6
ELECTRICAL ACCESSORIES
4-6
STEERING / UNDERCARRIAGE
5-1
TRACK FRAMES / GUIDES
5-1
RECOIL MECHANISM / TRACK ADJUSTERS / IDLERS
5-1
TRACK ROLLERS / SPROCKETS
5-2
TRACK CHAINS & SHOES
5-3
POWER TRAIN
6-1
PUMP DRIVE
6-2
HYDRAULIC (HYDROSTATIC) TRANSMISSION RESERVOIRS & FILTERS
6-2
HYDRAULIC TRANSMISSION PUMPS
6-3
HYDRAULIC TRANSMISSION MOTORS
6-3
HYDRAULIC TRANSMISSION VALVES
6-3
HYDRAULIC TRANSMISSION LINES
6-3
PLANETARIES
6-5
FINAL DRIVES
6-5
OPERATOR CONTROLS - POWERTRAIN
6-5
BRAKES
7-1
BRAKE SYSTEM HYDRAULICS
7-1
BRAKE VALVES
7-1
BRAKE CYLINDERS
7-1
OPERATOR CONTROLS
7-2
HYDRAULIC SYSTEMS
8-1
HYDRAULIC RESERVOIRS & FILTERS
8-1
HYDRAULIC PUMPS
8-2
HYDRAULIC LINES (BETWEEN RESERVOIR & VALVE)
8-2
HYDRAULIC VALVES
8-3
DOZER HYDRAULIC LINES
8-4
DOZER HYDRAULIC CYLINDERS
8-6
OIL COOLERS / MANIFOLDS
8-6
DOZER HYDRAULIC EQUIPMENT CONTROLS
8-7
RIPPER HYDRAULIC LINES
8-7
RIPPER HYDRAULIC CYLINDERS
8-7
CHASSIS / STRUCTURE MOUNTED EQUIPMENT
9-1
MAIN FRAME & CHASSIS
9-1
PROTECTIVE COVERINGS / APPEARANCE / CONVENIENCE
9-2
ENVIRONMENT CONTROLS
9-4
CAB
9-4
PROTECTIVE STRUCTURES
9-8
SEATS / BELTS / ADJUSTERS
9-8
DOZER GROUND ENGAGING COMPONENTS
9-9
DOZER PINS, BUSHINGS & LINKS
9-9
DOZER STRUCTURAL MEMBERS
9-10
RIPPER GROUND ENGAGING COMPONENTS
9-11
RIPPER PINS, BUSHINGS & LINKS
9-11
RIPPER STRUCTURAL MEMBERS
9-12
JOB CODE REQUEST FORM
10-1
DECEMBER 2006
INTRODUCTION TO THE CARES

MACHINE LOCATION & JOB CODE SYSTEM
2ND & 3RD DIGITS INDICATE

MAJOR COMPONENT ASSEMBLY
4TH & 5TH DIGITS INDICATE

SUBCOMPONENTS
6TH POSITION IS ALPHA

CHARACTERS, USED FOR JOB
CODES & LABOR TIME
1ST DIGIT INDICATES MACHINE

LOCATION, SAME AS SERVICE
MANUAL TABS
JOB CODE >
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
SAMPLE MACHINE LOCATION CODE

3
03
11
LOCATION = FUEL
FUEL TANK
DIESEL ENGINE
SAMPLE JOB CODE

3
03
LOCATION = FUEL
11
C
FUEL TANK, R&I = 2.0 HOURS
FUEL TANK
DIESEL ENGINE
MACHINE LOCATION & PRIME PART

THE MACHINE LOCATION MUST BE ENTERED ON A
WHERE THE PRIME PART IS LOCATED.
SAR TO IDENTIFY A SPECIFIC AREA OF THE MACHINE
PRIME PART IS THE CASE PART WHICH CAUSED THE FAILURE.

EXAMPLE:
CRAWLERS
1150K
MACHINE
LOCATION
82621
MAIN SYSTEM PUMP
JOB
CODE
EQUIPMENT HYDRAULIC PUMP, R&I
1.0
82621 A
EQUIPMENT HYDRAULIC PUMP, OVERHAUL

(INCLUDES JOB CODE 82621 A)
1.9
82621 B
THE ABOVE EXAMPLE SHOWS THE
MACHINE LOCATION AS 82621 WHICH REPRESENTS THE CRAWLER
EQUIPMENT HYDRAULIC PUMP.

IF THE PRIME PART IS A NUT, BOLT, O-RING, GASKET, SEAL OR OTHER HARDWARE ITEM, SELECT THE MACHINE
LOCATION CORRESPONDING TO THE LOCATION OF THE COMPONENT WHICH THE ITEM IS A PART OF, OR TO
WHICH IT IS ATTACHED. FOR EXAMPLE, IF A BOLT ON A CONNECTING ROD IS BROKEN, THE BOLT WOULD BE
LISTED AS THE PRIME PART AND THE MACHINE LOCATION OF THE CONNECTING ROD WOULD BE USED.
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
FOR A MORE SPECIFIC LOCATION.
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
MAIN SYSTEM PUMP
JOB
CODE
1.0
82621 A

1.9
82621 B
JOB CODE - (FIVE DIGIT NUMBER WITH ONE ALPHA SUFFIX)

THE JOB CODE MUST BE ENTERED ON THE SAR FORM IN ORDER TO BE REIMBURSED FOR LABOR COSTS.
SELECTION OF JOB CODES SHOULD COVER ALL REPAIRS PERFORMED IN CORRECTING THE PROBLEM. THE JOB
CODE DOES NOT HAVE TO MATCH THE MACHINE LOCATION CODE USED, BUT IT WILL MOST OF THE TIME.
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.
***
INDICATES THAT JOB CODE DOES NOT APPLY TO THIS MODEL.
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 :
NO JOB TIME PROVIDED
= 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.
3. TROUBLESHOOTING PERFORMED SHOULD BE REQUESTED BY THE APPROPRIATE TROUBLESHOOTING JOB CODE.
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
MAIN SYSTEM PUMP

1.0
82621 A

1.9
82621 B
SERVICE CODES
APPROVED FOR CARES SYSTEM
ADHESION/BONDING -005
ADJUSTMENT (WHY) - 010
APPEARANCE (DESCRIBE) - 015
MISALIGNMENT (HOW) - 205

MISFIRING/MISSING (ENGINE) - 210
MISMACHINED (HOW) - 215
MOISTURE/CONDENSATION - 220
BACKLASH (DESCRIBE) - 020

BENT/DENTED - 025
BLEW/BLOWN/BURST (WHERE) - 030
BLISTERED - 035
BLOCKED/OBSTRUCTED (DESCRIBED) -040
BROKEN (WHERE) - 045
BUCKLED/WARPED - 050
BURNED OUT - 055
BYPASSING/BLOW BY - 060
NOT SEALING PROPERLY - 225

OPEN CIRCUIT (ELECTRICAL) - 228
OUT OF GROOVE - 230
PART OMITTED - 231
PIN HOLE/SANDHOLE/POROUS -235
PITTED - 240
PRESSURE HIGH - 245
PRESSURE LOW - 250
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
RESTRICTION (WHERE) - 255

RUSTY/CORRODED - 260
SCORED/SCRATCHED/GALLED -265
SEIZED - 270
SERVICE MODIFICATION PROGRAM (ONLY)-275
SHEARED - 280
SHIFTING DIFFICULT - 285
SHORT CIRCUIT (ELECTRICAL) - 290
SLIPPING - 295
SOFT/SPONGY - 300
STICKING/BINDING - 305
STRETCHED - 310
STRIPPED/PULLED OUT - 315
SURGING/GALLOPING - 320
DOES NOT ENGAGE - 110

DOES NOT RELEASE - 115
ELONGATED/OUT OF ROUND - 120
END PLAY - 125
ERRATIC/FLUCTUATING - 130
FELL OUT/BACKED OUT -135
FIELD SURVEY - 136
FLAKING/PEELING - 140
FRAYED - 145
TEMPERATURE HIGH - 325

TEMPERATURE LOW - 330
TORQUE HIGH - 335
TORQUE LOW - 340
TURNED/SPUN - 345
TWISTED - 350
GLAZED/GRABBING - 150
GROOVED - 155
HIGH FUEL CONSUMPTION - 160
HIGH OIL CONSUMPTION - 165
VIBRATION (DESCRIBE) - 355

WEAR/WORN (DESCRIBE) - 360
WELD/BRAZE - CRACKED/BROKE - 365
WOULD NOT HOLD CHARGE - 370
INTERFERENCE/RUBBING - 170
JUMPS OUT OF GEAR - 175
KINKED/PINCHED - 180
POST-FACTORY, PRE-DELIVERY (ONLY FOR

ZERO TO FIVE HOURS) - 555
PLANT SHIPPED SHORTAGE
("ON SITE" ASSEMBLED
MACHINERY ONLY) - 950
LAMINATING (STEEL PLATE) - 185

LENGTH (DESCRIBE) - 195
LOOSE - 200
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
RUN ENGINE UNTIL IT REACHES OPERATING TEMPERATURE

(INCLUDES VISUAL INSPECTION & CHECKING ALL
INSTRUMENT PANEL INDICATORS)
0.3
20402 A
STALL SPEED, TEST

(INCLUDES CHECKING LOW & HIGH RPM; ALSO INCLUDES
JOB CODE 20402 A)
0.4
20402 B
INJECTION SYSTEM TEST - FUEL LINE & COMMON RAIL FUEL FLOW TEST
FOR ALL CYLINDERS
1.5
20402 C
CHECK INTAKE SYSTEM FOR AIR RESTRICTION OR

