Repair Labor Guidelines: 345D and 349D EXCAVATORS

October 2012
Repair Labor Guidelines

345D and 349D EXCAVATORS
JGB1-Up (Machine) RGG1-Up (Machine) GYR1-Up (Machine)
BYC1-Up (Machine) EEH1-Up (Machine) L5R1-Up (Machine)
P5D1-Up (Machine) KFH1-Up (Machine) KHS1-Up (Machine)
RGD1-Up (Machine) KLH1-Up (Machine) PBT1-Up (Machine)
WTD1-Up (Machine) RAJ1-Up (Machine) LKY1-UP (Machine)
RAE1-Up (Machine) RBJ1-Up (Machine)
YEE1-Up (Machine) MLK1-Up (Machine)
GKF1-Up (Machine) NLM1-Up (Machine)
NNF1-Up (Machine) DKN1-Up (Machine)
NEG1-Up (Machine) JKN1-Up (Machine)
PZG1-Up (Machine) MEN1-Up (Machine)
DISCLAIMER: The repair labor time information in this publication is provided for
informational purposes only. Any repair procedures and safety information in the applicable
published Caterpillar® service repair manuals should be followed. The repair labor time
information in this publication is not all inclusive and is available to provide approximate
repair labor times only. The repair operations and details listed in this publication are
provided to generally show what was included in developing the repair labor time.
Combined Repair Times For
345D, 349D HYDRAULIC EXCAVATOR
COMP JOB MOD QTY Code Description

1052 000 Turbocharger, Comb Repair Time (Wrnt)
Notes: z If required, add code (1052-002--) for Turbocharger, Transfer Components To/From.
z If required, add code (1052-017--) for Disassemble and Assemble Turbocharger.
Time Includes: 349D L
4.0
Labor Code Code Description
1052-035 Troubleshoot Turbocharger 0.7
1052-074 Wash Turbocharger 0.4
1052-010 Remove & Install Turbocharger 2.5
1052-030 Test After Repair Turbocharger 0.4

1052 000 GKO Turbocharger, Comb Repair Time (Wrnt), Gasket Only
3.6
1052-035 Troubleshoot Turbocharger 0.7
1052-074 Wash Turbocharger 0.4
1052-010 Remove & Install Turbocharger 2.5

1058 000 Inlet Manifold, Comb Repair Time (Wrnt)
Notes: None

2.1
1058-035 Troubleshoot Inlet Manifold 0.6
1058-074 Wash Inlet Manifold 0.4
1058-010 Remove & Install Inlet Manifold 0.7
1058-030 Test After Repair Inlet Manifold 0.4

1058 000 GKO Inlet Manifold, Comb Repair Time (Wrnt), Gasket Only
Notes: None

1.7
1058-035 Troubleshoot Inlet Manifold 0.6
1058-074 Wash Inlet Manifold 0.4
1058-010 Remove & Install Inlet Manifold 0.7

1059 000 Exhaust Manifold, Comb Repair Time (Wrnt)
Page 2 of 122
Notes: None

4.6
1059-035 Troubleshoot Exhaust Manifold 0.6
1059-074 Wash Exhaust Manifold 0.4
1059-010 Remove & Install Exhaust Manifold 3.2
1059-030 Test After Repair Exhaust Manifold 0.4

1059 000 GKO Exhaust Manifold, Comb Repair Time (Wrnt), Gasket Only
Notes: None

4.2
1059-035 Troubleshoot Exhaust Manifold 0.6
1059-074 Wash Exhaust Manifold 0.4
1059-010 Remove & Install Exhaust Manifold 3.2

1256 000 Fuel Transfer Pump, Comb Repair Time (Wrnt)
Notes: None

2.4
1256-035 Troubleshoot Fuel Transfer Pump 0.7
1256-074 Wash Fuel Transfer Pump 0.4
1256-010 Remove & Install Fuel Transfer Pump 0.7
1256-030 Test After Repair Fuel Transfer Pump 0.6

1256 000 GKO Fuel Transfer Pump, Comb Repair Time (Wrnt), Gasket Only
Notes: None

1.8
1256-035 Troubleshoot Fuel Transfer Pump 0.7
1256-074 Wash Fuel Transfer Pump 0.4
1256-010 Remove & Install Fuel Transfer Pump 0.7

1302 000 Engine Oil Pan, Comb Repair Time (Wrnt)
Notes: None
Page 3 of 122
3.7
1302-035 Troubleshoot Engine Oil Pan 0.6
1302-074 Wash Engine Oil Pan 0.4
1302-010 Remove & Install Engine Oil Pan 2.3
1302-030 Test After Repair Engine Oil Pan 0.4

1302 000 GKO Engine Oil Pan, Comb Repair Time (Wrnt), Gasket Only
Notes: None

3.3
1302-035 Troubleshoot Engine Oil Pan 0.6
1302-074 Wash Engine Oil Pan 0.4
1302-010 Remove & Install Engine Oil Pan 2.3

1306 000 Eng Oil Filter Hsg/Base, Comb Repair Time (Wrnt)
Notes: None

2.6
1306-035 Troubleshoot Eng Oil Filter Hsg/Base 0.6
1306-074 Wash Eng Oil Filter Hsg/Base 0.4
1306-010 Remove & Install Eng Oil Filter Hsg/Base 1.2
1306-030 Test After Repair Eng Oil Filter Hsg/Base 0.4

1306 000 GKO Eng Oil Filter Hsg/Base, Comb Repair Time (Wrnt), Gasket Only
Notes: None

2.2
1306-035 Troubleshoot Eng Oil Filter Hsg/Base 0.6
1306-074 Wash Eng Oil Filter Hsg/Base 0.4
1306-010 Remove & Install Eng Oil Filter Hsg/Base 1.2

1355 000 Thermostat/Water Temp Reg, Comb Repair Time (Wrnt)
Notes: None

3.7
1355-035 Troubleshoot Thermostat/Water Temp Reg 0.7
1355-074 Wash Thermostat/Water Temp Reg 0.4
Page 4 of 122
1355-010 Remove & Install Thermostat/Water Temp Reg 2.0
1355-030 Test After Repair Thermostat/Water Temp Reg 0.6

1355 000 GKO Thermostat/Water Temp Reg, Comb Repair Time (Wrnt), Gasket Only
Notes: None

3.1
1355-035 Troubleshoot Thermostat/Water Temp Reg 0.7
1355-074 Wash Thermostat/Water Temp Reg 0.4
1355-010 Remove & Install Thermostat/Water Temp Reg 2.0

1361 000 Water Pump, Comb Repair Time (Wrnt)
Notes: None

7.4
1361-035 Troubleshoot Water Pump 0.6
1361-074 Wash Water Pump 0.4
1361-010 Remove & Install Water Pump 6.0
1361-030 Test After Repair Water Pump 0.4

1361 000 GKO Water Pump, Comb Repair Time (Wrnt), Gasket Only
Notes: None

7.0
1361-035 Troubleshoot Water Pump 0.6
1361-074 Wash Water Pump 0.4
1361-010 Remove & Install Water Pump 6.0

1378 000 Engine Oil Cooler, Comb Repair Time (Wrnt)
Notes: None

4.3
1378-035 Troubleshoot Engine Oil Cooler 0.7
1378-074 Wash Engine Oil Cooler 0.4
1378-010 Remove & Install Engine Oil Cooler 2.6
1378-030 Test After Repair Engine Oil Cooler 0.6
Page 5 of 122
SEGMENTED REPAIR TIMES FOR
345D, 349D HYDRAULIC EXCAVATOR

1000 010 Engine, Remove & Install
Notes: None

17.5
Remove 7.2
Open Compartment Door, Left Front
Separate Disconnect Switch, Machine
Open Hood
Remove Exhaust Pipe, Extension
Install Hood, Lift
Remove Hood, Bolt(S), Limited Quantity
Remove Hood, Right Side
Separate Exhaust Pipe, Turbocharger To Exhaust
Separate Exhaust Pipe, With Turbocharger
Separate Muffler, Drain Line
Install Muffler, Lift
Remove Muffler, Clamp, Both
Remove Muffler
Remove Bottom Guard, Access Cover
Open Radiator, Drain
Drain Engine Coolant
Remove Bottom Guard, Right Side
Close Fuel Shutoff, Main
Remove Bottom Guard, Center
Remove Bottom Guard, Center, Remaining
Drain Engine Oil
Separate Engine Oil Pan, Wiring Harness
Remove Engine Oil Pan, Bolt(S), Set (All)
Remove Engine Oil Pan
Remove Engine Enclosure, Support
Remove Air Line/Pipe, Support
Remove Air Line/Pipe, Aftercooler To Manifold
Remove Air Line/Pipe, Turbo To Aftercooler
Separate Radiator Hose, Top
Separate Ether Starting Aid, Tube
Remove Engine Sound Suppression, Top
Remove Bottom Guard, Left Rear
Remove Radiator & Oil Cooler, Arms & Braces, Both
Remove Engine Sound Suppression, Bottom
Separate Fuel Transfer Pump, Hose(S)
Remove Serpentine Belt
Separate Refrigerant Compressor, Wiring Harness
Remove Refrigerant Compressor, Bolt(S)
Turn/Reposition Refrigerant Compressor
Separate Alternator, Wiring Harness, Set (All)
Separate Water Pump, Hose(S)
Separate Air Line/Pipe, Filter To Turbocharger
Remove Engine Enclosure, Handle
Remove Firewall, Left Side, Remaining
Install Muffler, Lift, Limited Quantity
Page 6 of 122
Remove Muffler, Support
Remove Bottom Guard, Right Rear
Remove Bottom Guard, Right Side, First One
Remove Firewall, Bottom
Separate Piston & Gear Pump, Hose(S), Limited Quantity
Turn/Reposition Eng Oil Filter Hsg/Base
Remove Firewall
Separate Fuel Supply/Return Lines, Return
Separate Eng Oil Filter Hsg/Base, Hose(S), Both
Close Cab Heater, Water Valve, Both
Separate Heater Hose/Lines, Engine, Both
Separate Eng Electronic Cont Mod, Wiring Harness, Set (All)
Turn/Reposition Eng Electronic Cont Mod, Wiring Harness
Separate Ground/Static Strap, Frame
Separate Electric Starting Motor, Wiring, Set (All)
Install Piston & Gear Pump, Lift, Limited Quantity
Remove Piston & Gear Pump, Bolt(S), Set (All)
Lift & Block Piston & Gear Pump
Install Engine, Lift
Remove Engine Mount, Bolt(S), Set (All)
Remove Engine
Clean 0.3
Clean Piston & Gear Pump, Hose(S), Set (All)
Clean Radiator, Hose(S), Set (All)
Clean Engine, Limited Quantity
Install 10.0
Install Engine
Install Piston & Gear Pump
Install Piston & Gear Pump, Bolt(S), Set (All)
Lower Piston & Gear Pump
Install Engine Mount, Bolt(S), Set (All)
Remove Engine, Lift
Torque Engine Mount, Bolt(S), Set (All)
Connect Electric Starting Motor, Wiring, Set (All)
Connect Ground/Static Strap, Frame
Install Engine Wiring Harness, Clamp
Connect Eng Electronic Cont Mod, Wiring Harness
Connect Heater Hose/Lines, Engine, Both
Open Cab Heater, Water Valve, Both
Connect Eng Oil Filter Hsg/Base, Hose(S), Both
Connect Fuel Supply/Return Lines, Return
Install Firewall
Install Eng Oil Filter Hsg/Base
Connect Piston & Gear Pump, Hose(S), Limited Quantity
Install Firewall, Bottom
Install Bottom Guard, Right Rear
Install Bottom Guard, Right Side, First One
Install Muffler, Support
Remove Muffler, Lift, Limited Quantity
Install Firewall, Assembled
Install Firewall, Handle
Connect Air Line/Pipe, Filter To Turbocharger, Both
Connect Water Pump, Hose(S)
Connect Alternator, Wiring Harness, Set (All)
Install Refrigerant Compressor, Bolt(S), Set (All)
Connect Refrigerant Compressor, Wiring Harness
Install Serpentine Belt
Connect Fuel Transfer Pump, Hose(S)
Install Engine Sound Suppression, Bottom
Install Radiator & Oil Cooler, Arms & Braces, Both
Install Bottom Guard, Left Rear
Page 7 of 122
Install Engine Sound Suppression, Top
Connect Ether Starting Aid, Tube
Connect Radiator Hose, Top
Install Air Line/Pipe, Turbo To Aftercooler
Install Air Line/Pipe, Aftercooler To Manifold
Install Air Line/Pipe, Support
Install Engine Enclosure, Support
Install Engine Oil Pan
Install Engine Oil Pan, Bolt(S), Set (All)
Torque Engine Oil Pan, Bolt(S), Set (All)
Refill Engine Oil
Connect Engine Oil Pan, Wiring Harness
Install Bottom Guard, Center
Install Bottom Guard, Center, Remaining
Open Fuel Shutoff
Install Bottom Guard, Right Side
Close Radiator, Drain
Refill Engine Coolant
Install Bottom Guard, Access Cover
Install Muffler
Install Muffler, Clamp, Both
Tighten Muffler, Clamp, Both
Remove Muffler, Lift
Connect Muffler, Drain Line
Connect Exhaust Pipe, With Turbocharger
Connect Exhaust Pipe, Turbocharger To Exhaust
Install Hood, Right Side
Install Hood, Bolt(S), Limited Quantity
Remove Hood, Lift, First One
Install Exhaust Pipe, Extension
Close Hood
Connect Disconnect Switch, Machine
Close Compartment Door, Left Front