INTAKE AIR LEAKS
0.4
20402 D
COOLING SYSTEM PRESSURE TEST
0.3
20402 E
TROUBLESHOOT ENGINE, INCLUDES

- CHECK COMPRESSION, CRANKCASE & BOOST PRESSURE
- ELECTRONIC DIAGNOSTIC TESTING
0.8
20402 F
- AIR CLEANER
TROUBLESHOOTING
2-1
ENGINES
1150K
MACHINE
LOCATION
JOB CODE
REMOVAL & INSTALLATION OR

OVERHAUL
NOTE: FOR UNITS WITH AIR CONDITIONING,
USE JOB CODE 90001 A (IF NECESSARY)
ALONG WITH CODES IN THIS AREA.
ENGINE ASSEMBLY, R&I (INCLUDES)
- R&I OF ANY ITEM OR COMPONENT NECESSARY
TO ACCESS ENGINE
14.0
20403 A
SHORT BLOCK ASSEMBLY, R&I (INCLUDES)

- ENGINE, R&I
- STUDS & FITTINGS, R&I
- CHECK ALL SPECIFICATIONS & TOLERANCES
- FILTER ELEMENTS, REPLACE
- DO RUN-IN PROCEDURES & ADJUSTMENTS
- CLEANING & PAINTING
25.1
20403 B
ENGINE ASSEMBLY, OVERHAUL (INCLUDES)

- ENGINE, R&I & COMPLETE DISASSEMBLY
- CLEAN ALL COMPONENTS & PASSAGES
- ASSEMBLE TO ALL SPECIFICATIONS & TOLERANCES
- DO RUN-IN PROCEDURES & ADJUSTMENTS
- CLEANING & PAINTING
35.9
20403 C
RADIATOR CAP, R&I
0.1
20411 A
COOLANT LINES, R&I

- UPPER RADIATOR HOSE (ONE)
0.4
20411 B
- LOWER RADIATOR HOSE (ONE)
0.5
20411 C
3.0
20411 D
COOLING SYSTEM
RADIATOR CAP & HOSES
20411
RADIATOR ASSEMBLY, R&I (INCLUDES)

- HOOD, HOSES & LINES R&I
- DRAIN & RE-FILL
COOLING SYSTEM FRAME, R&I
(INCLUDES REMOVING COOLING SYSTEM & HOOD R&I)
20411 E
DRAIN HOSE / CAP PLUG OR SHUT OFF VALVE COOLING SYSTEM, R&I
0.4
20411 F
COOLANT RECOVERY RESERVOIR, R&I
0.4
20411 G
2-2
ENGINES
1150K
MACHINE
LOCATION
SHROUDS & SCREENS
JOB CODE
20413
RADIATOR FAN SHROUD, R&I

(INCLUDES HOOD, R&I)
2.0
20413 A
DRIVE BELT, R&I

(ALTERNATOR, WATER PUMP, AIR CONDITIONING)
1.0
20415 A
BELT TENSIONER ASSEMBLY, R&I
0.4
20415 B
BRACKET FOR BELT TENSIONER, R&I
0.4
20415 C
RADIATOR FAN & PULLEY, R&I
1.9
20415 D
FAN HUB, BRACKET ASSEMBLY, R&I
2.0
20415 E
0.7
20417 A
THERMOSTAT, R&I
(INCLUDES REPLACING GASKETS)
0.7
20419 A
THERMOSTAT HOUSING, R&I

0.7
20419 B
WATER INLET HOUSING, R&I

0.8
20419 C
FANS, BELTS
20415
WATER PUMP & HOUSING
20417
WATER PUMP, R&I

WATER MANIFOLD, OUTLETS,

THERMOSTATS
20419
2-3
ENGINES
1150K
MACHINE
LOCATION
JOB CODE
INTAKE SYSTEM
AIR CLEANER & PRE-CLEANER
20421
AIR CLEANER INLET TUBE OR PRECLEANER, R&I
0.3
20421 A
AIR CLEANER COVER, R&I

(INCLUDES RETAINING HARDWARE)
0.2
20421 B
AIR CLEANER DUST VALVE (EVACUATOR), R&I
0.1
20421 C
AIR CLEANER ASSEMBLY, R&I

(INCLUDES MOUNTING BANDS & HARDWARE)
0.8
20421 D
MOUNTING BRACKET - AIR CLEANER, R&I
0.5
20421 E
HOSES & / OR TUBES, R&I

(BETWEEN AIR CLEANER & TURBOCHARGER)
0.3
20423 A
HOSES & / OR TUBES, R&I

(AIR COOLER TO TURBOCHARGER)
0.5
20423 B
TURBOCHARGER, R&I
1.4
20425 A
TURBOCHARGER, OVERHAUL
2.9
20425 B
ACTUATOR, R&I (TURBO WASTEGATE)

(INCLUDES ADJUSTMENTS)
0.9
20425 C
TUBE, R&I (WASTEGATE ACTUATOR)
0.3
20425 D
INTAKE HOSES & TUBES
20423
TURBOCHARGER
20425
2-4
ENGINES
1150K
MACHINE
LOCATION
INTAKE MANIFOLDS
JOB CODE
20427
COVER FOR INTAKE MANIFOLD, R&I

(INCLUDES REPLACING GASKET)
1.2
20427 A
CHARGE AIR COOLER, R&I
0.7
20427 B
EXTENSION PIPE - EXHAUST, R&I
0.3
20431 A
MUFFLER, R&I
0.3
20431 B
MOUNTING BRACKET - MUFFLER, R&I
0.5
20431 C
2.3
20433 A
COLD START AIDS
20429
NOTE: FOR COLD START ELECTRICAL SYSTEM, REFER TO

MACHINE LOCATION 44550.
EXHAUST SYSTEM
EXHAUST MUFFLERS & EXTENSIONS
20431
EXHAUST MANIFOLDS & PIPES
20433
EXHAUST MANIFOLD ASSEMBLY, R&I

(INCLUDES TURBOCHARGER, R&I)
2-5
ENGINES
1150K
MACHINE
LOCATION
JOB CODE
CYLINDER HEADS & VALVES

VALVE COVER & BREATHERS
20441
0.3
20441 A
1.0
20443 A
3.5
20443 B
ROCKER ARM ASSEMBLY, OVERHAUL

- ONE CYLINDER (INCLUDES JOB CODE 20443 A)
1.2
20443 C
- ALL CYLINDERS (INCLUDES JOB CODE 20443 B)
3.5
20443 D
6.0
20445 A
7.0
20445 B
VALVE COVER FOR CYLINDER HEAD, R&I
ROCKER ARM ASSEMBLY & PUSH RODS
20443
ROCKER ARM ASSEMBLY & PUSH RODS, R&I

- ONE CYLINDER
- ALL CYLINDERS
CYLINDER HEADS
,
,(
20445
- CLEANING HEAD
- REPLACING GASKETS
- ADJUSTING VALVES
CYLINDER HEAD, REPLACE, (INCLUDES)
- TRANSFER OF PARTS
- JOB CODE 20445 A
20445 C
EXPANSION PLUG FOR CYLINDER HEAD, REPLACE
2-6
ENGINES
1150K
MACHINE
LOCATION
VALVES, SEATS & GUIDES
JOB CODE
20447
VALVES & SPRINGS, R&I

6.8
20447 A
GRIND VALVE FACE & VALVE SEAT

8.3
20447 B
CYLINDER HEAD, OVERHAUL (INCLUDES)

- GRINDING VALVE FACE & SEATS
- TEST SPRINGS
- REPLACE VALVE GUIDES & SEAT INSERTS,
WHERE NECESSARY
8.5
20447 C
20447 D
VALVE SEAL, VALVE SPRING, OR RETAINER, R&I
SLEEVES, PISTONS & RODS

SLEEVES, PISTONS & RINGS
20451
REPLACE RINGS ON PISTON, (INCLUDES)

- REMOVE GLAZE FROM SLEEVE
- CHECKING PISTON & CYLINDER TOLERANCES
- ONE PISTON
- 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
1150K
MACHINE
LOCATION
CONNECTING RODS, BEARINGS & PINS
JOB CODE
20455
CONNECTING RODS BEARING, R&I

- ONE
8.2
20455 A
10.0
20455 B
17.9
20455 C
19.7
20455 D
CRANKSHAFT PULLEY, R&I
0.8
20461 A
CRANKSHAFT OIL SEAL (FRONT), R&I

(INCLUDES JOB CODE 20461A & REPLACING WEAR SLEEVE)
1.5
20461 B
COVER - ACCESSORY DRIVE, R&I
0.3
20461 C
TIMING GEAR HOUSING, R&I

(REAR OF ENGINE)
9.5
20461 D
TIMING PIN - CAMSHAFT GEAR, R&I

(INCLUDES HOUSING & O-RING)
0.3
20461 E
CRANKSHAFT GEAR, R&I
10.2
20463 A
CAMSHAFT GEAR, R&I

(INCLUDES REPLACING THRUST FLANGE)
7.6
20463 B
- ALL
CONNECTING ROD ASSEMBLY, R&I
- ONE
- ALL
CRANKSHAFT, CAMSHAFT &

TIMING TRAIN
CRANKSHAFT PULLEY, TIMING COVER &
SEAL
TIMING GEARS
20461
20463
2-8
ENGINES
1150K
MACHINE
LOCATION
CAMSHAFT, BUSHING & LIFTERS
JOB CODE
20465
CAMSHAFT & TAPPETS, R&I
15.6
20465 A
LIFTERS, R&I
17.2
20465 B
CRANKSHAFT OIL SEAL, R&I (REAR)

(INCLUDES R&I CARRIER & GASKET)
7.5
20467 A
CRANKSHAFT ASSEMBLY & MAIN BEARINGS, R&I

(INCLUDES CHECKING ALL TOLERANCES)
12.3
20467 B
31.5
20468 A
CRANKSHAFT, MAIN BEARINGS & SEALS
ENGINE BLOCK CASTING
20467
20468
ENGINE BLOCK CASTING, R&I (INCLUDES)

- COMPONENTS, STUDS & FITTINGS, R&I
(FROM OLD BLOCK TO NEW BLOCK)
- CHECK & SET ALL ENGINE SPECIFICATIONS
& TOLERANCES
- FILTER ELEMENTS, REPLACE
- RUN-IN PROCEDURES
- CLEAN & PAINT
20468 B
EXPANSION PLUG, R&I - BLOCK - (ONE)
FLYWHEEL & FLYWHEEL HOUSING
20469
FLYWHEEL, R&I
7.0
20469 A
RING GEAR ON FLYWHEEL, R&I
7.5
20469 B
FLYWHEEL HOUSING, R&I
7.3
20469 C
2-9
ENGINES
1150K
MACHINE
LOCATION
JOB CODE
LUBRICATION SYSTEM
OIL PAN & DIPSTICK
20471
OIL LEVEL DIPSTICK, R&I
0.1
20471 A
DIPSTICK TUBE, R&I
0.4
20471 B
OIL FILLER TUBE, R&I
0.4
20471 C
CAP / DRAIN HOSE FOR ENGINE OIL, R&I
0.3
20471 D
OIL PAN ASSEMBLY, R&I

(INCLUDES GASKET REPLACEMENT)
2.5
20471 E
OIL INLET TUBE & SCREEN, R&I

(INCLUDES JOB CODE20471 E)
3.0
20473 A
OIL PUMP ASSEMBLY, R&I

(INCLUDES JOB CODE 20461 D)
2.2
20473 B
OIL PUMP & BALANCER
20473
OIL PUMP DRIVE GEAR, R&I - ON CRANKSHAFT (INCLUDES JOB CODE 20461 D)
20473 C
HEAT EXCHANGER, OIL FILTERS & BASE
20475
ENGINE OIL COOLER, R&I

(INCLUDES REPLACING GASKET)
1.2
20475 A
RELIEF VALVE ASSEMBLY - OIL PUMP, R&I
1.0
20475 B
OIL SUPPLY LINE TO TURBOCHARGER, R&I
0.4
20477 A
OIL DRAIN LINE FROM TURBOCHARGER, R&I
0.4
20477 B
EXTERNAL LUBRICATION
TUBES & HOSES
20477
2-10
FUEL SYSTEM

1150K
MACHINE
LOCATION
JOB CODE
CASE DIESEL ENGINES

MAINTENANCE
0.5
30401 A
1.2
30402 A
FUEL TANK CAP, R&I
0.1
30411 A
DRAIN VALVE OR PLUG, R&I
0.4
30411 B
FUEL TANK, R&I
2.0
30411 C
FITTING - FUEL TANK OUTLET, R&I
0.4
30413 A
FUEL SHUTOFF VALVE, R&I
0.4
30413 B
FUEL LINE - FUEL TANK OUTLET TO PUMP, R&I
0.9
30413 C
FUEL LINE - PUMP TO FILTER HEAD (ONE), R&I
0.3
30413 D
LINE - RETURN - FILTER HEAD TO T CONNECTOR
0.3
30413 E
LINE - RETURN - RAIL OR BLOCK TO T CONNECTOR, R&I
0.3
30413 F
CONNECTOR - FUEL HOSE OR LINE FITTING, R&I (ONE)

(INCLUDES REPLACING WASHERS)
0.2
30413 G
FUEL RETURN LINE - TO TANK, R&I
0.9
30413 H
FUEL FILTERS, REPLACE
TROUBLESHOOTING
FUEL INJECTION PUMP, CHECK & ADJUST TIMING
FUEL TANK, LINES & TRANSFER PUMP

FUEL TANK
30411
FUEL LINES, TUBES, HOSES
30413
3-1
FUEL SYSTEM

1150K
MACHINE
LOCATION
JOB CODE
FUEL FILTER SYSTEM

FUEL FILTERS
30421
HEAD ASSEMBLY - FUEL FILTER, R&I

0.9
30421 A
INLINE FUEL FILTER, REPLACE
0.2
30421 B
FUEL INJECTION PUMP, R&I
2.5
30431 A
DRIVE GEAR - INJECTION PUMP, R&I
4.1
30431 B
CONNECTORS FOR FUEL INJECTION LINES, R&I (ONE)

(INCLUDES REPLACING WASHER)
0.3
30431 C
CLAMP ASSEMBLY FOR INJECTOR LINES, R&I
0.3
30433 A
FUEL INJECTOR LINE, R&I

(INCLUDES REPLACING SEAL)
- #1 CYLINDER
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
COMMON RAIL, R&I
1.3
30433 I
RELIEF VALVE, R&I
0.3
30433 J
FUEL INJECTION SYSTEM

FUEL INJECTION PUMP
30431
FUEL INJECTOR LINES
30433
3-2
FUEL SYSTEM

1150K
MACHINE
LOCATION
FUEL INJECTORS
JOB CODE
30435
FUEL INJECTORS, R&I (INCLUDES REPLACING SEAL)

- ONE
- ALL
1.2
30435 A
2.7
30435 B
0.5
30443 A
0.7
30443 B
FUEL SYSTEM CONTROLS

FUEL SHUTOFF & THROTTLE
30443
HAND THROTTLE LEVER, R&I
DECELERATOR FOOT PEDAL ASSEMBLY, R&I
(INCLUDES BUSHINGS)
NOTE: FOR FUEL ELECTRICAL SYSTEM, REFER

TO ELECTRICAL SECTION.
3-3
NOTES
ELECTRICAL
1150 K
MACHINE
LOCATION
JOB CODE
ELECTRICAL
TROUBLESHOOTING
BATTERY, CHECK & TEST - ALL
(HYDROMETER & LOAD TEST)
0.5
40002 A
CHARGING SYSTEM, CHECK & TEST

0.8
40002 B
STARTING SYSTEM, CHECK & TEST

(INCLUDES JOB CODE 40002 B)
1.0
40002 C
TROUBLESHOOT ELECTRICAL CIRCUITS

WITH OHM METER OR VOLTMETER
1.0
40002 D
ELECTRONIC SYSTEM DIAGNOSTIC TEST WITH SERVICE TOOL

(INCLUDES TOOL CONNECTION )
1.0
40002 E
DOWNLOAD ELECTRONIC CONTROLLER SOFTWARE
0.3
40002 F
POSITIVE BATTERY CABLE, R&I
1.4
40110 A
NEGATIVE CABLE, R&I

- BATTERY
0.5
40110 B
0.3
40110 C
ELECTRICAL HARNESS, R&I

- ENGINE, RIGHT SIDE
2.0
40120 A
- REAR AND LEFT SIDE
1.5
40120 B
- EQUIPMENT CONTROL AND MASTER DISCONNECT

SWITCH
1.5
40120 C
- PUMPS AND HYDRAULIC MOTORS
1.5
40120 D
WIRING & HARNESSES

BATTERY & GROUND CABLES
40110
- MASTER DISCONNECT SWITCH
MAIN WIRING
40120
4-1
ELECTRICAL
1150 K
MACHINE
LOCATION
LAMP WIRING
JOB CODE
40160
LAMP HARNESS - ROPS, R&I
0.8
40160 A
LAMP HARNESS - CAB, R&I
1.0
40160 B
1.0
40170 A
- ROPS MAIN AND MICRO CONTROLLER
2.0
40170 B
- CAB MAIN AND MICRO CONTROLLER
2.5
40170 C
- AIR CONDITIONING
2.0
40170 D
CIRCUIT BREAKER, R&I
0.1
40510 A
RELAY, R&I (ONE)
0.1
40510 B
FUSE, R&I
0.1
40520 A
FUSE HOLDER, R&I
0.8
40520 B
0.4
40530 A
0.4
41512 A
CAB / ROPS WIRING
40170
ELECTRICAL HARNESS, R&I

- FRONT CONSOLE, CAB OR ROPS
CIRCUIT BREAKERS / FUSES

& RELAYS
CIRCUIT BREAKERS / RELAYS
40510
FUSES
40520
RESISTORS
40530
RESISTOR, R&I
SWITCHES & CONTROLS

IGNITION / KEY SWITCH
41512
IGNITION SWITCH, R&I
4-2
ELECTRICAL
1150 K
MACHINE
LOCATION
FUEL SHUTOFF
JOB CODE
41513
0.2
41513 A
DRIVE CONTROL UNIT & LEVER - FORWARD, REVERSE, R&I
0.5
41515 A
BLADE CONTROL UNIT & LEVER - LIFT, TILT, ANGLE, R&I
0.5
41515 B
THROTTLE ASSEMBLY, R&I
0.6
41515 C
RIPPER & AUXILIARY EQUIPMENT CONTROL LEVER, R&I
0.5
41515 D
0.2
41531 A
0.5
41540 A
1.0
41540 B
REVERSE RATIO SWITCH, R&I
0.6
41540 C
ELECTRONIC CONTROL UNIT / MICROPROCESSOR, R&I
0.5
41540 D
BRAKE / DECELERATOR ROTARY POSITION SENSOR, R&I
0.5
41540 E
TRANSMISSION SPEED BUTTON, R&I (TWO)