1000 031 OX Engine, Dynamometer Test, Out F/Out Hull/Off Site
Notes: z This time has been adjusted to include the 1.2 times claimable labor rate for a warranty repair.
z This dyno test should only be performed in conjunction with a major repair, such as R&I crankshaft.
z To be eligible for this time the dealer technician performing the PAR “must be” PAR Certified.
5.0
Dynamometer Test 5.0

Move Engine, With Dynamometer Test
Connect Engine, Out F/Out Hull/Off Site
Separate Engine Coolant, Line(S)
Separate Fuel, Line(S)
Connect Engine Test Equipment, Battery
Connect Auxiliary Power Unit
Dynamometer Test Engine, Out F/Out Hull/Off Site
Separate Auxiliary Power Unit
Separate Engine Test Equipment, Battery
Connect Fuel, Line(S)
Connect Engine Coolant, Line(S)
Separate Engine, Out F/Out Hull/Off Site
Move Engine
Page 8 of 122
1000 031 P0 Engine, Dynamometer Test, Par Preliminary Inspect
Notes: z This time is not eligible to be adjusted to the 1.2 times labor for claimable labor rate for a Dyno warranty repair.
0.9

Dynamometer Test Engine, Par Preliminary Inspect

1000 031 P1 Engine, Dynamometer Test, Par
Notes: z If PAR rerun is required, add (1000-031-P2-) or (1000-031-P3-)
z This time has been adjusted to include the 1.2 times claimable labor rate for a warranty repair.
z A stationary regeneration commanded by Cat ET must be completed prior to running an EPA 2007 engine for a PAR test.
z To be eligible for this time, the dealer technician performing the PAR must be PAR Certified.
2.8

Dynamometer Test Engine, Par

1000 031 P2 Engine, Dynamometer Test, Par After Repair
Notes: z Add this code to (1000-031-P1-) for initial par dyno test.
0.8

Dynamometer Test Engine, Par After Repair

1000 031 P3 Engine, Dynamometer Test, Par After Repair & Unhook
Notes: z Add this code to (1000-031-P1-) for initial par dyno test.
2.4

Dynamometer Test Engine, Par After Repair & Unhook

1000 072 Engine, Paint
Notes: z This time is for a complete painting of the engine as necessary, after a major repair.
1.7
Paint 1.7
Paint Engine

1000 072 MN Engine, Paint, Minor
Notes: z For component touch-up after a minor repair.
z Use only if not already included & documented in service report.
Page 9 of 122
0.2
Paint 0.2
Paint Engine, Minor

1000 074 Engine, Wash
Notes: z This time is for a complete exterior wash of the engine, as necessary, prior to a major repair.
0.4
Wash 0.4
Wash Engine

1000 074 MN Engine, Wash, Minor
Notes: z This time is for a localized washing of an engine around an individual component, it is not a complete engine wash.
0.4
Wash 0.4
Wash Engine, Minor

1050 034 Air Induction & Exh Sys, Crack/Leak Test
Notes: None

0.2
Crack/Leak Test 0.2

Crack/Leak Test Air Induction & Exh Sys

1050 040 Air Induction & Exh Sys, Inspect
Notes: z This code includes air filter R&I for inspection and inspecting the intake and exhaust system components for damage and leaks with
the engine running.
0.2
Inspect 0.2
Remove & Install Air Cleaner, Filter
Inspect Air Induction & Exh Sys, Tube
Inspect Air Cleaner, Filter
Inspect Exhaust Pipe

1051 010 HG Air Cleaner, Remove & Install, Housing
Notes: None
Page 10 of 122
1.5
Remove 1.1
Remove Air Cleaner, Cover
Remove Air Cleaner, Filter, Both
Separate Air Cleaner, Wiring Harness
Separate Air Cleaner, Hose(S)
Remove Air Cleaner, Bolt(S), Set (All)
Remove Air Cleaner, Housing
Clean 0.1
Clean Air Cleaner, Housing
Install 0.3
Install Air Cleaner, Housing
Install Air Cleaner, Bolt(S), Set (All)
Connect Air Cleaner, Hose(S)
Connect Air Cleaner, Wiring Harness
Install Air Cleaner, Filter, Both
Install Air Cleaner, Cover

1052 002 Turbocharger, Tfr Components To/From
Notes: z If required, claim this code when replacing the Turbocharger with an exchange Turbocharger.
0.1
Tfr Components To/From 0.1

Remove & Install Turbocharger, Fitting, Set (All)

1052 010 Turbocharger, Remove & Install
2.5
Remove 0.8
Open Hood, Center
Remove Platform/Deck, Step
Separate Turbocharger, Supply Line
Separate Turbocharger, Drain Line
Separate Coolant Hose/Lines, With Turbocharger, Set (All)
Install Turbocharger, Lift
Remove Turbocharger, Nut(S), Set (All)
Remove Turbocharger
Clean 0.2
Clean Turbocharger, Line(S), Both
Clean Exhaust Manifold, Limited Quantity
Clean Turbocharger
Install 1.5
Install Turbocharger
Page 11 of 122
Install Turbocharger, Nut(S), Set (All)
Torque Turbocharger, Nut(S), Set (All)
Remove Turbocharger, Lift
Connect Coolant Hose/Lines, With Turbocharger, Set (All)
Connect Turbocharger, Drain Line
Connect Turbocharger, Supply Line
Connect Air Line/Pipe, Filter To Turbocharger
Install Platform/Deck, Step
Close Hood

1052 017 Turbocharger, Disassemble & Assemble
Notes: None

0.2
Disassemble 0.1
Loosen Turbo Compressor Housing, Clamp
Loosen Turbo Turbine Housing, Clamp
Remove Turbocharger Cartridge
Assemble 0.1
Install Turbocharger Cartridge
Tighten Turbo Turbine Housing, Clamp
Tighten Turbo Compressor Housing, Clamp

1052 030 Turbocharger, Test After Repair
Notes: None

0.4
Test After Repair 0.4

Test After Repair Turbocharger

1052 035 Turbocharger, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Turbocharger

1052 040 Turbocharger, Inspect
Page 12 of 122
Notes: z Use this code to inspect turbo shaft for end play, side play, and compressor wheel damage.
z Use this code when diagnosing engine performance problems, do not also submit code (1052-082--).
0.2
Inspect 0.2
Inspect Turbocharger

1052 074 Turbocharger, Wash
Notes: None

0.4
Wash 0.4
Wash Turbocharger

1052 082 Turbocharger, Measure
Notes: z Use this code when diagnosing engine performance problems, do not also submit code (1052-040--).
0.4
Measure 0.4
Measure Turbocharger

1058 010 Inlet Manifold, Remove & Install
Notes: None

0.7
Remove 0.3
Open Hood
Separate Inlet Manifold, Wiring Harness, Both
Remove Inlet Manifold, Bolt(S), Set (All)
Remove Inlet Manifold
Clean 0.1
Clean Inlet Manifold, Gasket
Install 0.3
Install Inlet Manifold
Install Inlet Manifold, Bolt(S), Set (All)
Connect Inlet Manifold, Wiring Harness, Both
Close Hood
Page 13 of 122
1058 030 Inlet Manifold, Test After Repair
Notes: None

0.4

Test After Repair Inlet Manifold

1058 035 Inlet Manifold, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Inlet Manifold

1058 074 Inlet Manifold, Wash
Notes: None

0.4
Wash 0.4
Wash Inlet Manifold

1058 082 PX Inlet Manifold, Measure, Pressure(S)
Notes: z Claim this code when this procedure is performed as part of the troubleshooting process.
0.3
Measure 0.3
Measure Inlet Manifold, Pressure(S)

1059 010 Exhaust Manifold, Remove & Install
Notes: None

3.2
Remove 0.9
Open Hood, Center
Page 14 of 122
Separate Turbocharger, Supply Line
Separate Turbocharger, Drain Line
Install Exhaust Manifold, Lift
Remove Exhaust Manifold, Nut(S), Set (All)
Remove Exhaust Manifold
Remove Turbocharger, Nut(S), Limited Quantity
Remove Turbocharger, Out F/Out Hull/Off Site
Clean 0.3
Clean Exhaust Manifold
Clean Turbocharger, Line(S), Both
Clean Turbocharger
Install 2.0
Install Turbocharger, Out F/Out Hull/Off Site
Install Turbocharger, Nut(S), Limited Quantity
Install Exhaust Manifold
Install Exhaust Manifold, Nut(S), Set (All)
Torque Exhaust Manifold, Nut(S), Set (All)
Torque Turbocharger, Nut(S), Set (All)
Remove Exhaust Manifold, Lift
Connect Turbocharger, Drain Line
Connect Turbocharger, Supply Line
Connect Air Line/Pipe, Filter To Turbocharger
Close Hood

1059 030 Exhaust Manifold, Test After Repair
Notes: None

0.4

Test After Repair Exhaust Manifold

1059 035 Exhaust Manifold, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Exhaust Manifold

1059 074 Exhaust Manifold, Wash
Page 15 of 122
Notes: None

0.4
Wash 0.4
Wash Exhaust Manifold

1062 010 Muffler, Remove & Install
Notes: None

2.3
Remove 1.0
Open Hood, Center
Install Hood, Lift
Remove Muffler
Install 1.3
Install Muffler
Close Hood

1063 010 Aftercooler, Remove & Install
Notes: None

1.9
Remove 0.7
Page 16 of 122
Remove Compartment Door, Bolt(S), Set (All)
Open Compartment Door, Left Rear
Install Hood, Lift
Remove Hood, Bolt(S), Set (All)
Remove Hood, Left Side
Remove Hood, Support, One Side
Separate Aftercooler, Hose(S), Both
Install Aftercooler, Lift
Remove Aftercooler, Bolt(S), Set (All)
Remove Aftercooler
Install 1.2
Install Aftercooler
Install Aftercooler, Bolt(S), Set (All)
Remove Aftercooler, Lift
Connect Aftercooler, Hose(S), Both
Install Hood, Support, One Side
Install Hood, Left Side
Install Hood, Bolt(S)
Remove Hood, Lift
Close Compartment Door, Left Rear
Install Compartment Door, Bolt(S), Set (All)

1063 034 AA Aftercooler, Crack/Leak Test, Air To Air
Notes: z Claim this code when this procedure is performed as part of the troubleshooting process
0.6
Crack/Leak Test 0.6

Crack/Leak Test Aftercooler, Air To Air

1064 034 AA Aftercooler Core, Crack/Leak Test, Air To Air
Notes: None

0.6
Crack/Leak Test 0.6

Crack/Leak Test Aftercooler Core, Air To Air

1064 046 AA Aftercooler Core, Flush, Air To Air
Notes: None

1.1
Flush 1.1
Flush Aftercooler Core, Air To Air
Page 17 of 122
108E 030 Exhaust Combustion Lines, Test After Repair
Notes: None

0.4

Test After Repair Exhaust Combustion Lines

1100 030 Cylinder Head Assembly, Test After Repair
Notes: None

1.2

Test After Repair Cylinder Head Assembly

1100 035 Cylinder Head Assembly, Troubleshoot
Notes: None

1.4
Troubleshoot 1.4
Troubleshoot Cylinder Head Assembly

1100 074 Cylinder Head Assembly, Wash
Notes: None

0.6
Wash 0.6
Wash Cylinder Head Assembly

1101 034 Cylinder Head (Bare), Crack/Leak Test
Notes: None

1.4
Crack/Leak Test 1.4
Page 18 of 122
Clean Cylinder Head (Bare)
Remove, Clean & Install Cylinder Head (Bare), Plate
Crack/Leak Test Cylinder Head (Bare)

1101 040 CK Cylinder Head (Bare), Inspect, Crack(S)
Notes: z This is the only valid verification of cylinder head casting failure that Caterpillar will accept for warranty.
3.9
Remove & Install 1.0

Remove & Install Valve Spring, Set (All)
Remove & Install Inlet/Exhaust Valve, Set (All)
Remove & Install Valve Guide, Seal, Set (All)
Check Valve Guide, Set (All)
Crack/Leak Test 1.4
Clean Cylinder Head (Bare)
Remove, Clean & Install Cylinder Head (Bare), Plate
Crack/Leak Test Cylinder Head (Bare)
Remove & Install High-Pressure Turbo, Out F/Out Hull/Off Site
Remove & Install Exhaust Manifold, Out F/Out Hull/Off Site
Remove & Install Exhaust Manifold, Stud(S), Set (All)
Remove & Install Thermostat/Water Temp Reg, Out F/Out Hull/Off Site
Remove & Install Lifting Eye/Bracket, Out F/Out Hull/Off Site
Remove & Install Inlet Air Temp Sensor, Out F/Out Hull/Off Site
Remove & Install Boost Pressure Sensor, Out F/Out Hull/Off Site
Remove & Install Heater Hose/Lines, Fitting
Unpack & Pack Cylinder Head Assembly
Steam Clean Cylinder Head Assembly
Paint Cylinder Head Assembly