( HANDLE GRIP REPLACEMENT REQUIRED)
0.3
41540 F
FUEL SHUTOFF SOLENOID, R&I
MACHINE FUNCTION CONTROLS
41515
CAB RELAYS
41531
CAB RELAY, R&I
ELECTRICAL CONTROLS
41540
LOCKOUT LEVER PROXIMITY SENSOR, R&I (ONE)

(INCLUDES ADJUSTMENT)
- RIGHT
- LEFT
4-3
ELECTRICAL
1150 K
MACHINE
LOCATION
JOB CODE
INSTRUMENTATION
GAUGES, INDICATOR LAMPS & SENDERS
42010
0.4
42010 A
AUDIBLE / WARNING ALARM, R&I
0.5
42010 B
WATER / COOLANT TEMPERATURE SENDER, R&I
0.5
42010 C
ENGINE OIL PRESSURE SWITCH, R&I
0.5
42010 D
AIR FILTER RESTRICTION SWITCH, R&I
0.4
42010 E
FUEL LEVEL SENDER, R&I
2.0
42010 F
ENGINE SPEED SENSOR, R&I
0.5
42010 G
0.3
42040 A
STARTER MOTOR, R&I
0.8
42510 A
STARTER DRIVE ASSEMBLY, R&I

1.6
42510 B
STARTER MOTOR, OVERHAUL

2.8
42510 C
0.4
42550 A
1.0
42550 B
0.5
42550 C
INDICATOR / WARNING LAMP, R&I
(ONE)
INSTRUMENT PANEL
42040
INSTRUMENT CLUSTER ASSEMBLY, R&I
ELECTRICAL STARTER & BATTERY

STARTER MOTOR
42510
BATTERIES
42550
BATTERY, R&I (ONE)
- BOTH
BATTERY SUPPORT BRACKET, R&I
4-4
ELECTRICAL
1150 K
MACHINE
LOCATION
JOB CODE
ELECTRICAL CHARGING
COMPONENTS
ALTERNATOR
43010
ALTERNATOR, R&I
0.8
43010 A
ALTERNATOR, OVERHAUL (INCLUDES JOB CODE 43010 A)
1.8
43010 B
ALTERNATOR PULLEY, R&I
0.3
43010 C
0.4
43030 A
SEALED BEAM FOR LAMP, R&I
0.3
43550 A
LAMP ASSEMBLY, R&I
0.3
43550 B
LAMP SWITCH, R&I
0.3
43550 C
INSTRUMENT PANEL LAMP, R&I
0.4
43560 A
DOME LAMP ASSEMBLY, R&I
0.3
43560 B
BULB - DOME LAMP, R&I
0.2
43560 C
REGULATOR & RECTIFIERS
43030
REGULATOR & BRUSH ASSEMBLY, R&I
ELECTRIC LAMPS
WORK LAMPS
43550
CONSOLE LAMPS
(DOME, PANEL)
43560
4-5
ELECTRICAL
1150 K
MACHINE
LOCATION
JOB CODE
ELECTRIC MOTORS
HEATER / AIR CONDITIONER
44010
BLOWER MOTOR, R&I

- HEATER
2.0
44010 A
- AIR CONDITIONING CONDENSER (ONE)
2.0
44010 B
PRESSURE SWITCH FOR AIR CONDITIONING, R&I

(INCLUDES CAPTURE / EVACUATE & CHARGE)
1.4
44010 C
TEMPERATURE SWITCH, R&I
0.5
44010 D
BLOWER SWITCH, R&I
0.5
44010 E
BLOWER MOTOR, R&I
0.7
44010 F
AC CONTROLLER
0.5
44010 G
0.7
44020 A
- REAR
0.6
44020 B
- DOOR
0.6
44020 C
DOOR CONTACT PLATE - WIPER, R&I
0.3
44020 D
LINKAGE / WIPER, R&I
0.3
44020 E
SWITCH, R&I
0.4
44020 F
BACKUP ALARM, R&I
0.3
44510 A
SWITCH - BACKUP ALARM, R&I
0.5
44510 B
HORN, R&I
0.3
44510 C
SWITCH - HORN, R&I
0.3
44510 D
WIPER MOTOR
44020
WIPER MOTOR, R&I

- FRONT
ELECTRICAL ACCESSORIES
BACKUP ALARM / HORN
44510
4-6
ELECTRICAL
1150 K
MACHINE
LOCATION
COLD START AIDS
JOB CODE
44550
BLOCK HEATER, R&I
0.7
44550 A
OIL PAN HEATER, R&I
0.4
44550 B
INTAKE MANIFOLD GRID HEATER, R&I
1.0
44550 C
RADIO / PLAYER, R&I
0.5
44570 A
SPEAKER, R&I
0.3
44570 B
ANTENNA, R&I
0.1
44570 C
ANTENNA CABLE, R&I
2.0
44570 D
CONVERTER - 24V/12V POWER, R&I
0.5
44570 E
0.3
44580 A
RADIO / SOUND SYSTEM
44570
OPERATOR CONVENIENCE &

ACCESSORIES
44580
AUXILIARY POWER OUTLET SOCKET, R&I
4-7
NOTES
STEERING / CRAWLER UNDERCARRIAGE

1150K
MACHINE
LOCATION
JOB CODE
CRAWLER UNDERCARRIAGE
MAINTENANCE
1.8
55001 A
TRACK FRAME ASSEMBLY, R&I
5.9
55011 A
TRACK FRAME, REPLACE

8.0
55011 B
0.8
55013 A
- CENTER
1.1
55013 B
- REAR
1.1
55013 C
SPROCKET GUARD, R&I (ONE SIDE)
0.4
55013 D
TRACK FRAME COVERS, R&I (ONE SIDE)
0.8
55013 E
1.0
55021 A
TRACK ADJUSTER CYLINDER, R&I
1.0
55023 A
TRACK ADJUSTER CYLINDER, OVERHAUL

(INCLUDES JOB CODE 55023A)
2.7
55023 B
CHECK VALVE ASSEMBLY, R&I
0.3
55023 C
ALIGN DRIVE SPROCKET TO REAR ROLLER
TRACK FRAMES / GUIDES

TRACK FRAME
55011
TRACK GUIDES / GUARDS
55013
TRACK FRAME GUARDS, R&I (ONE TRACK)

- FRONT
RECOIL MECHANISM /
TRACK ADJUSTERS / IDLERS
TRACK RECOIL MECHANISM
55021
RECOIL MECHANISM, R&I

(INCLUDES COVER)
TRACK ADJUSTERS
55023
5-1

1150K
MACHINE
LOCATION
TRACK IDLER WHEEL
JOB CODE
55025
IDLER WHEEL, R&I

(INCLUDES INSTALLING SHIMS, WEAR
PLATES & THRUST BLOCK)
1.3
55025 A
IDLER WHEEL, REPLACE SEALS & FILL WITH LUBRICANT

2.6
55025 B
IDLER WHEEL, REPLACE BEARINGS OR BUSHINGS,

SHAFT & SEALS, & FILL WITH LUBRICANT
3.2
55025 C
CARRIER ROLLER, R&I
0.5
55031 A
CARRIER ROLLER, REPLACE SEALS & FILL

WITH LUBRICANT (INCLUDES JOB CODE 55031 A)
1.1
55031 B
CARRIER ROLLER, REPLACE SEAL, BUSHING & SHAFT, & FILL WITH
LUBRICANT (INCLUDES JOB CODE 55031 A)
1.3
55031 C
BRACKET - CARRIER ROLLER, R&I
0.5
55031 D
BOTTOM ROLLER, R&I

- WITHOUT TRACK GUARDS
1.1
55033 A
- WITH TRACK GUARDS
2.1
55033 B
1.8
55033 C
3.0
55033 D
2.4
55033 E
3.5
55033 F
TRACK ROLLERS / SPROCKETS

TRACK CARRIER ROLLERS
55031
TRACK ROLLERS
55033
BOTTOM ROLLER, REPLACE SEAL & FILL WITH

LUBRICANT (ONE)
- WITHOUT TRACK GUARD
- WITH TRACK GUARDS
BOTTOM ROLLER, REPLACE SEAL, BUSHING & SHAFT, & FILL WITH
LUBRICANT (ONE)
- WITHOUT TRACK GUARDS
- WITH TRACK GUARDS
5-2

1150K
MACHINE
LOCATION
TRACK DRIVE SPROCKETS
JOB CODE
55035
DRIVE SPROCKET, R&I

- ONE
(INCLUDES INSTALLING SHIMS - ALIGNMENT)
1.5
55035 A
- TWO
(INCLUDES INSTALLING SHIMS - ALIGNMENT)
3.0
55035 B
CONNECTOR LINK, R&I
0.8
55041 A
CHAIN ASSEMBLY, R&I (ONE LINK)
1.7
55041 B
SPLIT MASTER LINK , R&I

2.1
55041 C
CHAIN ASSEMBLY, REPLACE (ONE SIDE)

(INCLUDES 55041 B & R&I OF ALL TRACK SHOES)
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
TRACK CHAINS & SHOES

TRACK CHAINS, PINS, & BUSHINGS
55041
TRACK SHOES
55045
TRACK SHOE, R&I

- ONE
5-3
NOTES
POWER TRAIN

1150K
MACHINE
LOCATION
JOB CODE
POWER TRAIN
MAINTENANCE
DRAIN & FILL
- FINAL DRIVE OIL (ONE)
0.4
60001 A
TEST - PRESSURE RELIEF VALVES (BOTH PUMPS)
0.5
60002 A
DIAGNOSTIC PANEL CHECKS

- CHARGE CIRCUIT PRESSURE
0.5
60002 B
- RIGHT TRACK CIRCUIT
1.5
60002 C
- LEFT TRACK CIRCUIT
1.5
60002 D
- EQUIPMENT VALVE CIRCUIT
0.5
60002 E
NOTE: FOR FILTER ELEMENT REPLACE REFER TO

JOB CODE 80001 B.
TROUBLESHOOTING
NOTE: ALL POWER TRAIN TROUBLESHOOTING
CODES INCLUDE 20302 A.
6-1
POWER TRAIN

1150K
MACHINE
LOCATION
JOB CODE
REMOVAL & INSTALLATION

OR OVERHAUL
TANDEM PUMP ASSEMBLY, R&I
(INCLUDES CAB TILT)
6.5
60003 A
TANDEM PUMP ASSEMBLY, OVERHAUL (ONE SECTION)

60003 B
TANDEM PUMP ASSEMBLY, OVERHAUL -COMPLETE(INCLUDES JOB CODE 60003 A)
60003 C
HYDROSTATIC DRIVE MOTOR, R&I (ONE)
3.0
HYDROSTATIC DRIVE MOTOR, OVERHAUL

60003 D
60003 E
PLANETARY ASSEMBLY, R&I (ONE)
3.0
60003 F
PLANETARY ASSEMBLY, OVERHAUL (ONE)

(INCLUDES JOB CODE 60003 F)
3.7
60003 G
FINAL DRIVE ASSEMBLY, R&I (ONE)
3.5
60003 H
FINAL DRIVE ASSEMBLY, OVERHAUL (ONE)

(INCLUDES JOB CODE 60003 H & BRAKES)
5.7
60003 J
DRIVE SHAFT - TANDEM PISTON PUMP, R&I
2.0
61031 A
UNIVERSAL JOINTS, REPLACE

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

1150K
MACHINE
LOCATION
FILTERS
JOB CODE
62713
0.8
62713 A
1.0
62741 A
SUPPLY LINE, R&I

(HYDRAULIC TANK TO INLET IN REAR PUMP)
1.0
62751 A
SUPPLY LINE FITTING, R&I

(INLET IN REAR PUMP)
0.7
62751 B
HEAD - CHARGE PUMP FILTER, R&I

NOTE: FOR EQUIPMENT FILTER, REFER TO
HYDRAULIC TRANSMISSION PUMPS

MAIN PUMPS
62721
NOTE: FOR REPAIRS IN THIS MACHINE LOCATION,

REFER TO JOB CODES 60003.
HYDRAULIC TRANSMISSION MOTORS

TRANSMISSION DRIVE MOTORS
62731

REFER TO JOB CODES 60003.
HYDRAULIC TRANSMISSION VALVES

MAIN RELIEF VALVES
62741
MAIN CIRCUIT RELIEF VALVE, R&I & OVERHAUL (ONE)

(INCLUDES CAB TILT)
HYDRAULIC TRANSMISSION LINES

PUMP INLET LINES
62751
6-3
POWER TRAIN

1150K
MACHINE
LOCATION
CONTROL CIRCUIT
DIAGNOSTIC LINES
JOB CODE
62754
CONTROL VALVE GAGE PORT LINE, R&I
0.5
62754 A
CHARGE PRESSURE LINE, R&I
0.5
62754 B
FORWARD DRIVE LINE, R&I (ONE)
0.5
62754 C
REVERSE DRIVE LINE, R&I (ONE)
0.5
62754 D
FITTING - PRESSURE PORT, R&I (ONE)
0.3
62754 E
DIAGNOSTIC CHECK FITTING, R&I (ONE)
0.2
62754 F
CASE DRAIN LINE, R&I (ONE)

(PUMP CASE DRAIN LINE)
0.7
62755 A
RETURN LINE, R&I

(HYDROSTATIC FILTER LINE TO HYDRAULIC TANK)
0.5
62755 B
RETURN LINE FITTING, R&I

(OUTLET OF FILTER)
0.5
62755 C
RETURN LINE FITTING, R&I

(INLET OF HYDRAULIC TANK)
0.5
62755 D
0.7
62759 A
0.7
62759 B
0.7
62759 C
0.7
62759 D
CASE DRAIN CROSSOVER LINE, R&I

(BETWEEN MOTORS)
0.5
62759 E
CASE DRAIN LINE, R&I

(MOTORS - HYDRAULIC TANK)
0.5
62759 F
CASE DRAIN LINE FITTING, R&I

(HYDRAULIC TANK)
0.5
62759 G
RETURN LINES
62755
MOTOR LINES
62759
REAR PUMP TO LEFT HAND MOTOR LINE, R&I

- UPPER
- LOWER
FRONT PUMP TO RIGHT HAND MOTOR LINE, R&I
- UPPER
- LOWER
6-4
POWER TRAIN

1150K
MACHINE
LOCATION
JOB CODE
PLANETARIES
PLANETARY SHAFTS, BEARINGS &
BUSHINGS
63121

USE 60003 JOB CODES.
PLANETARY GEARS
63123

PLANETARY HOUSING
63127

FINAL DRIVES
SHAFTS, BEARINGS & BUSHINGS
63131

FINAL DRIVE GEARS
63133

FINAL DRIVE HOUSING
63135

OPERATOR CONTROLS - POWERTRAIN

CONTROL PEDALS / QUADRANTS /
LEVERS
65010
DRIVE CONTROL HANDLE & TRANSMISSION SHIFT BUTTONS, R&I
0.3
65010 A
DRIVE CONTROL UNIT, R&I
0.5
65010 B
NOTE: FOR REPAIRS TO PARKING BRAKE / LOCKOUT LEVERS

USE JOB CODE 71083 A.
6-5
NOTES
BRAKES

1150K
MACHINE
LOCATION
JOB CODE
BRAKES
MAINTENANCE
0.5
70001 A
BRAKE SUPPLY LINE, R&I

(FRONT CHARGE PUMP TO SOLENOID VALVE)
0.3
71041 A
BRAKE SUPPLY LINE, R&I

(SOLENOID VALVE TO MOTOR)
0.3
71041 B
BRAKE DRAIN LINE, R&I

(SOLENOID VALVE RETURN TO RESERVOIR / TANK)
0.3
71041 C
BRAKE CROSSOVER LINE, R&I
0.3
71041 D
FITTING - BRAKE LINE CIRCUIT, R&I (ONE)
0.3
71041 E
0.8
71053 A
4.5
71061 A
4.5
71073 A
CHECK BRAKE SYSTEM
BRAKE SYSTEM HYDRAULICS

HYDRAULIC BRAKE LINES
71041
BRAKE VALVES
CONTROL VALVES
71053
BRAKE SOLENOID VALVE, R&I
BRAKE CYLINDERS
BRAKE CYLINDERS
71061
PARK BRAKE- PISTON ASSEMBLY, OVERHAUL (ONE SIDE)

(INCLUDES R&I FROM FINAL DRIVE HOUSING JOB CODE 71075 A)
BRAKE DISCS
71073
BRAKE DISCS, R&I (ONE SIDE)

7-1
BRAKES

1150K
MACHINE
LOCATION
BRAKE HOUSINGS
(FINAL DRIVE HOUSING)
JOB CODE
71075
BRAKE HOUSING, R&I

- ONE SIDE
3.4
71075 A
- BOTH SIDES
5.9
71075 B
BRAKE PEDAL, R&I
1.1
71081 A
FOOT REST, R&I
0.3
71081 B
1.0
71085 A
OPERATOR CONTROLS
PEDALS & LEVERS
71081
PARK BRAKE LINKAGE
71085
PARKING BRAKE / LOCKOUT LEVER ASSEMBLY, R&I (ONE)

(INCLUDES ADJUSTMENTS)
7-2
HYDRAULICS
1150K
MACHINE
LOCATION
JOB CODE
HYDRAULIC SYSTEM
MAINTENANCE
DRAIN & FILL
- HYDRAULIC OIL RESERVOIR
0.5
80001 A
FILTER ELEMENT - HYDRAULIC SYSTEM, REPLACE
0.3
80001 B
INSTALL PORTABLE FILTER TO FILTER OIL IN HYDRAULIC SYSTEM

(INCLUDES JOB CODES 80001 A & B )
1.5
80001 C
TEST MAIN RELIEF VALVE WITH PRESSURE GAUGE

0.4
80002 A
ADJUST MAIN RELIEF VALVE

0.6
80002 B
TEST & ADJUST CIRCUIT RELIEF VALVE

- 'A' PORT
0.7
80002 C
1.1
80002 D
2.4
80002 E
FILL CAP, R&I
0.1
82611 A
SIGHT GAUGE, R&I
0.3
82611 B
ACCESS COVER, R&I
0.7
82611 C
RESERVOIR, R&I - HYDRAULIC OIL (INCLUDES JOB CODE 80001 A)
2.0
82611 D
FILTER HEAD OR BLOCK, R&I
0.8
82613 A
STRAINER / FILTER - HYDRAULIC RESERVOIR, R&I (ONE)