1101 063 Cylinder Head (Bare), Machine/Grind/Mill
Notes: None

1.6
Machine/Grind/Mill 1.6
Machine/Grind/Mill Cylinder Head (Bare)

1101 064 Cylinder Head (Bare), Ream/Bore/Drill
Notes: z This code is used for broken exhaust manifold studs, claim this as actual reasonable time.
0.0
Ream/Bore/Drill 0.0
Ream/Bore/Drill Cylinder Head (Bare)

1102 030 Rocker Shaft Assembly, Test After Repair
Page 19 of 122
Notes: None

0.4

Test After Repair Rocker Shaft Assembly

1102 035 Rocker Shaft Assembly, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Rocker Shaft Assembly

1102 074 Rocker Shaft Assembly, Wash
Notes: None

0.4
Wash 0.4
Wash Rocker Shaft Assembly

1103 063 E Valve Seat/Insert, Machine/Grind/Mill, Each
Notes: None

0.2
Machine/Grind/Mill 0.2
Machine/Grind/Mill Valve Seat/Insert, Each

1105 020 E Inlet/Exhaust Valve, Recondition, Each
Notes: z Claim this code once for each cylinder.
0.2
Recondition 0.2
Recondition Inlet/Exhaust Valve, Each
Page 20 of 122
1105 020 S Inlet/Exhaust Valve, Recondition, Set (All)
Notes: None

1.1
Recondition 1.1
Recondition Inlet/Exhaust Valve, Set (All)

1105 030 Inlet/Exhaust Valve, Test After Repair
Notes: None

0.4

Test After Repair Inlet/Exhaust Valve

1105 035 Inlet/Exhaust Valve, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Inlet/Exhaust Valve

1105 074 Inlet/Exhaust Valve, Wash
Notes: None

0.4
Wash 0.4
Wash Inlet/Exhaust Valve

1107 010 Valve Cover, Remove & Install
Notes: None

1.0
Remove 0.5
Page 21 of 122
Open Hood, Center
Remove Valve Cover, Nut(S), Set (All)
Remove Valve Cover
Clean 0.1
Clean Valve Cover
Install 0.4
Install Valve Cover
Install Valve Cover, Nut(S), Set (All)
Torque Valve Cover, Nut(S), Set (All)
Close Hood, Center

1107 030 Valve Cover, Test After Repair
Notes: None

0.4

Test After Repair Valve Cover

1107 035 Valve Cover, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Valve Cover

1107 074 Valve Cover, Wash
Notes: None

0.4
Wash 0.4
Wash Valve Cover

1120 030 Valve Cover Base, Test After Repair
Notes: None
Page 22 of 122
0.4

Test After Repair Valve Cover Base

1120 035 Valve Cover Base, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Valve Cover Base

1120 074 Valve Cover Base, Wash
Notes: None

0.4
Wash 0.4
Wash Valve Cover Base

1123 030 Rocker Arm, Test After Repair
Notes: None

0.4

Test After Repair Rocker Arm

1123 035 Rocker Arm, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Rocker Arm

1123 074 Rocker Arm, Wash
Notes:
None
Page 23 of 122
0.4
Wash 0.4
Wash Rocker Arm

1130 030 Valve Actuator, Test After Repair
Notes: None

0.4

Test After Repair Valve Actuator

1130 035 Valve Actuator, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Valve Actuator

1130 074 Valve Actuator, Wash
Notes: None

0.4
Wash 0.4
Wash Valve Actuator

1156 010 Flywheel, Remove & Install
Notes: None

9.8
Remove 4.1
Open Hood
Install Hood, Lift
Page 24 of 122
Remove Muffler
Remove Hydraulic Tank, Access Cover
Drain Hydraulic Oil
Remove Hydraulic Hoses/Lines, Plug(S)
Drain Hydraulic Oil, Remaining
Remove Firewall, Assembled
Separate Piston & Gear Pump, Wiring Harness, Set (All)
Turn/Reposition Piston & Gear Pump, Wiring Harness
Separate Piston & Gear Pump, Hose(S), Set (All)
Separate Piston & Gear Pump, Elbow
Remove Firewall
Install Piston & Gear Pump, Lift
Remove Piston & Gear Pump, Main
Remove Eng Output Dr As/Coupling, Bolt(S), Set (All)
Remove Eng Output Dr As/Coupling
Remove Flywheel, Bolt(S), Limited Quantity
Install Flywheel, Lift
Remove Flywheel, Bolt(S), Remaining
Remove Flywheel
Clean 0.2
Clean Piston Pump, Hose(S), Set (All)
Clean Flywheel
Install 5.5
Install Flywheel
Install Flywheel, Bolt(S), Limited Quantity
Remove Flywheel, Lift
Install Flywheel, Bolt(S), Remaining
Install Eng Output Dr As/Coupling
Install Eng Output Dr As/Coupling, Bolt(S)
Torque Eng Output Dr As/Coupling, Bolt(S), Set (All)
Install Piston & Gear Pump, Main
Remove Piston & Gear Pump, Lift
Install Firewall
Connect Piston & Gear Pump, Hose(S), Set (All)
Connect Piston & Gear Pump, Elbow
Connect Piston & Gear Pump, Wiring Harness, Set (All)
Install Engine Enclosure, Handle
Install Hydraulic Hoses/Lines, Plug(S)
Refill Hydraulic Oil
Install Hydraulic Tank, Access Cover
Page 25 of 122
Remove Hydraulic System, Air
Install Muffler
Close Hood

1156 074 Flywheel, Wash
Notes: None

0.6
Wash 0.6
Wash Flywheel

1157 030 Flywheel Housing, Test After Repair
Notes: None

0.4

Test After Repair Flywheel Housing

1157 035 Flywheel Housing, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Flywheel Housing

1157 074 Flywheel Housing, Wash
Notes: None
Page 26 of 122
0.6
Wash 0.6
Wash Flywheel Housing

1160 030 Crankshaft Front Seal, Test After Repair
Notes: None

0.4

Test After Repair Crankshaft Front Seal

1160 035 Crankshaft Front Seal, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Crankshaft Front Seal

1160 074 Crankshaft Front Seal, Wash
Notes: None

0.4
Wash 0.4
Wash Crankshaft Front Seal

1161 030 Crankshaft Rear Seal, Test After Repair
Notes: None

0.4

Test After Repair Crankshaft Rear Seal

1161 035 Crankshaft Rear Seal, Troubleshoot
Notes: None
Page 27 of 122
0.7
Troubleshoot 0.7
Troubleshoot Crankshaft Rear Seal

1161 074 Crankshaft Rear Seal, Wash
Notes: None

0.4
Wash 0.4
Wash Crankshaft Rear Seal

1162 030 Timing Gear Housing, Test After Repair
Notes: None

0.4

Test After Repair Timing Gear Housing

1162 035 Timing Gear Housing, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Timing Gear Housing

1162 074 Timing Gear Housing, Wash
Notes: None

0.6
Wash 0.6
Wash Timing Gear Housing
Page 28 of 122
1163 030 Timing Gear Housing Plate, Test After Repair
Notes: None

0.4

Test After Repair Timing Gear Housing Plate

1163 035 Timing Gear Housing Plate, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Timing Gear Housing Plate

1163 074 Timing Gear Housing Plate, Wash
Notes: None

0.6
Wash 0.6
Wash Timing Gear Housing Plate

1166 030 Timing Gear Housing Cover, Test After Repair
Notes: None

0.4

Test After Repair Timing Gear Housing Cover

1166 035 Timing Gear Housing Cover, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Timing Gear Housing Cover
Page 29 of 122
1166 074 Timing Gear Housing Cover, Wash
Notes: None

0.4
Wash 0.4
Wash Timing Gear Housing Cover

1201 014 PG E Cylinder Block, Replace Gasket/Reseal, Plug(S), Each
Notes: None

0.3
Replace Gasket/Reseal 0.3

Replace Gasket/Reseal Cylinder Block, Plug(S), Each

1201 030 Cylinder Block, Test After Repair
Notes: None

1.2

Test After Repair Cylinder Block

1201 035 Cylinder Block, Troubleshoot
Notes: None

1.4
Troubleshoot 1.4
Troubleshoot Cylinder Block

1201 082 PX Cylinder Block, Measure, Pressure(S)
Notes: z Claim this code when the procedure is performed as part of the troubleshooting process.
0.3
Measure 0.3
Measure Cylinder Block, Pressure(S)
Page 30 of 122
1202 010 PSN Crankshaft, Remove & Install, Position Sensor
Notes: z AKA: Primary Speed/Timing Sensor
z If required, add code (1912-524--) for Engine Speed/Timing Sensor, Calibrate.
0.6
Remove 0.3
Open Hood
Separate Eng Speed/Timing Sensor, Wiring Harness
Remove Eng Speed/Timing Sensor, Bolt(S)
Remove Crankshaft, Position Sensor
Install 0.3
Install Crankshaft, Position Sensor
Install Eng Speed/Timing Sensor, Bolt(S)
Connect Eng Speed/Timing Sensor, Wiring Harness
Close Hood

1202 030 Crankshaft, Test After Repair
Notes: None

1.2

Test After Repair Crankshaft

1202 035 Crankshaft, Troubleshoot
Notes: None

1.4
Troubleshoot 1.4
Troubleshoot Crankshaft

1202 074 Crankshaft, Wash
Notes: None

0.6
Wash 0.6
Wash Crankshaft
Page 31 of 122
1209 074 Cam Rlr Fol/Valve Lifter, Wash
Notes: None

0.6
Wash 0.6
Wash Cam Rlr Fol/Valve Lifter

1210 010 PSN Camshaft, Remove & Install, Position Sensor
Notes: z AKA: Secondary Speed/Timing Sensor
z If required, add code (1912-524--) for Engine Speed/Timing Sensor, Calibrate.
0.4
Remove 0.2
Open Hood
Separate Eng Speed/Timing Sensor, Wiring Harness
Remove Eng Speed/Timing Sensor, Bolt(S)
Remove Camshaft, Position Sensor
Install 0.2
Install Camshaft, Position Sensor
Install Eng Speed/Timing Sensor, Bolt(S)
Connect Eng Speed/Timing Sensor, Wiring Harness
Close Hood

1210 030 Camshaft, Test After Repair
Notes: None

1.2

Test After Repair Camshaft

1210 035 Camshaft, Troubleshoot
Notes: None

1.4
Troubleshoot 1.4
Page 32 of 122
Troubleshoot Camshaft

1210 074 Camshaft, Wash
Notes: None

0.6
Wash 0.6
Wash Camshaft

1212 025 Camshaft Gear, Adjust
Notes: None

0.7
Adjust 0.7
Install Dial Ind&Cntc Pnt M&A Tls
Adjust Camshaft Gear
Remove Dial Ind&Cntc Pnt M&A Tls
Torque Camshaft Gear

1212 030 Camshaft Gear, Test After Repair
Notes: None

0.6

Test After Repair Camshaft Gear

1212 035 Camshaft Gear, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Camshaft Gear

1212 074 Camshaft Gear, Wash
Notes:
None
Page 33 of 122
0.6
Wash 0.6
Wash Camshaft Gear

1214 020 A Piston, Recondition, Each Additional
Notes: None

0.2
Recondition 0.2
Remove Piston Rings, Each Additional
Wash Piston, Each Additional
Recondition Piston, Each Additional
Check Piston Rings, Groove, Each Additional
Clean & Inspect Piston, Each Additional

1214 020 F Piston, Recondition, First One
Notes: None

0.4
Recondition 0.4
Remove Piston Rings, First One
Wash Piston, First One
Recondition Piston, First One
Check Piston Rings, Groove, First One
Clean & Inspect Piston, First One

1214 020 S Piston, Recondition, Set (All)
Notes: None

1.6
Recondition 1.6
Remove Piston Rings, Set (All)
Wash Piston, Set (All)
Recondition Piston, Set (All)
Check Piston Rings, Groove, Set (All)
Clean & Inspect Piston, Set (All)

1216 020 FH E Cylinder Liner, Recondition, Flex Hone, Each
Page 34 of 122
Notes: None

0.3
Recondition 0.3
Inspect Cylinder Liner, Flex Hone, Each
Measure Cylinder Liner, Flex Hone, Each
Recondition Cylinder Liner, Flex Hone, Each
Wash Cylinder Liner, Flex Hone, Each
Lubricate Cylinder Liner, Flex Hone, Each

1216 020 FH S Cylinder Liner, Recondition, Flex Hone, Set (All)
Notes: None

1.6
Recondition 1.6
Inspect Cylinder Liner, Flex Hone, Set (All)
Measure Cylinder Liner, Flex Hone, Set (All)
Recondition Cylinder Liner, Flex Hone, Set (All)
Wash Cylinder Liner, Flex Hone, Set (All)
Lubricate Cylinder Liner, Flex Hone, Set (All)

1216 020 HH E Cylinder Liner, Recondition, Hard Hone, Each
Notes: None

0.6
Recondition 0.6
Inspect Cylinder Liner, Hard Hone, Each
Measure Cylinder Liner, Hard Hone, Each
Recondition Cylinder Liner, Hard Hone, Each
Wash Cylinder Liner, Hard Hone, Each
Lubricate Cylinder Liner, Hard Hone, Each