0.8
82613 B
STRAINER/ FILTERS - HYDRAULIC RESERVOIR, OVERHAUL

(ALL) (INCLUDES JOB CODE 80001 A)
1.5
82613 C
TROUBLESHOOTING
- 'B' PORT
FLOW & PRESSURE TEST
COMPLETE EQUIPMENT HYDRAULIC SYSTEM
(INCLUDES JOB CODES 80002 A, B, C, & D)
HYDRAULIC RESERVOIR & FILTERS

HYDRAULIC RESERVOIR
82611
HYDRAULIC FILTERS
82613
8-1
HYDRAULICS
1150K
MACHINE
LOCATION
BREATHERS & RELIEF VALVE

(HYDRAULIC RESERVOIR)
JOB CODE
82615
0.3
82615 A
EQUIPMENT HYDRAULIC PUMP, R&I (WITHOUT PTO)
1.0
82621 A

1.9
82621 B
EQUIPMENT HYDRAULIC PUMP, R&I (WITH PTO)
1.3
82621 C

(INCLUDES JOB CODE 82621 C)
2.2
82621 D
0.7
82629 A
LINE - RESERVOIR OUTLET TO PUMP, R&I
1.2
82631 A
FITTING - PUMP INLET, R&I
0.6
82631 B
FITTING - PUMP OUTLET, R&I
0.6
82633 A
LINE - PUMP OUTLET - VALVE INLET, R&I
1.2
82633 B
RESERVOIR BREATHER, R&I
HYDRAULIC PUMPS
NOTE: REFER TO MACHINE LOCATION & JOB CODES IN 60003
FOR HYDROSTATIC TRANSMISSION PUMPS.
MAIN SYSTEM PUMP
82621
PUMP DRIVE COMPONENTS
82629
PUMP DRIVE COUPLING, R&I (EQUIPMENT PUMP WITHOUT PTO)
HYDRAULIC LINES
(BETWEEN RESERVOIR & VALVE)
PUMP INLET CIRCUIT LINES
82631
PUMP TO VALVE CIRCUIT LINE
82633
8-2
HYDRAULICS
1150K
MACHINE
LOCATION
RETURN CIRCUIT LINES
JOB CODE
82635
FITTING - VALVE OUTLET, R&I
0.4
82635 A
LINE - VALVE OUTLET TO THERMAL BYPASS VALVE, R&I
1.0
82635 B
LINE - HYDRAULIC RESERVOIR INLET, R&I

(FROM COOLER)
1.0
82635 C
1.0
82637 A
- OIL COOLER TO TEE IN THERMAL BYPASS VALVE
1.0
82637 B
- TEE IN THERMAL BYPASS VALVE TO

HYDRAULIC OIL FILTER
0.8
82637 C
MAIN RELIEF VALVE, R&I

0.7
82641 A
MAIN RELIEF VALVE, OVERHAUL

1.0
82641 B
ANTI - CAVITATION VALVE, R&I
0.5
82643 A
LOAD CHECK VALVE, R&I
0.6
82643 B
DETENT OR CENTERING SPRING REPAIR (ONE SPOOL)
1.2
82643 C
CONTROL VALVE ASSEMBLY, R&I
2.6
82643 D
CONTROL VALVE, OVERHAUL - ONE SECTION

3.4
82643 E
5.1
82643 F
3.0
82643 G
COOLING LINES
82637
HYDRAULIC LINE, R&I

- THERMAL BYPASS VALVE TO OIL COOLER
HYDRAULIC VALVES
MAIN RELIEF VALVE
82641
CONTROL VALVE (DIRECTIONAL FLOW)
- ALL SECTIONS
CONTROL VALVE, REPLACE (ONE SECTION)
8-3
82643
HYDRAULICS
1150K
MACHINE
LOCATION
CIRCUIT RELIEF VALVES
JOB CODE
82645
CIRCUIT RELIEF VALVE, R&I

- 'A' PORT
1.2
82645 A
- 'B' PORT
1.2
82645 B
1.0
82647 A
0.5
82651 A
0.6
82651 B
0.8
82651 C
0.8
82651 D
CROSSOVER LINE OR FITTING, R&I
0.8
82651 E
LINE - CYLINDER PORT, R&I
0.4
82651 F
FITTING - CYLINDER PORT, R&I
0.3
82651 G
0.5
82653 A
0.6
82653 B
0.8
82653 C
0.8
82653 D
FLOW / PRESSURE DIVIDER VALVES
82647
THERMAL BYPASS VALVE, R&I
DOZER HYDRAULIC LINES

DOZER LIFT CIRCUIT LINES
82651
FITTING - CONTROL VALVE, R&I

- 'A' PORT
- 'B' PORT
LINE - CONTROL VALVE, R&I
- 'A' PORT
- 'B' PORT
DOZER ANGLE CIRCUIT LINES
82653

- 'A' PORT
- 'B' PORT
- 'A' PORT
- 'B' PORT
8-4
HYDRAULICS
1150K
MACHINE
LOCATION
JOB CODE
CROSSOVER LINE R&I
0.5
82653 E
LINE - CYLINDER PORT, R&I (ONE)
0.5
82653 F
0.4
82653 G
LUBRICATION LINE - CLOSED END OF ANGLE CYLINDER, R&I
0.3
82653 H
0.5
82655 A
0.6
82655 B
0.9
82655 C
0.8
82655 D
LINE - CYLINDER PORT, R&I (ONE)
0.7
82655 E
0.5
82655 F
HAND PUMP, R&I
0.4
82656 A
FITTING - HAND PUMP, R&I
0.3
82656 B
LINE - HAND PUMP TO CYLINDER PORT, R&I (ONE)
0.5
82656 C
FITTING - CYLINDER, R&I
0.5
82656 D
CAB TILT CYLINDER, R&I
1.4
82656 E
CAB TILT CYLINDER, OVERHAUL

(INCLUDES JOB CODE 82656 E)
2.2
82656 F
DOZER TILT CIRCUIT LINES
82655

- 'A' PORT
- 'B' PORT
- 'A' PORT
- 'B' PORT
CAB TILT CIRCUIT
82656
8-5
HYDRAULICS
1150K
MACHINE
LOCATION
POWER ASSIST AUXILIARY CIRCUIT LINES
JOB CODE
82659

- 'A' PORT
0.4
82659 A
0.4
82659 B
DOZER LIFT CYLINDER, R&I
0.6
82661 A
CYLINDER SEAL KIT, REPLACE

1.6
82661 B
CYLINDER TUBE, R&I

1.8
82661 C
DOZER ANGLING CYLINDER, R&I
0.8
82663 A

1.8
82663 B
CYLINDER TUBE, R&I

2.0
82663 C
DOZER TILT CYLINDER, R&I
0.6
82665 A

1.6
82665 B
CYLINDER TUBE, R&I

1.8
82665 C
3.5
82681 A
- 'B' PORT
DOZER HYDRAULIC CYLINDERS

DOZER LIFT CYLINDERS
82661
DOZER ANGLE CYLINDER
82663
DOZER TILT CYLINDERS
82665
OIL COOLERS / MANIFOLDS

HYDRAULIC OIL COOLER
82681
HYDRAULIC OIL COOLER, R&I

8-6
HYDRAULICS
1150K
MACHINE
LOCATION
JOB CODE
DOZER HYDRAULIC EQUIPMENT CONTROLS

PEDALS / QUADRANTS / LEVERS
82691
NOTE: FOR REPAIRS TO CONTROLS, REFER TO

CABLES / LINKAGE
82693
NOTE: FOR REPAIRS TO CONTROLS, REFER TO

RIPPER HYDRAULIC LINES

LIFT CIRCUIT LINES
85051

- 'A' PORT
0.5
85051 A
0.7
85051 B
0.6
85051 C
0.7
85051 D
LINE - CYLINDER PORT, R&I
0.3
85051 E
0.3
85051 F
RIPPER LIFT CYLINDER, R&I
0.5
85061 A

1.2
85061 B
CYLINDER TUBE, R&I

1.6
85061 C
- 'B' PORT
- 'A' PORT
- 'B' PORT
RIPPER HYDRAULIC CYLINDERS

RIPPER LIFT CYLINDER
85061
NOTE: FOR RIPPER HYDRAULIC EQUIPMENT CONTROLS,

REFER TO MACHINE LOCATION 41540.
8-7
NOTES
CHASSIS
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
WINCH ASSEMBLY, R&I
3.6
90003 A
RIPPER ASSEMBLY, R&I
3.4
90003 B
CAPTURE, EVACUATE & CHARGE AIR CONDITIONING SYSTEM
TROUBLESHOOTING
TEST AIR CONDITIONING SYSTEM USING
LEAK DETECTOR & MANIFOLD GAUGES
REMOVAL & INSTALLATION

OR OVERHAUL
MAIN FRAME & CHASSIS

CHASSIS OR MAIN FRAME
90111
90111 A
DOZER MAIN FRAME, REPLACE
MOUNTS & SUSPENSION
90115
FRONT ENGINE MOUNT, R&I
7.5
90115 A
RUBBER CUSHIONS FOR ENGINE MOUNTS, R&I