1216 020 HH S Cylinder Liner, Recondition, Hard Hone, Set (All)
Notes: None

3.7
Recondition 3.7
Inspect Cylinder Liner, Hard Hone, Set (All)
Measure Cylinder Liner, Hard Hone, Set (All)
Recondition Cylinder Liner, Hard Hone, Set (All)
Wash Cylinder Liner, Hard Hone, Set (All)
Page 35 of 122
Lubricate Cylinder Liner, Hard Hone, Set (All)

1216 082 LJ S Cylinder Liner, Measure, Liner Projection, Set (All)
Notes: None

0.8
Measure 0.8
Install Meas & Ck Fixt M&A Tools
Measure Cylinder Liner, Liner Projection, Set (All)
Remove Meas & Ck Fixt M&A Tools

1216 571 S Cylinder Liner, Clean & Inspect, Set (All)
Notes: None

0.8
Clean & Inspect 0.8

Clean & Inspect Cylinder Liner, Set (All)

1218 020 MJ A Connecting Rod, Recondition, Major, Each Additional
Notes: None

0.8
Recondition 0.8
Recondition Connecting Rod, Major, Each Additional

1218 020 MJ F Connecting Rod, Recondition, Major, First One
Notes: z If con-rods required only measure check, use code (1218-082--F).
z Major recondition includes measure/check rods and machining crankshaft & piston pin bore.
1.6
Recondition 1.6
Recondition Connecting Rod, Major, First One

1218 020 MJ S Connecting Rod, Recondition, Major, Set (All)
Notes: z If con-rods required only measure check, use code (1218-082--S).
z Major recondition includes measure/check rods and machining crankshaft & piston pin bore.
5.7
Page 36 of 122
Recondition 5.7
Recondition Connecting Rod, Major, Set (All)

1218 020 MN A Connecting Rod, Recondition, Minor, Each Additional
Notes: None

0.3
Recondition 0.3
Recondition Connecting Rod, Minor, Each Additional

1218 020 MN F Connecting Rod, Recondition, Minor, First One
Notes: z If con-rods required only measure check, use code (1218-082--F).
z Minor recondition includes measure/check rods and machining piston pin bore.
1.1
Recondition 1.1
Recondition Connecting Rod, Minor, First One

1218 020 MN S Connecting Rod, Recondition, Minor, Set (All)
Notes: z If con-rods required only measure check, use code (1218-082--S).
z Minor recondition includes measure/check rods and machining piston pin bore.
2.8
Recondition 2.8
Recondition Connecting Rod, Minor, Set (All)

1218 082 A Connecting Rod, Measure, Each Additional
Notes: None

0.2
Measure 0.2
Polish Bearings, Each Additional
Install Bearings, Each Additional
Measure Crankshaft, Each Additional
Polish Crankshaft, Each Additional
Measure Connecting Rod, Each Additional

1218 082 F Connecting Rod, Measure, First One
Notes: z If pin bore and/or crank journal bore require machining, use instead, either (1218-020-MN-F) or (1218-020-MJ-F).
Page 37 of 122
0.5
Measure 0.5
Polish Bearings, First One
Install Bearings, First One
Measure Crankshaft, First One
Polish Crankshaft, First One
Measure Connecting Rod, First One

1218 082 S Connecting Rod, Measure, Set (All)
Notes: z If pin bore and/or crank journal bore require machining, use instead, either code (1218-020-MN-S) or (1218-020-MJ-S).
1.7
Measure 1.7
Polish Bearings, Set (All)
Install Bearings, Set (All)
Measure Crankshaft, Set (All)
Polish Crankshaft, Set (All)
Measure Connecting Rod, Set (All)

1223 040 IT S Cylinder Block Cylinder, Inspect, Using Borescope, Set (All)
Notes: z Time includes inspecting all six cylinders with bore-o-scope through injector tip hole (includes rotating the crankshaft).
0.6
Inspect 0.6
Inspect Cylinder Block Cylinder, Using Borescope, Set (All)

1223 082 E Cylinder Block Cylinder, Measure, Each
Notes: z Use dial bore gauge to check and record size, roundness and taper of each cylinder or liner.
0.1
Measure 0.1
Measure Cylinder Block Cylinder, Each

1239 020 E Cylinder Pack, Recondition, Each
Notes: None

0.7
Recondition 0.7
Remove Piston & Connecting Rod, Each
Disassemble Piston & Connecting Rod, Each
Remove Piston Rings, Each
Clean Piston, Each
Page 38 of 122
Hone Cylinder Liner, Each
Assemble Piston & Connecting Rod, Each
Install Piston Rings, Each
Install Piston & Connecting Rod, Each

1239 020 S Cylinder Pack, Recondition, Set (All)
Notes: None

3.9
Recondition 3.9
Remove Piston & Connecting Rod, Out F/Out Hull/Off Site, Set (All)
Disassemble Piston & Connecting Rod, Set (All)
Remove Piston Rings, Set (All)
Clean Piston, Set (All)
Hone Cylinder Liner, Set (All)
Assemble Piston & Connecting Rod, Set (All)
Install Piston Rings, Set (All)
Install Piston & Connecting Rod, Out F/Out Hull/Off Site, Set (All)

1239 030 Cylinder Pack, Test After Repair
Notes: None

1.2

Test After Repair Cylinder Pack

1239 035 Cylinder Pack, Troubleshoot
Notes: None

1.4
Troubleshoot 1.4
Troubleshoot Cylinder Pack

1239 074 Cylinder Pack, Wash
Notes: None

0.6
Wash 0.6
Page 39 of 122
Wash Cylinder Pack

1250 046 Fuel System, Flush
Notes: None

0.6
Flush 0.6
Flush Fuel System

1250 082 PX Fuel System, Measure, Pressure(S)
Notes: None

0.3
Measure 0.3
Measure Fuel System, Pressure(S)

1250 535 Fuel System, Check
Notes: None

0.5
Check 0.5
Remove Air Inlet, Aftercooler To Manifold
Remove Fuel Pressure Sensor
Install Pressure Gauges & Probes
Install Fuel Pressure Gauge
Start Electrical Test Equipment
Modify Pers Mod-Chg Eng Paramtr, Using Ecap / Et
Run Engine, AT Low Idle
Run Engine, AT High Idle
Check Fuel Pressure Gauge, Pressure(S)
Remove Fuel Pressure Gauge
Remove Pressure Gauges & Probes
Install Fuel Pressure Sensor
Install Air Inlet, Aftercooler To Manifold

1256 010 Fuel Transfer Pump, Remove & Install
Notes: None

0.7
Page 40 of 122
Remove 0.3
Open Hood
Separate Fuel Transfer Pump, Hose(S), Both
Remove Fuel Transfer Pump, Bolt(S), Set (All)
Remove Fuel Transfer Pump
Clean 0.1
Clean Fuel Transfer Pump
Install 0.3
Install Fuel Transfer Pump
Install Fuel Transfer Pump, Bolt(S), Both
Connect Fuel Transfer Pump, Hose(S), Set (All)
Close Hood

1256 030 Fuel Transfer Pump, Test After Repair
Notes: None

0.6

Test After Repair Fuel Transfer Pump

1256 035 Fuel Transfer Pump, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Fuel Transfer Pump

1256 074 Fuel Transfer Pump, Wash
Notes: None

0.4
Wash 0.4
Wash Fuel Transfer Pump

1258 030 Fuel Priming Pump, Test After Repair
Notes:
None
Page 41 of 122
0.4

Test After Repair Fuel Priming Pump

1258 035 Fuel Priming Pump, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Fuel Priming Pump

1258 040 CV Fuel Priming Pump, Inspect, Check Valve
Notes: None

0.2
Inspect 0.2
Remove Fuel Priming Pump
Inspect Fuel Priming Pump, Check Valve
Install Fuel Priming Pump

1258 074 Fuel Priming Pump, Wash
Notes: None

0.4
Wash 0.4
Wash Fuel Priming Pump

1262 010 PY Fuel Filter Housing/Base, Remove & Install, Primary
Notes: None

0.8
Remove 0.4
Page 42 of 122
Close Fuel Shutoff
Drain Water Separator, Filter
Separate Fuel Filter Housing/Base, Wiring Harness
Separate Fuel Filter Housing/Base, Hose(S), Set (All)
Remove Fuel Filter, Primary
Remove Fuel Filter Housing/Base, Bolt(S), Set (All)
Remove Fuel Filter Housing/Base, Primary
Clean 0.1
Clean Fuel Filter Housing/Base, Primary
Install 0.3
Install Fuel Filter Housing/Base, Primary
Install Fuel Filter Housing/Base, Bolt(S), Set (All)
Install Fuel Filter, Primary
Connect Fuel Filter Housing/Base, Hose(S), Set (All)
Connect Fuel Filter Housing/Base, Wiring Harness
Open Fuel Shutoff

1262 010 SE Fuel Filter Housing/Base, Remove & Install, Secondary
Notes: None

0.6
Remove 0.3
Close Fuel Shutoff
Separate Fuel Filter Housing/Base, Wiring Harness, Limited Quantity
Separate Fuel Filter Housing/Base, Hose(S), Limited Quantity
Remove Fuel Filter, Secondary
Remove Fuel Filter Housing/Base, Secondary
Clean 0.1
Clean Fuel Filter Housing/Base, Secondary
Install 0.2
Install Fuel Filter Housing/Base, Secondary
Install Fuel Filter, Secondary
Connect Fuel Filter Housing/Base, Hose(S), Limited Quantity
Connect Fuel Filter Housing/Base, Wiring Harness, Limited Quantity
Open Fuel Shutoff

1262 030 Fuel Filter Housing/Base, Test After Repair
Notes:
None
Page 43 of 122
0.4

Test After Repair Fuel Filter Housing/Base

1262 035 Fuel Filter Housing/Base, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Fuel Filter Housing/Base

1262 074 Fuel Filter Housing/Base, Wash
Notes: None

0.4
Wash 0.4
Wash Fuel Filter Housing/Base

1273 010 Fuel Tank, Remove & Install
Notes: None

2.6
Remove 1.4
Open Fuel Tank Valve
Drain Fuel Tank
Remove Ladder/Step
Remove Handrail
Separate Fuel Tank, Wiring Harness, Set (All)
Remove Fuel Tank, Access Cover, Set (All)
Remove Fuel Tank, Bolt(S), Set (All)
Separate Fuel Tank, Hose(S), Set (All)
Install Fuel Tank, Lift
Remove Fuel Tank
Install 1.2
Install Fuel Tank
Install Fuel Tank, Bolt(S), Set (All)
Remove Fuel Tank, Lift
Connect Fuel Tank, Hose(S), Set (All)
Install Fuel Tank, Access Cover, Set (All)
Page 44 of 122
Connect Fuel Tank, Wiring Harness, Set (All)
Install Handrail
Install Ladder/Step
Refill Fuel Tank
Open Fuel Tank Valve

1274 030 Fuel Supply/Return Lines, Test After Repair
Notes: None

0.4

Test After Repair Fuel Supply/Return Lines

1274 035 Fuel Supply/Return Lines, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Fuel Supply/Return Lines

1274 042 Fuel Supply/Return Lines, Inspect & Maintain
Notes: z This code is a visual inspection of the fuel lines for cracks and/or leaks.
0.2
Inspect & Maintain 0.2

Separate Fuel, Line(S), Limited Quantity
Inspect Fuel Supply/Return Lines
Connect Fuel, Line(S), Limited Quantity

1274 074 Fuel Supply/Return Lines, Wash
Notes: None

0.4
Wash 0.4
Wash Fuel Supply/Return Lines
Page 45 of 122
1280 038 PX Fuel, Diagnostic Test, Pressure(S)
Notes: z This code does not include time to isolate and repair problem.
0.4
Diagnostic Test 0.4

Diagnostic Test Fuel, Pressure(S)

1280 082 Fuel, Measure
Notes: None

0.2
Measure 0.2
Measure Fuel

1290 030 Unit Injector, Test After Repair
Notes: None

0.6

Test After Repair Unit Injector

1290 035 Unit Injector, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Unit Injector

1290 038 I3 A Unit Injector, Diagnostic Test, Using Cyl Cut-Out Test, Each Additional
Notes: z If required, add this code if Unit Injector, Cylinder Cut-Out Test must be repeated.
0.6
Diagnostic Test 0.6

Diagnostic Test Unit Injector, Using Cyl Cut-Out Test, Each Additional

1290 038 I3 S Unit Injector, Diagnostic Test, Using Cyl Cut-Out Test, Set (All)
Page 46 of 122
Notes: z Claim this code when this procedure is performed as part of the troubleshooting and test after repair process.
z If required, add code (1290-038-I3-A) if Unit Injector, Cylinder Cut-Out Test must be repeated.
0.6
Diagnostic Test 0.6

Diagnostic Test Unit Injector, Using Cyl Cut-Out Test, Set (All)

1290 074 Unit Injector, Wash
Notes: None

0.4
Wash 0.4
Wash Unit Injector

1290 081 OD S Unit Injector, Test, Solenoid, Set (All)
Notes: None

0.6
Test 0.6
Test Unit Injector, Solenoid, Set (All)

1302 010 Engine Oil Pan, Remove & Install
Notes: None

2.3
Remove 1.1
Open Hood, Center
Drain Engine Oil
Separate Engine Oil Pan, Wiring Harness
Remove Engine Oil Pan, Bolt(S), Set (All)
Remove Engine Oil Pan
Clean 0.1
Clean Engine Oil Pan
Install 1.1
Install Engine Oil Pan
Install Engine Oil Pan, Bolt(S), Set (All)
Torque Engine Oil Pan, Bolt(S), Set (All)
Connect Engine Oil Pan, Wiring Harness
Refill Engine Oil
Page 47 of 122
Close Hood, Center

1302 030 Engine Oil Pan, Test After Repair
Notes: None

0.4

Test After Repair Engine Oil Pan

1302 035 Engine Oil Pan, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Engine Oil Pan

1302 064 Engine Oil Pan, Ream/Bore/Drill
Notes: None

0.7
Ream/Bore/Drill 0.7
Ream/Bore/Drill Engine Oil Pan

1302 074 Engine Oil Pan, Wash
Notes: None

0.4
Wash 0.4
Wash Engine Oil Pan

1304 002 Engine Oil Pump, Tfr Components To/From
Notes: z If required, claim this code when replacing the Engine Oil Pump with an exchange Oil Pump.
Page 48 of 122
0.2

Tfr Components To/From Engine Oil Pump

1304 030 Engine Oil Pump, Test After Repair
Notes: None

0.4

Test After Repair Engine Oil Pump

1304 035 Engine Oil Pump, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Engine Oil Pump

1304 040 Engine Oil Pump, Inspect
Notes: None

0.2
Inspect 0.2
Inspect Engine Oil Pump

1304 074 Engine Oil Pump, Wash
Notes: None

0.4
Wash 0.4
Wash Engine Oil Pump

1306 010 Eng Oil Filter Hsg/Base, Remove & Install
Page 49 of 122
Notes: None

1.2
Remove 0.5
Separate Eng Oil Filter Hsg/Base, Hose(S), Set (All)
Separate Eng Oil Filter Hsg/Base, Tube
Remove Eng Oil Filter Hsg/Base, Bolt(S), Set (All)
Remove Eng Oil Filter Hsg/Base
Clean 0.1
Clean Eng Oil Filter Hsg/Base
Install 0.6
Install Eng Oil Filter Hsg/Base
Install Eng Oil Filter Hsg/Base, Bolt(S), Set (All)
Connect Eng Oil Filter Hsg/Base, Tube
Connect Eng Oil Filter Hsg/Base, Hose(S), Set (All)

1306 030 Eng Oil Filter Hsg/Base, Test After Repair
Notes: None

0.4

Test After Repair Eng Oil Filter Hsg/Base

1306 035 Eng Oil Filter Hsg/Base, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Eng Oil Filter Hsg/Base

1306 074 Eng Oil Filter Hsg/Base, Wash
Notes: None

0.4
Wash 0.4
Page 50 of 122
Wash Eng Oil Filter Hsg/Base

1308 507 Engine Oil Filter, Cut & Analyze
Notes: None

0.3
Cut & Analyze 0.3

Cut & Analyze Engine Oil Filter

1316 035 Engine Oil Filler, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Engine Oil Filler

1316 074 Engine Oil Filler, Wash
Notes: None

0.4
Wash 0.4
Wash Engine Oil Filler

1317 010 Crankcase Breather, Remove & Install
Notes: None

0.5
Remove 0.2
Open Hood, Center
Separate Crankcase Breather, Hose(S)
Remove Crankcase Breather
Clean 0.1
Clean Crankcase Breather
Install 0.2
Install Crankcase Breather
Connect Crankcase Breather, Hose(S)
Page 51 of 122
Close Hood, Center

1317 030 Crankcase Breather, Test After Repair
Notes: None

0.4

Test After Repair Crankcase Breather

1317 035 Crankcase Breather, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Crankcase Breather

1317 074 Crankcase Breather, Wash
Notes: None

0.4
Wash 0.4
Wash Crankcase Breather

1326 025 Eng Oil Level Ga/Dipstick, Adjust
Notes: None

1.1
Adjust 1.1
Adjust Eng Oil Level Ga/Dipstick

1326 030 Eng Oil Level Ga/Dipstick, Test After Repair
Notes: None
Page 52 of 122
0.4

Test After Repair Eng Oil Level Ga/Dipstick

1326 035 Eng Oil Level Ga/Dipstick, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Eng Oil Level Ga/Dipstick

1326 074 Eng Oil Level Ga/Dipstick, Wash
Notes: None

0.4
Wash 0.4
Wash Eng Oil Level Ga/Dipstick

1331 081 S Piston Cooling Jet, Test, Set (All)
Notes: None

0.3
Test 0.3
Test Piston Cooling Jet, Set (All)

1348 008 SM Engine Oil, Take & Analyze S-O-S From, Sample
Notes: None

0.2
Take & Analyze S-O-S From 0.2

Take & Analyze S-O-S From Engine Oil, Sample

1348 082 PX Engine Oil, Measure, Pressure(S)
Notes: None
Page 53 of 122
0.3
Measure 0.3
Measure Engine Oil, Pressure(S)

1350 034 Engine Cooling System, Crack/Leak Test
Notes: None

0.3
Crack/Leak Test 0.3

Crack/Leak Test Engine Cooling System

1350 038 Q3 Engine Cooling System, Diagnostic Test, Using Bottle Test
Notes: None

0.5
Diagnostic Test 0.5

Diagnostic Test Engine Cooling System, Using Bottle Test

1350 046 Engine Cooling System, Flush
Notes: z Do not use this code in conjunction with any repair code that includes drain & refill coolant, instead use (1350-046-ES-).
2.0
Flush 2.0
Flush Engine Cooling System

1350 046 ES Engine Cooling System, Flush, Excludes Some R&I
Notes: z This code does not include draining old antifreeze and refilling with new.
1.5
Flush 1.5
Flush Engine Cooling System, Excludes Some R&I

1350 046 WD Engine Cooling System, Flush, With Dynamometer Test
Notes: None
Page 54 of 122
0.7
Flush 0.7
Flush Engine Cooling System, With Dynamometer Test

1351 010 PKG Radiator & Oil Cooler, Remove & Install, Package
Notes: None

9.9
Remove 4.5
Drain Hydraulic Oil
Open Hood, Center
Install Hood, Lift
Separate Radiator Hose, Lower
Remove Fan Guard, Bracket
Separate Hydraulic Fan Motor, Hose(S), Set (All)
Remove Hydraulic Oil Cooler, Tube, First One
Separate Hydraulic Oil Cooler, Tube, Remaining
Remove Hydraulic Oil Cooler, Support, Both
Separate Ether Starting Aid, Wiring Harness
Remove Ether Starting Aid
Turn/Reposition Fuel Cooler
Remove Radiator & Oil Cooler, Panel, Both Sides
Install Radiator & Oil Cooler, Lift
Remove Radiator & Oil Cooler, Bolt(S), Set (All)
Remove Radiator & Oil Cooler, Package
Clean 0.3
Clean Hydraulic Oil Cooler, Hose(S), Set (All)
Clean Aftercooler, Hose(S), Set (All)
Clean Radiator Guard, Bottom
Clean Hydraulic Fan Motor, Hose(S), Set (All)
Install 5.1
Install Radiator & Oil Cooler, Package
Install Radiator & Oil Cooler, Bolt(S), Set (All)
Page 55 of 122
Remove Radiator & Oil Cooler, Lift
Install Fuel Cooler, Bolt(S), Set (All)
Install Ether Starting Aid
Connect Ether Starting Aid, Wiring Harness
Install Hydraulic Oil Cooler, Support, Both
Install Hydraulic Oil Cooler, Tube, First One
Connect Hydraulic Oil Cooler, Tube, Remaining
Connect Radiator Hose, Lower
Install Fan Guard, Bracket
Connect Hydraulic Fan Motor, Hose(S), Set (All)
Remove Hood, Lift
Install Bottom Guard

1353 010 Radiator, Remove & Install
Notes: None

9.3
Remove 3.9
Install Hood, Lift
Remove Hood, Support, One Side
Separate Aftercooler, Hose(S), Both
Remove Aftercooler
Page 56 of 122
Separate Radiator, Hose(S)
Remove Radiator Enclosure/Shroud, Bolt(S), Set (All)
Install Hydraulic Fan Motor, Lift
Install Hydraulic Fan Motor, Work Tool
Turn/Reposition Hydraulic Fan Motor, Support
Remove Hydraulic Fan Motor, Lift
Remove Radiator & Oil Cooler, Top
Remove Aftercooler, Baffle
Install Radiator, Eye, Both
Install Radiator, Lift
Remove Radiator, Bolt(S), Set (All)
Remove Radiator
Clean 0.1
Install 5.3
Install Radiator
Remove Radiator, Lift
Remove Radiator, Eye, Both
Install Fuel Cooler, Bolt(S), Limited Quantity
Install Radiator, Bolt(S), Set (All)
Install Aftercooler, Baffle
Install Radiator & Oil Cooler, Top
Install Hydraulic Fan Motor, Support
Remove Hydraulic Fan Motor, Work Tool
Install Radiator Enclosure/Shroud, Bolt(S), Set (All)
Connect Radiator, Hose(S)
Install Aftercooler
Connect Aftercooler, Hose(S), Both
Install Hood, Support, One Side
Remove Hood, Lift
Page 57 of 122
1355 010 Thermostat/Water Temp Reg, Remove & Install
Notes: None

2.0
Remove 1.3
Drain Engine Coolant, Partial
Remove Water Temp Regulator Hsg, Bolt(S), Set (All)
Separate Thermostat/Water Temp Reg, Tube
Remove Water Temp Regulator Hsg
Remove Thermostat/Water Temp Reg
Clean 0.1
Clean Water Temp Regulator Hsg
Install 0.6
Install Thermostat/Water Temp Reg
Install Water Temp Regulator Hsg
Install Water Temp Regulator Hsg, Tube
Install Water Temp Regulator Hsg, Bolt(S), Set (All)
Refill Engine Coolant, Partial

1355 030 Thermostat/Water Temp Reg, Test After Repair
Notes: None

0.6

Test After Repair Thermostat/Water Temp Reg

1355 035 Thermostat/Water Temp Reg, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Thermostat/Water Temp Reg
Page 58 of 122
1355 038 Thermostat/Water Temp Reg, Diagnostic Test
Notes: None

0.3
Diagnostic Test 0.3

Diagnostic Test Thermostat/Water Temp Reg

1355 074 Thermostat/Water Temp Reg, Wash
Notes: None

0.4
Wash 0.4
Wash Thermostat/Water Temp Reg

1356 010 Fan, Remove & Install
Notes: None

8.0
Remove 3.5
Drain Hydraulic Oil
Open Hood, Center
Install Hood, Lift
Install Fan Drive, Lift
Remove Fan Drive, Bolt(S), Set (All)
Remove Fan, Assembled
Page 59 of 122
Remove Radiator Enclosure/Shroud
Install Fan, Lift
Remove Fan, Bolt(S)
Remove Fan
Remove Fan, Lift
Clean 0.1
Clean Fan Drive
Install 4.4
Install Fan, Lift
Install Fan
Install Fan, Bolt(S), Set (All)
Remove Fan, Lift
Install Radiator Enclosure/Shroud
Install Fan, Assembled
Install Fan Drive, Bolt(S), Set (All)
Remove Fan Drive, Lift
Remove Hood, Lift
Close Hood, Center

1356 082 VF Fan, Measure, Speed
0.3
Measure 0.3
Measure Fan, Speed

1358 035 Belt Tensioner, Troubleshoot
Notes: None

0.6
Page 60 of 122
Troubleshoot 0.6
Troubleshoot Belt Tensioner

1359 010 Fan Drive, Remove & Install
Notes: None

8.5
Remove 3.7
Drain Hydraulic Oil
Open Hood, Center
Install Hood, Lift
Install Fan Drive, Lift
Remove Fan Drive, Bolt(S), Set (All)
Remove Radiator Enclosure/Shroud
Install Fan, Lift
Remove Fan, Bolt(S)
Remove Fan
Remove Fan, Lift
Remove Fan Drive, Bolt(S)
Remove Hydraulic Fan Motor, Out F/Out Hull/Off Site
Remove Fan Drive
Clean 0.1
Clean Fan Drive
Install 4.7
Install Fan Drive
Install Hydraulic Fan Motor, Out F/Out Hull/Off Site
Install Fan Drive, Bolt(S)
Install Fan, Lift
Page 61 of 122
Install Fan
Install Fan, Bolt(S), Set (All)
Remove Fan, Lift
Install Radiator Enclosure/Shroud
Install Fan Drive, Bolt(S), Set (All)
Remove Fan Drive, Lift
Remove Hood, Lift
Close Hood, Center