- FRONT
1.2
90115 B
1.2
90115 C
0.5
90115 D
1.0
90115 E
CAB / ROPS MOUNT- BUSHING, R&I (TWO) RIGHT SIDE
0.8
90115 F
CAB / ROPS MOUNT- BUSHING, R&I (TWO) LEFT SIDE
1.5
90115 G
- REAR
TANDEM PUMP MOUNT, R&I
- ONE
- ALL
9-1
CHASSIS
1150K
MACHINE
LOCATION
COUNTERWEIGHTS, DRAWBARS & HITCH
JOB CODE
90117
COUNTERWEIGHT, R&I
1.4
90117 A
DRAWBAR, R&I
0.4
90117 B
TOW HOOK, R&I

- FRONT
0.4
90117 C
- REAR
0.3
90117 D
HOOD ASSEMBLY, R&I
0.4
90131 A
ENGINE SIDE DOOR, R&I (ONE)
0.4
90131 B
LATCH ASSEMBLY, R&I
0.5
90131 C
DOOR STRUT, R&I
0.2
90131 D
ENGINE SIDE SHIELDS, R&I LOWER (ONE)
0.1
90131 E
HYDRAULIC RESERVOIR SIDE DOOR, R&I
0.3
90131 F
DOOR LATCH ASSEMBLY, R&I

(INCLUDES ADJUSTMENT)
0.3
90131 G
REAR SIDE PANEL, R&I (RIGHT OR LEFT)

(UNDER CAB REAR CORNERS)
0.4
90131 H
LATCH ASSEMBLY, R&I
0.3
90131 J
GAS STRUT, R&I
0.1
90131 K
PROTECTIVE COVERINGS
APPEARANCE / CONVENIENCE
HOOD & SIDE PANELS
90131
9-2
CHASSIS
1150K
MACHINE
LOCATION
SHROUDS & GRILLES
JOB CODE
90132
RADIATOR GRILLE, R&I

(HINGED)
0.4
90132 A
UPPER ACCESS PLATE FOR RADIATOR, R&I

(MOUNTS TO GRILLE)
0.2
90132 B
GRILLE FRAME & COVER PLATE, R&I (ONE SIDE)
0.6
90132 C
RADIATOR BRUSH SCREEN, R&I (UPPER & LOWER)
0.3
90132 D
GUARD - TRACK ADJUSTER RECOIL HOUSING, R&I
0.4
90135 A
POWER TRAIN GUARD (BELLY PAN), R&I
0.4
90135 B
FRONT COVER PLATE - (BELLY PAN), R&I
0.3
90135 C
REAR BOX COVER PLATE (FRAME END), R&I
0.4
90135 D
CAB REAR WINDOW SCREEN, R&I
0.3
90135 E
LOCKUP PANEL - INSTRUMENT PANEL, R&I
0.3
90136 A
COAT HOOK, R&I
0.2
90136 B
INSIDE CAB GRAB HANDLE, R&I
0.3
90136 C
GUARDS & SHIELDS
90135
LOCKUP KIT / TOOL BOX &

MISCELLANEOUS CONVENIENCE
90136
PAINT & DECALS
90137
NOTE: WHEN USING PAINT / DECAL JOB CODES,

A DETAILED EXPLANATION (TELLING WHAT, WHY,
& HOW MUCH) IS REQUIRED.
PAINTING
90137 A
REPLACE DECALS
90137 B
9-3
CHASSIS
1150K
MACHINE
LOCATION
JOB CODE
ENVIRONMENT CONTROLS
SOUND CONTROL
90141
90141 A
FOAM INSULATION PADS, R&I
AIR SYSTEM CONTROL
90142
HOUSING - CAB AIR FILTER, R&I
1.6
90142 A
DOOR - AIR RECIRCULATION, R&I

1.7
90142 B
CONTROL CABLE, R&I

(AIR RECIRCULATION DOOR)
2.0
90142 C
CAB AIR FILTER, R&I (OUTER - FRESH AIR)
0.2
90142 D
CAB AIR FILTER, R&I (INNER - RECIRCULATION AIR)
0.4
90142 E
PANEL ASSEMBLY - CAB AIR FLOW, R&I
1.4
90142 F
LOUVER, R&I (ONE)
0.2
90142 G
CAB TILT
0.4
90311 A
CAB TILT (UNITS WITH BRUSH GUARD)
0.8
90311 B
CAB ASSEMBLY, R&I
2.8
90311 C
CAB
CAB FRAME & HARDWARE
90311
NOTE: FOR UNITS WITH AIR CONDITIONING, ADD

JOB CODE 90001 A, WITH JOB CODE 90311C.
9-4
CHASSIS
1150K
MACHINE
LOCATION
WINDOWS, DOORS & MIRRORS
JOB CODE
90313
DOOR LOCK & LATCH, R&I (ONE)
0.3
90313 A
DOOR ASSEMBLY, R&I
0.5
90313 B
HINGE ASSEMBLY, R&I
0.2
90313 C
DOOR HANDLE, R&I
0.2
90313 D
DOOR LOCK, R&I
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
- FRAMED WINDOW (OPERABLE)
0.5
90313 K
REAR VIEW MIRROR, R&I
0.2
90313 L
REAR VIEW MIRROR BRACKET, R&I
0.3
90313 M
SUN SHADE, R&I (ONE)
0.2
90313 N
WINDOW WASHER RESERVOIR, R&I
0.3
90313 P
WINDSHIELD WASHER PUMP, R&I (FRONT OF RESERVOIR)
0.1
90313 Q
WINDSHIELD WASHER PUMP, R&I (BACK OF RESERVOIR)
0.4
90313 R
WINDSHIELD WASHER HOSE / NOZZLE, R&I (ONE)
0.1
90313 S
ROPS GRAB HANDLE, R&I (ONE)
0.3
90313 T
9-5
CHASSIS
1150K
MACHINE
LOCATION
HEATER & DEFROSTER SYSTEM
JOB CODE
90315
SHUTOFF VALVE AT ENGINE - HEATER, R&I
0.8
90315 A
HEATER ASSEMBLY, R&I
1.8
90315 B
HEATER HOSES, R&I

- HEATER CORE
1.0
90315 C
1.0
90315 D
HEATER / AIR CONDITIONING CONTROL, R&I
0.6
90315 E
HEATER AIR DUCT, R&I
1.0
90315 F
AIR CONDITIONER AIR DUCT, R&I
1.0
90315 G
HEATER / AIR CONDITIONER AIR HOSE / TUBE, R&I (ONE)
0.5
90315 H
EVAPORATOR CORE, R&I
0.8
90317 A
EXPANSION VALVE, R&I
0.7
90317 B
AIR CONDITIONING LINE AT EXPANSION VALVE, R&I
0.7
90317 C
INTERMEDIATE LINE BETWEEN EXPANSION

VALVE & DRYER, R&I
0.7
90317 D
AIR CONDITIONING LINE AT DRYER, R&I
0.7
90317 E
INTERMEDIATE LINE BETWEEN EVAPORATOR

CORE & COMPRESSOR, R&I
0.7
90317 F
AIR CONDITIONING LINE AT COMPRESSOR, R&I
0.9
90317 G
AIR CONDITIONING CONDENSER, R&I
1.0
90317 H
AIR CONDITIONING LINE BETWEEN CONDENSER &

COMPRESSOR OR DRYER, R&I
1.2
90317 J
- ENGINE
AIR CONDITIONING SYSTEM

NOTE: JOB CODE 90001 A, IS NOT INCLUDED IN THESE AIR
CONDITIONING CODES.
ADD 90001 A, ONE TIME PER A/C SYSTEM REPAIR,
IF NECESSARY.
9-6
90317
CHASSIS
1150K
MACHINE
LOCATION
JOB CODE
AIR CONDITIONING COMPRESSOR, R&I
0.7
90317 K
AIR CONDITIONING COMPRESSOR, OVERHAUL

(INCLUDES JOB CODE 90317 J)
1.9
90317 L
COMPRESSOR MOUNTING BRACKET, R&I

(INCLUDES COMPRESSOR SWING AWAY)
0.6
90317 M
COMPRESSOR CLUTCH ASSEMBLY, R&I
1.2
90317 N
COMPRESSOR PULLEY - ENGINE CRANKSHAFT OR FAN, R&I
1.5
90317 P
BELT - COMPRESSOR, R&I
0.4
90317 Q
RECEIVER - DRYER, R&I
0.7
90317 R
COVER / PANEL FOR CONDENSER, R&I

- TOP
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
FLOOR MAT, R&I
0.4
90319 B
SUPPORT - BLOWER MOTORS, R&I
OPERATORS CONSOLE /
INSTRUMENT PANEL HOUSING
90318
CAB / ROPS SIDE CONSOLES, R&I

- LEFT SIDE
- RIGHT SIDE
HEADLINER & FLOOR MAT
90319
9-7
CHASSIS
1150K
MACHINE
LOCATION
JOB CODE
PROTECTIVE STRUCTURES
ROLL OVER PROTECTION - ROPS
90321
BRUSH SWEEP GUARD, R&I
0.8
90321 A
ROPS PROTECTION SCREEN, R&I

- SIDE (ONE)
0.3
90321 B
0.3
90321 C
2.5
90321 D
SEAT ASSEMBLY, R&I (ROPS)
0.5
90331 A
SEAT ASSEMBLY, R&I (CAB)
1.5
90331 B
SEAT CUSHIONS, R&I