1361 010 Water Pump, Remove & Install
Notes: None

6.0
Remove 2.9
Remove Water Temp Regulator Hsg, Bolt(S), Set (All)
Separate Water Temp Regulator Hsg, Tube
Remove Water Temp Regulator Hsg
Remove Thermostat/Water Temp Reg
Remove Alternator, Support
Install Hood, Lift
Turn/Reposition Firewall, Top
Page 62 of 122
Remove Belt Tensioner
Remove Water Pump, Elbow
Remove Water Pump, Outlet
Remove Water Pump, Bolt(S), Set (All)
Remove Water Pump
Clean 0.2
Clean Water Temp Regulator Hsg
Clean Water Pump
Install 2.9
Install Water Pump
Install Water Pump, Bolt(S), Set (All)
Install Water Pump, Outlet
Install Water Pump, Elbow
Install Belt Tensioner
Tighten Firewall, Top
Remove Hood, Lift
Install Alternator, Support
Install Thermostat/Water Temp Reg
Install Water Temp Regulator Hsg
Install Water Temp Regulator Hsg, Tube
Install Water Temp Regulator Hsg, Bolt(S), Set (All)

1361 030 Water Pump, Test After Repair
Notes: None

0.4

Test After Repair Water Pump

1361 035 Water Pump, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Water Pump
Page 63 of 122
1361 074 Water Pump, Wash
Notes: None

0.4
Wash 0.4
Wash Water Pump

1361 535 PX Water Pump, Check, Pressure(S)
0.3
Check 0.3
Check Water Pump, Pressure(S)

1374 010 Hydraulic Oil Cooler, Remove & Install
Notes: None

13.2
Remove 5.9
Drain Hydraulic Oil
Open Hood, Center
Install Hood, Lift
Remove Hydraulic Oil Cooler, Tube, First One
Separate Hydraulic Oil Cooler, Hose(S), First One
Remove Hydraulic Oil Cooler, Support, Both
Page 64 of 122
Install Radiator & Oil Cooler, Lift
Remove Radiator & Oil Cooler, Bolt(S), Set (All)
Remove Radiator & Oil Cooler, Package
Install Fan, Lift
Remove Fan Drive, Bolt(S), Limited Quantity
Remove Aftercooler
Remove Aftercooler, Baffle
Remove Radiator & Oil Cooler, Top
Remove Hydraulic Oil Cooler, Bolt(S), Limited Quantity
Remove Hydraulic Oil Cooler, Bracket
Install Hydraulic Oil Cooler, Eye, Both
Install Hydraulic Oil Cooler, Lift
Remove Hydraulic Oil Cooler, Bolt(S), Remaining
Remove Hydraulic Oil Cooler
Clean 0.2
Clean Hydraulic Oil Cooler, Hose(S), Set (All)
Clean Aftercooler, Hose(S), Set (All)
Clean Hydraulic Oil Cooler
Install 7.1
Install Hydraulic Oil Cooler
Install Hydraulic Oil Cooler, Bolt(S), Remaining
Remove Hydraulic Oil Cooler, Lift
Remove Hydraulic Oil Cooler, Eye, Both
Install Hydraulic Oil Cooler, Bracket
Install Hydraulic Oil Cooler, Bolt(S), Limited Quantity
Install Radiator & Oil Cooler, Top
Install Aftercooler, Baffle
Install Aftercooler
Install Fan Drive, Bolt(S), Limited Quantity
Remove Fan, Lift
Install Radiator & Oil Cooler, Package
Install Radiator & Oil Cooler, Bolt(S), Set (All)
Remove Radiator & Oil Cooler, Lift
Install Radiator & Oil Cooler, Panel, Both Sides
Install Hydraulic Oil Cooler, Support, Both
Install Hydraulic Oil Cooler, Tube, First One
Connect Hydraulic Oil Cooler, Hose(S), Remaining
Install Hydraulic Oil Cooler, Hose(S), First One
Page 65 of 122
Remove Hood, Lift

1378 010 Engine Oil Cooler, Remove & Install
Notes: None

2.6
Remove 1.2
Separate Heater Hose/Lines, Engine, Both
Remove Engine Oil Cooler, Valve, Both
Separate Engine Oil Cooler, Hose(S)
Remove Turbocharger, Drain Line
Remove Engine Oil Cooler, Bolt(S), Set (All)
Remove Engine Oil Cooler
Install 1.4
Install Engine Oil Cooler
Install Engine Oil Cooler, Bolt(S), Set (All)
Install Turbocharger, Drain Line
Connect Engine Oil Cooler, Hose(S)
Install Engine Oil Cooler, Valve, Both
Connect Heater Hose/Lines, Engine, Both

1378 030 Engine Oil Cooler, Test After Repair
Notes:
None
Page 66 of 122
0.6

Test After Repair Engine Oil Cooler

1378 034 Engine Oil Cooler, Crack/Leak Test
Notes: z This is an external leak test.
0.6
Crack/Leak Test 0.6

Crack/Leak Test Engine Oil Cooler

1378 035 Engine Oil Cooler, Troubleshoot
Notes: None

0.7
Troubleshoot 0.7
Troubleshoot Engine Oil Cooler

1378 074 Engine Oil Cooler, Wash
Notes: None

0.4
Wash 0.4
Wash Engine Oil Cooler

1382 034 Radiator Cap, Crack/Leak Test
0.2
Crack/Leak Test 0.2

Crack/Leak Test Radiator Cap

1386 010 Hydraulic Fan Motor, Remove & Install
Notes: None
Page 67 of 122
4.6
Remove 2.4
Release Hydraulic System, Pressure(S)
Install Hydraulic System, Vacuum
Open Hood, Center
Install Hood, Lift
Remove Hydraulic Fan Motor, Bolt(S), Both
Remove Hydraulic Fan Motor
Install 2.2
Install Hydraulic Fan Motor
Install Hydraulic Fan Motor, Bolt(S)
Remove Hood, Lift
Open Hood, Center
Remove Hydraulic System, Vacuum

1387 010 Hydraulic Fan Pump, Remove & Install
Notes: None

2.5
Remove 1.3
Drain Hydraulic Oil
Separate Hydraulic Fan Pump, Wiring Harness
Separate Hydraulic Fan Pump, Hose(S), Set (All)
Separate Hydraulic Fan Pump, Tube, Set (All)
Remove Hydraulic Fan Pump, Bolt(S), Set (All)
Remove Hydraulic Fan Pump
Clean 0.1
Page 68 of 122
Clean Hydraulic Fan Pump
Install 1.1
Install Hydraulic Fan Pump
Install Hydraulic Fan Pump, Bolt(S), Set (All)
Connect Hydraulic Fan Pump, Tube, Set (All)
Connect Hydraulic Fan Pump, Hose(S), Set (All)
Connect Hydraulic Fan Pump, Wiring Harness

1395 044 Engine Coolant, Drain & Refill
Notes: None

0.7
Drain 0.4
Refill 0.3

1395 081 Engine Coolant, Test
Notes: None

0.2
Test 0.2
Test Engine Coolant

1395 082 TA Engine Coolant, Measure, Temperature(S)
Notes: None

0.2
Measure 0.2
Measure Engine Coolant, Temperature(S)
Page 69 of 122
1397 025 Serpentine Belt, Adjust
Notes: None

0.2
Adjust 0.2
Adjust Serpentine Belt

1400 038 VO Electric System, Diagnostic Test, Using Voltmeter
Notes: None

0.2
Diagnostic Test 0.2

Diagnostic Test Electric System, Using Voltmeter

1401 010 S Battery, Remove & Install, Set (All)
Notes: None

1.0
Remove 0.5
Remove Vandalism Guard, Battery
Remove Battery, Cover, Both
Remove Battery, Holder, Set (All)
Separate Battery Cable, Set (All)
Install Battery, Lift
Remove Battery, Set (All)
Clean 0.1
Clean Battery Cable, Set (All)
Install 0.4
Install Battery, Set (All)
Remove Battery, Lift
Connect Battery Cable, Set (All)
Install Battery, Holder, Set (All)
Install Battery, Cover, Both
Install Vandalism Guard, Battery

1401 038 G3 Battery, Diagnostic Test, Using Battery Load Test
Notes: None
Page 70 of 122
0.2
Diagnostic Test 0.2

Diagnostic Test Battery, Using Battery Load Test

1405 010 Alternator, Remove & Install
Notes: None

1.1
Remove 0.5
Open Hood, Center
Separate Alternator, Wiring Harness, Set (All)
Remove Alternator, Bolt(S), Set (All)
Remove Alternator
Install 0.6
Install Alternator
Install Alternator, Bolt(S), Set (All)
Connect Alternator, Wiring Harness, Set (All)
Close Hood

1408 010 SA Wiring Harness, Remove & Install, Seal
Notes: z Claim this code when removing and installing the receptacle or seal at the cylinder head, where the internal and external harnesses
plug in.
0.3
Remove & Install 0.3

Remove & Install Wiring Harness, Seal

1408 030 Wiring Harness, Test After Repair
Notes: None

0.4

Test After Repair Wiring Harness

1408 035 Wiring Harness, Troubleshoot
Notes:
None
Page 71 of 122
0.7
Troubleshoot 0.7
Troubleshoot Wiring Harness

1408 510 C4 Wiring Harness, Replace, 3-Pin Connector
Notes: None

0.1
Replace 0.1
Replace Wiring Harness, 3-Pin Connector

Notes: None

0.4
Replace 0.4

Notes: None

1.3
Replace 1.3

1408 510 C7P Wiring Harness, Replace, 70-Pin Connector
Notes: None

1.9
Replace 1.9

1408 510 SA Wiring Harness, Replace, Seal
Page 72 of 122
Notes: z Claim this code when removing and installing the receptacle or seal at the cylinder head, where the internal and external harnesses
plug in.
0.3
Replace 0.3
Replace Wiring Harness, Seal

1408 535 SHR Wiring Harness, Check, Short
Notes: None

0.2
Check 0.2
Separate Wiring Harness, Coil
Inspect Wiring Harness, Connector(S)
Run Ignition System, Using Ecap / Et
Check Electrical Test Equipment, Parameters/Diagnostics
Modify Pers Mod-Chg Eng Paramtr, Using Ecap / Et

1453 010 Electric Starting Motor, Remove & Install
Notes: None

1.6
Remove 0.8
Open Hood, Center
Separate Electric Starting Motor, Wiring, Set (All)
Install Electric Starting Motor, Lift
Remove Electric Starting Motor, Bolt(S), Set (All)
Remove Electric Starting Motor
Install 0.8
Install Electric Starting Motor
Install Electric Starting Motor, Bolt(S), Set (All)
Remove Electric Starting Motor, Lift
Connect Electric Starting Motor, Wiring, Set (All)
Close Hood

1456 010 Ether Starting Aid, Remove & Install
Notes: None
Page 73 of 122
0.4
Remove 0.2
Install 0.2

1712 010 Fuel Cooler, Remove & Install
Notes: None

0.8
Remove 0.3
Separate Fuel Cooler, Hose(S), Both
Remove Fuel Cooler, Bolt(S), Set (All)
Remove Fuel Cooler
Install 0.5
Install Fuel Cooler
Connect Fuel Cooler, Hose(S), Both
Open Fuel Shutoff, Main
Prime Fuel System

1717 030 Fuel Transfer & Prim Pump, Test After Repair
Notes: None

0.4
Page 74 of 122
Test After Repair Fuel Transfer & Prim Pump

1717 035 Fuel Transfer & Prim Pump, Troubleshoot
Notes: None

0.6
Troubleshoot 0.6
Troubleshoot Fuel Transfer & Prim Pump

1717 074 Fuel Transfer & Prim Pump, Wash
Notes: None

0.4
Wash 0.4
Wash Fuel Transfer & Prim Pump

1802 010 Refrigerant Compressor, Remove & Install
Notes: None

2.2
Remove 1.0
Open Hood, Center
Connect Quickevac, Hose(S), Both
Evacuate & Save Refrigerant
Separate Refrigerant Compressor, Wiring Harness
Separate Refrigerant Compressor, Hose(S), Both
Remove Refrigerant Compressor, Bolt(S)
Remove Refrigerant Compressor
Install 1.2
Install Refrigerant Compressor
Install Refrigerant Compressor, Bolt(S), Set (All)
Connect Refrigerant Compressor, Hose(S), Both
Connect Refrigerant Compressor, Wiring Harness
Vacuum Refrigerant
Charge Refrigerant
Page 75 of 122
1805 010 Refrigerant Condenser, Remove & Install
Notes: None

2.0
Remove 0.9
Open Hood, Center
Remove Refrigerant Condenser, Cover
Separate Refrigerant Condenser, Hose(S), Both
Remove Condenser Fan
Remove Refrigerant Condenser, Bolt(S), Set (All)
Remove Refrigerant Condenser
Install 1.1
Install Refrigerant Condenser
Install Refrigerant Condenser, Bolt(S)
Install Condenser Fan
Connect Refrigerant Condenser, Hose(S), Both
Install Refrigerant Condenser, Cover
Vacuum Refrigerant
Charge Refrigerant

1809 597 Refrigerant, Evacuate & Charge
Notes: None

1.6
Evacuate & Save 0.7

Open Hood, Center
Separate & Connect Quickevac, Hose(S), Both
Charge 0.9
Vacuum Refrigerant
Charge Refrigerant

1901 010 Eng Electronic Cont Mod, Remove & Install
Notes:
None
Page 76 of 122
1.2
Remove 0.6
Separate Eng Electronic Cont Mod, Hose(S), Set (All)
Separate Eng Electronic Cont Mod, Wiring Harness, Set (All)
Remove Eng Electronic Cont Mod, Bolt(S), Set (All)
Remove Eng Electronic Cont Mod
Install 0.6
Install Eng Electronic Cont Mod
Install Eng Electronic Cont Mod, Bolt(S), Set (All)
Connect Eng Electronic Cont Mod, Wiring Harness
Connect Eng Electronic Cont Mod, Hose(S), Set (All)
Open Fuel Shutoff, Main
Prime Fuel System

1901 025 V3 Eng Electronic Cont Mod, Adjust, Full Load/Torque Setting
Notes: None

0.5
Adjust 0.5
Adjust Eng Electronic Cont Mod, Full Load/Torque Setting

1901 030 Eng Electronic Cont Mod, Test After Repair
Notes: None

0.6

Test After Repair Eng Electronic Cont Mod

1901 035 Eng Electronic Cont Mod, Troubleshoot
Notes:
None
Page 77 of 122
1.4
Troubleshoot 1.4
Troubleshoot Eng Electronic Cont Mod

1901 074 Eng Electronic Cont Mod, Wash
Notes: z This code applies for 1998 and earlier models only.
0.0
Wash 0.0
Wash Eng Electronic Cont Mod

1901 081 E3 Eng Electronic Cont Mod, Test, Using Test Ecm
Notes: None

1.1
Test 1.1
Test Eng Electronic Cont Mod, Using Test Ecm

1901 554 XW Eng Electronic Cont Mod, Obtain, Password(S)
Notes: None

0.2
Obtain 0.2
Obtain Eng Electronic Cont Mod, Password(S)

1901 591 Eng Electronic Cont Mod, Reprogram
Notes: None

0.6
Reprogram 0.6
Connect Engine Test Equipment
Reprogram Eng Electronic Cont Mod
Separate Engine Test Equipment

1906 010 Water Temperature Sensor, Remove & Install
Page 78 of 122
Notes: None

0.7
Remove 0.4
Open Hood
Separate Water Temperature Sensor, Wiring Harness
Remove Water Temperature Sensor
Install 0.3
Install Water Temperature Sensor
Connect Water Temperature Sensor, Wiring Harness
Close Hood

1912 025 Eng Speed/Timing Sensor, Adjust
Notes: z For Adjust, use this code for (1202-010-PSN) or (1210-010-PSN).
0.5
Adjust 0.5
Adjust Eng Speed/Timing Sensor

1912 030 Eng Speed/Timing Sensor, Test After Repair
Notes: z For Test After Repair, use this code for (1202-010-PSN) or (1210-010-PSN).
0.4

Test After Repair Eng Speed/Timing Sensor

1912 035 Eng Speed/Timing Sensor, Troubleshoot
Notes: z For Troubleshoot, use this code for (1202-010-PSN) or (1210-010-PSN).
0.7
Troubleshoot 0.7
Troubleshoot Eng Speed/Timing Sensor

1912 074 Eng Speed/Timing Sensor, Wash
Page 79 of 122
Notes: z For Wash, use this code for (1202-010-PSN) or (1210-010-PSN).
0.4
Wash 0.4
Wash Eng Speed/Timing Sensor

1912 524 Eng Speed/Timing Sensor, Calibrate
Notes: z A timing calibration is required for a new engine, replacing an Electronic Control Module (ECM) that fails to communicate or following
work on the front gear train, the camshaft, or the crankshaft.
z Claim this code once for both engine speed/timing sensors (Primary speed/timing sensor = Crankshaft position sensor and
Secondary speed/timing sensor = Camshaft position sensor).
0.5
Calibrate 0.5
Connect Engine Test Equipment
Start Engine
Calibrate Eng Speed/Timing Sensor
Separate Engine Test Equipment

1917 010 Boost Pressure Sensor, Remove & Install
Notes: None

0.2
Remove 0.1
Open Hood
Separate Boost Pressure Sensor, Wiring Harness
Remove Boost Pressure Sensor
Install 0.1
Install Boost Pressure Sensor
Connect Boost Pressure Sensor, Wiring Harness
Close Hood

1917 081 Boost Pressure Sensor, Test
Notes: None

0.3
Test 0.3
Test Boost Pressure Sensor
Page 80 of 122
1921 010 Inlet Air Temp Sensor, Remove & Install
Notes: None

0.2
Remove 0.1
Open Hood
Separate Inlet Air Temp Sensor, Wiring Harness
Remove Inlet Air Temp Sensor
Install 0.1
Install Inlet Air Temp Sensor
Connect Inlet Air Temp Sensor, Wiring Harness
Close Hood

1922 010 Fuel Temperature Sensor, Remove & Install
Notes: None

0.4
Remove 0.2
Open Hood
Separate Fuel Temperature Sensor, Wiring Harness
Remove Fuel Temperature Sensor
Install 0.2
Install Fuel Temperature Sensor
Install Fuel Temperature Sensor, Wiring Harness
Close Hood

1923 010 Atmospheric Press Sensor, Remove & Install
Notes: None

0.3
Remove 0.2
Open Hood
Separate Atmospheric Press Sensor, Wiring Harness
Remove Atmospheric Press Sensor
Install 0.1
Install Atmospheric Press Sensor
Page 81 of 122
Connect Atmospheric Press Sensor, Wiring Harness
Close Hood

1924 010 Eng Oil Pressure Sensor, Remove & Install
Notes: None

0.4
Remove 0.2
Open Hood
Separate Eng Oil Pressure Sensor, Wiring Harness
Remove Eng Oil Pressure Sensor
Install 0.2
Install Eng Oil Pressure Sensor
Connect Eng Oil Pressure Sensor, Wiring Harness
Close Hood

3279 010 Eng Output Dr As/Coupling, Remove & Install
Notes: None

9.4
Remove 3.9
Open Hood
Install Hood, Lift
Remove Muffler
Drain Hydraulic Oil
Page 82 of 122
Remove Firewall
Remove Eng Output Dr As/Coupling, Bolt(S), Set (All)
Remove Eng Output Dr As/Coupling
Clean 0.2
Clean Flywheel
Install 5.3
Install Eng Output Dr As/Coupling
Install Eng Output Dr As/Coupling, Bolt(S)
Torque Eng Output Dr As/Coupling, Bolt(S), Set (All)
Install Firewall
Install Firewall, Handle
Install Muffler
Close Hood

4050 010 E Final Drive, Remove & Install, Each
Notes: z If required, add code (4050-017--E) for Disassemble and Assemble Final Drive.
7.6
Separate 2.8
Page 83 of 122
Loosen Track Assembly, Tensioner
Raise Machine, Undercarriage, One Side
Turn/Reposition Track Assembly, Pin
Remove Track Shoe, Bolt(S), Set (All)
Remove Track Shoe, Pair
Install Track Assembly, Work Tool
Remove Track Assembly, Pin
Separate Track Assembly
Remove Track Motor Guard, Cover
Separate St Counterbalance Vlv, Hose(S), Set (All)
Remove St Counterbalance Vlv
Separate Hyd Propel/Drive Motor, Hose(S), Both
Install Hyd Propel/Drive Motor, Lift
Remove Hyd Propel/Drive Motor, Bolt(S), Limited Quantity
Remove Hyd Propel/Drive Motor
Remove Final Drive, Bolt(S), Set (All)
Install Final Drive, Lift
Remove Final Drive
Clean 0.4
Clean Track Shoe, Pair
Clean Track Assembly, Pin
Clean Track Assembly, Bore
Clean St Counterbalance Vlv
Clean Hyd Propel/Drive Motor
Clean Final Drive
Connect 4.4
Install Final Drive
Remove Final Drive, Lift
Install Final Drive, Bolt(S), Set (All)
Install Hyd Propel/Drive Motor
Install Hyd Propel/Drive Motor, Bolt(S), Limited Quantity
Remove Hyd Propel/Drive Motor, Lift
Connect Hyd Propel/Drive Motor, Hose(S), Both
Install St Counterbalance Vlv
Connect St Counterbalance Vlv, Hose(S), Set (All)
Install Track Motor Guard, Cover
Connect Track Assembly
Install Track Assembly, Pin
Remove Track Assembly, Work Tool
Refill Tr Pin & Bshg (S&L), Oil
Install Track Shoe, Pair
Install Track Shoe, Bolt(S), Set (All)
Lift, Block & Lower Machine
Adjust Track Assembly, Tensioner

4050 017 E Final Drive, Disassemble & Assemble, Each
Notes: z If required, add code (4054-571-NW-E) to unpack and steam clean new final drive hub.
z Oil drain and refill is included in Final Drive R&I segment.
6.0
Disassemble 1.0
Recondition Fnl Dr - Outer Section, Hole, Both
Page 84 of 122
Remove Fnl Dr - Outer Section, Plug(S), Both
Remove Fnl Dr - Outer Section, Cover, One Side
Remove Final Drive, Gear
Remove & Install Final Drive Hub, Lift, Set (All)
Remove & Install FD Plan Crr Hub & Ring Gr, Lift, Set (All)
Turn/Reposition Final Drive, Set (All)
Move Final Drive, Set (All)
Remove Final Drive Gears, Planetary Set One
Remove Final Drive Gears, Planetary Set Two
Remove FD Plan Crr Hub & Ring Gr, Planetary Set Three
Remove Final Drive, Ring Gear
Move Final Drive, Ring Gear
Remove Final Drive Gears, Gear Type, One
Remove Final Drive Hub, Bearing, Limited Quantity
Install Final Drive Hub, Lift
Remove Final Drive Hub, Bearing, Both Sides
Remove Final Drive, Duo-Cone Seal
Remove Final Drive Gears, Dowel, Remaining
Clean 1.8
Move Final Drive, Disassembled, Twice
Steam Clean Final Drive, Disassembled, Set (All)
Clean Fnl Dr - Outer Section, Cover
Remove Fnl Dr - Outer Section, Ring Gear
Clean Fnl Dr - Outer Section, Ring Gear
Clean Fnl Dr - Outer Section, Bolt(S), Set (All)
Clean Final Drive, Ring Gear
Clean Final Drive Hub, Duo-Cone Seal
Move Final Drive, Disassembled, Remaining
Steam Clean Final Drive, Disassembled, Remaining
Clean Final Drive Gears, Gear Type, One
Clean Final Drive Gears, Dowel, Set (All)
Clean Final Drive Gears, Bolt(S), Set (All)
Clean FD Plan Crr Hub & Ring Gr, Planetary Set One
Clean FD Plan Crr Hub & Ring Gr, Planetary Set Two
Clean FD Plan Crr Hub & Ring Gr, Planetary Set Three
Assemble 3.2
Install Final Drive Gears, Dowel, Remaining
Install Final Drive, Duo-Cone Seal
Install Final Drive Hub, Bearing, Both Sides
Measure Final Drive Hub, Bearing, Both Sides
Remove Final Drive Hub, Lift
Install Final Drive Hub, Outer
Install Final Drive Hub, Bearing, Limited Quantity
Install Final Drive Tools, Hub
Compress Final Drive, Bearing
Measure Final Drive, Bearing
Remove Final Drive Tools, Hub
Measure Final Drive Gears, With Shim
Install Final Drive Gears, Gear Type, One
Check Final Drive, Bearing
Install Seals & Gaskets, Ring Gear
Install FD Plan Crr Hub & Ring Gr, Ring Gear
Install FD Plan Crr Hub & Ring Gr, Planetary Set Three
Install FD Plan Crr Hub & Ring Gr, Planetary Set Two
Install FD Plan Crr Hub & Ring Gr, Planetary Set One
Move Final Drive, Set (All)
Turn/Reposition Final Drive, Set (All)
Remove & Install FD Plan Crr Hub & Ring Gr, Lift, Set (All)
Remove & Install Final Drive Hub, Lift, Set (All)
Page 85 of 122
Install Final Drive, Gear
Measure Final Drive, Cover
Measure Final Drive Tools, Ring Gear
Install Fnl Dr - Outer Section, With Shim
Install Seals & Gaskets, Cover
Install Final Drive, Cover
Tfr Components To/From Final Drive, Dust Cover

4054 571 NW E Final Drive Hub, Clean & Inspect, New, Each
Notes: z Only claim this code if uncrating and steam cleaning protective coating on a new updated final drive hub.
0.5
Clean & Inspect 0.5

Unpack Final Drive Hub, Each
Install Final Drive Hub, Lift, Each
Remove Final Drive Hub
Clean Final Drive Hub
Move Final Drive Hub

4084 017 GE C FD Plan Crr Hub & Ring Gr, Disassemble & Assemble, Gear, Each Section
Notes: z One planetary gear set.
0.7
Disassemble 0.1
Identify FD Plan Crr Hub & Ring Gr, Gear, Each Section
Disassemble FD Plan Crr Hub & Ring Gr, Gear, Each Section
Clean & Inspect 0.4
Clean & Inspect FD Plan Crr Hub & Ring Gr, Gear, Each Section
Assemble 0.2
Assemble FD Plan Crr Hub & Ring Gr, Gear, Each Section