- BACK
1.0
90331 C
- SEAT
1.0
90331 D
ARM REST, R&I
0.2
90331 E
SUPPORT, R&I
(INCLUDES CONSOLE REMOVAL)
0.9
90331 F
SLIDE OR SLIDE TUBES, R&I

(INCLUDES BUSHINGS)
0.8
90331 G
SEAT SUSPENSION ASSEMBLY, OVERHAUL

(INCLUDES SEAT, R&I)
3.0
90331 H
SHOCK ABSORBER, R&I
2.0
90331 J
BOOT / COVER FOR SUSPENSION, R&I
0.4
90331 K
WIRE HARNESS, R&I
0.8
90331 L
CONTROL SWITCH, R&I
0.7
90331 M
- REAR
ROPS AS AN ASSEMBLY, R&I
SEATS / BELTS / ADJUSTERS

SEAT & SUPPORTS
90331
9-8
CHASSIS
1150K
MACHINE
LOCATION
JOB CODE
AIR COMPRESSOR, R&I
1.2
90331 N
AIR SPRING, R&I
1.4
90331 P
AIR LINE, R&I
0.6
90331 Q
0.3
90333 A
DOZER BLADE, R&I
3.4
92611 A
CUTTING EDGE, R&I

- CENTER
1.0
92611 B
0.5
92611 C
PIN - ROD END OF LIFT CYLINDER, R&I
0.3
92621 A
BUSHINGS - LIFT CYLINDER, R&I

1.0
92621 B
PIN - CLOSED END OF LIFT CYLINDER, R&I
0.3
92621 C
PIN - ROD END OF ANGLE CYLINDER, R&I
0.3
92623 A
BUSHINGS - ANGLE CYLINDER, R&I

1.0
92623 B
PIN - CLOSED END OF ANGLE CYLINDER, R&I
0.3
92623 C
BUSHINGS - CLOSED END OF ANGLE CYLINDER, R&I

1.1
92623 D
SEAT BELTS
90333
SEAT BELT, R&I
DOZER GROUND ENGAGING

COMPONENTS
BLADE & CUTTING EDGES
92611
- END
DOZER PINS, BUSHINGS & LINKS

LIFT COMPONENTS, PINS & BUSHINGS
92621
ANGLE COMPONENTS, PINS & BUSHINGS
9-9
92623
CHASSIS
1150K
MACHINE
LOCATION
DOZER TILT COMPONENTS,

PINS & BUSHINGS
JOB CODE
92625
PIN - ROD END OF TILT CYLINDER, R&I
0.3
92625 A
BUSHINGS - ROD END OF TILT CYLINDER, R&I

0.7
92625 B
PIN - CLOSED END OF TILT CYLINDER, R&I
0.3
92625 C
BUSHINGS - CLOSED END OF TILT CYLINDER, R&I

1.1
92625 D
PITCH LINK ASSEMBLY, R&I
0.4
92625 E
PIN OR BEARING SUPPORT BLOCK - LOWER BLADE MOUNTING

OR LEVELING BEAM, R&I
1.0
92627 A
BUSHING - PIN OR BEARING SUPPORT BLOCK LOWER BLADE MOUNTING, R&I

2.0
92627 B
PIVOT BRACKET ASSEMBLY, R&I

2.5
92627 C
PIN - MOUNTING C - FRAME TO MOUNTING BRACKET, R&I
0.4
92629 A
BUSHINGS - PIN MOUNTING C - FRAME TO MOUNTING BRACKET, R&I

1.1
92629 B
4.5
92633 A
WEAR PLATE - LIFT FRAME, R&I
0.2
92639 A
GUARD - DOZER HYDRAULICS, R&I (ONE)
0.3
92639 B
DOZER BLADE MOUNTING PINS,

BUSHINGS & BRACKETS
92627
DOZER C - FRAME, PINS & BUSHINGS
92629
DOZER STRUCTURAL MEMBERS

DOZER LIFT C-FRAME
92633
DOZER LIFT C-FRAME, R&I
DOZER GUARD OR SHIELD
92639
9-10
CHASSIS
1150K
MACHINE
LOCATION
JOB CODE
RIPPER GROUND ENGAGING

COMPONENTS
RIPPER TEETH & SHANKS
95011
POINTS FOR RIPPER TEETH, R&I

- ONE
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
PINS - RIPPER LIFT CYLINDER, R&I
0.3
95021 G
BUSHINGS - CYLINDER PIN, R&I

(INCLUDES JOB CODE 95021 G)
0.7
95021 H
ARM / LINK, R&I

- UPPER
0.4
95021 J
1.4
95021 K
- ALL
SHANKS FOR RIPPER TEETH, R&I
- ONE
- ALL
RIPPER PINS, BUSHINGS & LINKS

RIPPER COMPONENT PINS,
BUSHINGS, & LINKS
95021
PINS - UPPER LINK, R&I

- ONE
- ALL
PINS FOR LOWER LINK, R&I
- ONE
- ALL
PINS OR ROD FOR MOUNTING SHANKS, R&I
- ONE
- ALL
- LOWER
9-11
CHASSIS
1150K
MACHINE
LOCATION
JOB CODE
RIPPER STRUCTURAL MEMBERS

RIPPER SHANK TOOL BAR
95031
RIPPER SHANK TOOL BAR, R&I
2.5
95031 A
RIPPER COUNTERWEIGHT, R&I
1.4
95031 B
1.8
95033 A
2.8
95033 B
RIPPER MOUNTING COMPONENTS
95033
RIPPER MOUNTING BRACKET, R&I

- ONE
- BOTH
9-12
REQUEST FOR ADDITIONAL JOB CODE

Form No.__________________of Machine Location Job Code Manual Used.
Model No._________________of Machine or Implement.
Machine Location No.___________________
Closest Available Job Code________________________________________________________

_________________________________________________________________________________
Job Code Requested _______________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
All Operations Included in Job Code Requested_______________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Dealer Name_____________________________________
City, State & Zip___________________________________
Phone No.________________________________________
Dealer Signature__________________________________
Date_____________________________________________
Mail Completed Form To:
Case Warranty
2690 Division Hwy.
New Holland, PA 17557
Attn: Warranty Administration
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

Bur 87634755NA - J.C.M. 1150K Tier 3 (ENG)

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Bur 87634755NA - J.C.M. 1150K Tier 3 (ENG)

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JOB CODE MANUAL

North American English

1150K TIER III

CYLINDER HEADS & VALVES

SLEEVES, PISTONS & RODS

CRANKSHAFT, CAMSHAFT & TIMING TRAIN

FUEL TANK, LINES & TRANSFER PUMP

FUEL FILTER SYSTEM

FUEL INJECTION SYSTEM

FUEL SYSTEM CONTROLS

WIRING & HARNESSES

CIRCUIT BREAKERS / FUSES & RELAYS

SWITCHES & CONTROLS

ELECTRICAL STARTER & BATTERY

ELECTRICAL CHARGING COMPONENTS

TRACK FRAMES / GUIDES

RECOIL MECHANISM / TRACK ADJUSTERS / IDLERS

TRACK ROLLERS / SPROCKETS

TRACK CHAINS & SHOES

HYDRAULIC (HYDROSTATIC) TRANSMISSION RESERVOIRS & FILTERS

HYDRAULIC TRANSMISSION PUMPS

HYDRAULIC TRANSMISSION MOTORS

HYDRAULIC TRANSMISSION VALVES

HYDRAULIC TRANSMISSION LINES

OPERATOR CONTROLS - POWERTRAIN

BRAKE SYSTEM HYDRAULICS

HYDRAULIC RESERVOIRS & FILTERS

HYDRAULIC LINES (BETWEEN RESERVOIR & VALVE)

DOZER HYDRAULIC LINES

DOZER HYDRAULIC CYLINDERS

OIL COOLERS / MANIFOLDS

DOZER HYDRAULIC EQUIPMENT CONTROLS

RIPPER HYDRAULIC LINES

RIPPER HYDRAULIC CYLINDERS

CHASSIS / STRUCTURE MOUNTED EQUIPMENT

MAIN FRAME & CHASSIS

PROTECTIVE COVERINGS / APPEARANCE / CONVENIENCE

SEATS / BELTS / ADJUSTERS

DOZER GROUND ENGAGING COMPONENTS

DOZER PINS, BUSHINGS & LINKS

DOZER STRUCTURAL MEMBERS

RIPPER GROUND ENGAGING COMPONENTS

RIPPER PINS, BUSHINGS & LINKS

RIPPER STRUCTURAL MEMBERS

JOB CODE REQUEST FORM

INTRODUCTION TO THE CARES

2ND & 3RD DIGITS INDICATE

4TH & 5TH DIGITS INDICATE

6TH POSITION IS ALPHA

1ST DIGIT INDICATES MACHINE

JOB CODE >

SAMPLE MACHINE LOCATION CODE

SAMPLE JOB CODE

MACHINE LOCATION & PRIME PART

SAR TO IDENTIFY A SPECIFIC AREA OF THE MACHINE

PRIME PART IS THE CASE PART WHICH CAUSED THE FAILURE.

MAIN SYSTEM PUMP

EQUIPMENT HYDRAULIC PUMP, R&I

EQUIPMENT HYDRAULIC PUMP, OVERHAUL

THE ABOVE EXAMPLE SHOWS THE

MACHINE LOCATION AS 82621 WHICH REPRESENTS THE CRAWLER

EQUIPMENT HYDRAULIC PUMP.

FOR A MORE SPECIFIC LOCATION.

MAIN SYSTEM PUMP