4084 017 GE S FD Plan Crr Hub & Ring Gr, Disassemble & Assemble, Gear, Set (All)
Notes: z All three planetary gear sets for each final drive.
1.7
Disassemble 0.5
Disassemble Planetary Fnl Dr Carrier, Planetary Set One, Set (All)
Identify FD Plan Crr Hub & Ring Gr, Planetary Set Two, Set (All)
Disassemble FD Plan Crr Hub & Ring Gr, Planetary Set Two, Set (All)
Remove Planetary Fnl Dr Carrier, Pin, Set (All)
Identify FD Plan Crr Hub & Ring Gr, Planetary Set Three, Set (All)
Disassemble FD Plan Crr Hub & Ring Gr, Planetary Set Three, Set (All)
Clean 0.8
Clean & Inspect FD Plan Crr Hub & Ring Gr, Planetary Set One, Set (All)
Clean & Inspect FD Plan Crr Thrust Surf, Planetary Set Two, Set (All)
Clean & Inspect Planetary Fnl Dr Carrier, Pin, Set (All)
Clean & Inspect FD Plan Crr Hub & Ring Gr, Planetary Set Three, Set (All)
Assemble 0.4
Assemble FD Plan Crr Hub & Ring Gr, Planetary Set Three, Set (All)
Assemble FD Plan Crr Hub & Ring Gr, Planetary Set Two, Set (All)
Page 86 of 122
Install Planetary Fnl Dr Carrier, Pin, Set (All)
Assemble FD Plan Crr Hub & Ring Gr, Planetary Set One, Set (All)

4150 040 Undercarriage, Inspect
Notes: None

1.0
Inspect 1.0
Inspect Undercarriage

4154 010 E Carrier Roller, Remove & Install, Each
Notes: z If required, add code (4154-017--E) to Disassemble and Assemble Carrier Roller.
0.8
Remove 0.3
Install Track Assembly, Lift
Remove Carrier Roller, Bolt(S)
Install Carrier Roller, Work Tool
Remove Carrier Roller
Clean 0.1
Clean Carrier Roller
Install 0.4
Install Carrier Roller
Install Carrier Roller, Bolt(S)
Remove Carrier Roller, Work Tool
Remove Track Assembly, Lift

4154 017 E Carrier Roller, Disassemble & Assemble, Each
Notes: None

1.1
Disassemble 0.4
Remove Carrier Roller, Bolt(S), Set (All)
Remove Carrier Roller, Cover
Remove Carrier Roller, Retainer
Remove Carrier Roller, Bearing, Both
Remove Carrier Roller, Shaft
Remove Carrier Roller, Duo-Cone Seal
Clean 0.2
Clean Carrier Roller, Shaft
Clean Carrier Roller, Internal Component(S)
Clean Carrier Roller, Cover
Clean Carrier Roller, Retainer
Assemble 0.5
Page 87 of 122
Install Carrier Roller, Duo-Cone Seal
Install Carrier Roller, Shaft
Install Carrier Roller, Bearing, Both
Install Carrier Roller, Retainer
Refill Carrier Roller, Oil
Install Carrier Roller, Cover
Install Carrier Roller, Bolt(S), Set (All)

4157 010 E Track Adjuster, Remove & Install, Each
Notes: z If required, add code (4157-017--E) to Disassemble and Assemble Track Adjuster.
4.5
Remove 1.9
Install Idler/Idler Wheel, Lift
Remove Recoil Spring, Bolt(S), Set (All)
Remove Idler/Idler Wheel
Remove Track Adjuster
Clean 0.4
Clean Track Roller Frame
Clean Track Adjuster
Install 2.2
Install Track Adjuster
Install Idler/Idler Wheel
Install Recoil Spring, Bolt(S), Set (All)
Remove Idler/Idler Wheel, Lift

4157 017 E Track Adjuster, Disassemble & Assemble, Each
Notes: None

1.4
Disassemble 0.3
Machine/Grind/Mill Track Adjuster, Bolt(S), Set (All)
Page 88 of 122
Remove Track Adjuster, Bolt(S), Both
Remove Track Adjuster, Bracket
Remove Track Adjuster, Plug(S)
Remove Track Adjuster, Piston
Remove Track Adjuster, Seal, Set (All)
Clean 0.7
Clean & Inspect Track Adjuster, Piston
Clean Track Adjuster, Cylinder
Assemble 0.4
Install Track Adjuster, Seal, Set (All)
Install Track Adjuster, Piston
Install Track Adjuster, Plug(S)
Install Track Adjuster, Bracket
Install Track Adjuster, Bolt(S)

4158 010 Recoil Spring, Remove & Install
Notes: None

4.2
Remove 1.8
Clean 0.3
Install 2.1

4159 010 E Idler/Idler Wheel, Remove & Install, Each
Notes: z If required, add code (4159-017--E) to Disassemble and Assemble Idler/Idler Wheel, Each.
Page 89 of 122
4.2
Remove 1.8
Clean 0.3
Install 2.1

4159 017 E Idler/Idler Wheel, Disassemble & Assemble, Each
Notes: None

2.6
Disassemble 1.0
Remove Idler/Idler Wheel, Retainer, Both Sides
Remove Idler/Idler Wheel, Arm, Both Sides
Remove Idler/Idler Wheel, Duo-Cone Seal, Both
Remove Idler/Idler Wheel, Shaft
Remove Idler/Idler Wheel, Bearing, Both
Clean 0.8
Clean Idler/Idler Wheel
Clean Idler/Idler Wheel, Shaft
Clean Idler/Idler Wheel, Arm, Both Sides
Assemble 0.8
Install Idler/Idler Wheel, Bearing, Both
Install Idler/Idler Wheel, Shaft
Install Idler/Idler Wheel, Duo-Cone Seal, Both
Install Idler/Idler Wheel, Arm, Both Sides
Install Idler/Idler Wheel, Retainer, Both Sides
Page 90 of 122
4164 010 E Sprocket Assembly, Remove & Install, Each
Notes: None

4.9
Remove 1.8
Remove Sprocket Assembly, Bolt(S), Set (All)
Install Sprocket Assembly, Lift
Remove Sprocket Assembly
Clean 0.7
Clean Sprocket Assembly
Clean Sprocket Assembly, Bolt(S), Set (All)
Install 2.4
Install Sprocket Assembly
Remove Sprocket Assembly, Lift
Install Sprocket Assembly, Bolt(S), Set (All)
Lower Machine, Undercarriage

4170 029 H Track Assembly, Separate & Connect, One Side
Notes: None

3.6
Separate 1.5
Clean 0.2
Page 91 of 122
Connect 1.9

4177 010 Track Guide/Guard, Remove & Install
Notes: None

1.1
Remove 0.4
Install Track Guide/Guard, Lift
Remove Track Guide/Guard, Bolt(S), Set (All)
Remove Track Guide/Guard
Install 0.7
Install Track Guide/Guard
Install Track Guide/Guard, Bolt(S), Set (All)
Remove Track Guide/Guard, Lift

4180 010 E Track Roller, Remove & Install, Each
Notes: z If required, add code (4177-010--) for R&I Track Guide/Guard.
z If required, add code (4180-017-S5-) to Disassemble and Assemble Track Roller.
1.2
Remove 0.4
Remove Track Roller, Bolt(S), Set (All)
Remove Track Roller, Each
Clean 0.1
Clean Track Roller, Each
Clean Track Roller Frame, Limited Quantity
Install 0.7
Install Track Roller
Install Track Roller, Bolt(S), Set (All)

4180 017 S5 Track Roller, Disassemble & Assemble, Single Flange
Notes:
None
Page 92 of 122
0.7
Disassemble 0.2
Disassemble Track Roller, Single Flange
Clean 0.2
Clean Track Roller, Single Flange
Assemble 0.3
Assemble Track Roller, Single Flange

4340 010 E St Counterbalance Vlv, Remove & Install, Each
Notes: z AKA: Steering Counterbalance Valve (Travel)
1.9
Remove 0.8
Clean 0.1
Install 1.0

4351 010 E Hyd Propel/Drive Motor, Remove & Install, Each
Notes: None

2.7
Remove 1.0
Separate Hyd Propel/Drive Motor, Hose(S), Both
Install Hyd Propel/Drive Motor, Lift
Remove Hyd Propel/Drive Motor, Bolt(S), Limited Quantity
Remove Hyd Propel/Drive Motor
Clean 0.1
Clean Hyd Propel/Drive Motor
Install 1.6
Install Hyd Propel/Drive Motor
Page 93 of 122
Install Hyd Propel/Drive Motor, Bolt(S), Limited Quantity
Remove Hyd Propel/Drive Motor, Lift
Connect Hyd Propel/Drive Motor, Hose(S), Both

5051 010 MV Hydraulic Control Valve, Remove & Install, Main
Notes: None

13.9
Remove 6.7
Remove Bottom Guard, Right Side, Limited Quantity
Drain Hydraulic Oil
Remove Deck Plate, Center
Separate Hydraulic Control Valve, Wiring Harness, Set (All)
Remove Bottom Guard, Front
Separate Hydraulic Control Valve, Hose(S), Set (All)
Separate Hydraulic Control Valve, Tube, Set (All)
Separate Hyd Oil Cooler Bypass Vlv, Hose(S)
Remove Hydraulic Control Valve, Support
Remove Hyd Oil Cooler Bypass Vlv
Remove Hydraulic Control Valve, Fitting, Limited Quantity
Install Hydraulic Control Valve, Eye, Set (All)
Install Hydraulic Control Valve, Lift
Remove Hydraulic Control Valve, Bolt(S), Set (All)
Remove Hydraulic Control Valve
Install 7.2
Install Hydraulic Control Valve
Install Hydraulic Control Valve, Bolt(S), Set (All)
Remove Hydraulic Control Valve, Lift
Tighten Hydraulic Control Valve, Bolt(S), Set (All)
Remove Hydraulic Control Valve, Eye, Set (All)
Connect Hydraulic Control Valve, Support
Install Hydraulic Control Valve, Fitting, Limited Quantity
Install Hyd Oil Cooler Bypass Vlv
Install Hydraulic Control Valve, Support
Connect Hyd Oil Cooler Bypass Vlv, Hose(S), Set (All)
Connect Hydraulic Control Valve, Tube, Set (All)
Connect Hydraulic Control Valve, Hose(S), Set (All)
Install Bottom Guard, Front
Connect Hydraulic Control Valve, Wiring Harness, Set (All)
Install Deck Plate, Center
Install Bottom Guard, Right Side, Limited Quantity
Page 94 of 122

5056 010 Hydraulic Tank, Remove & Install
Notes: None

6.0
Remove 2.7
Drain Hydraulic Oil
Remove Deck Plate, Center
Separate Hydraulic Tank, Hose(S), Set (All)
Separate Hydraulic Tank, Wiring Harness, Set (All)
Remove Hydraulic Tank, Bolt Hole, Set (All)
Install Hydraulic Tank, Lift
Remove Hydraulic Tank
Clean 0.3
Clean Hydraulic Tank
Clean Hydraulic Tank, Mounting
Install 3.0
Install Hydraulic Tank
Remove Hydraulic Tank, Lift
Connect Hydraulic Tank, Wiring Harness, Set (All)
Install Hydraulic Tank, Bolt(S), Set (All)
Connect Hydraulic Tank, Hose(S), Set (All)

5060 010 Swivel, Remove & Install
Notes: z If required, add code (5060-017--) to Disassemble and Assemble Swivel.
2.6
Remove 1.1
Remove Bottom Guard, Undercarriage
Remove Swivel, Hose(S), Set (All)
Remove Swivel, Bolt(S), Remaining
Page 95 of 122
Install Swivel, Lift
Remove Swivel
Clean 0.2
Steam Clean Swivel
Clean Bottom Guard, Undercarriage
Steam Clean Machine, Limited Quantity
Install 1.3
Install Swivel
Remove Swivel, Lift
Install Swivel, Bolt(S), Set (All)
Install Swivel, Hose(S), Set (All)
Install Bottom Guard, Undercarriage

5060 017 Swivel, Disassemble & Assemble
Notes: None

1.4
Disassemble 0.3
Remove Swivel, Bolt(S), Set (All)
Identify Swivel, Rotor
Remove Swivel, Rotor
Remove Swivel, Seal, Set (All)
Clean 0.1
Clean Swivel
Clean Swivel, Rotor
Assemble 1.0
Install Swivel, Seal, Set (All)
Lubricate Swivel, Groove, Set (All)
Install Swivel
Install Swivel, Bolt(S), Set (All)

507G 010 MV Piston & Gear Pump, Remove & Install, Main
Notes: None

9.2
Remove 3.9
Open Hood
Install Hood, Lift
Page 96 of 122
Remove Muffler
Drain Hydraulic Oil
Remove Firewall
Clean 0.2
Clean Engine, Access Cover, Set (All)
Install 5.1
Install Firewall
Install Engine Enclosure, Handle
Install Muffler
Close Hood
Page 97 of 122
5095 044 Hydraulic Oil, Drain & Refill
Notes: None

1.6
Drain 0.9
Drain Hydraulic Oil
Refill 0.7

5409 010 Counterweight Cylinder, Remove & Install
Notes: None

2.8
Remove 1.3
Raise Counterweight Cylinder
Remove Counterweight, Bolt(S), Set (All)
Turn/Reposition Counterweight, Mounting
Lower Counterweight
Install Counterweight, Lift
Remove Counterweight, Chain
Move Machine
Separate Counterweight Cylinder, Hose(S), Set (All)
Remove Counterweight Cylinder, Tube
Remove Counterweight Cylinder, Mounting
Install Counterweight Cylinder, Lift
Remove Counterweight Cylinder, Pin
Remove Counterweight Cylinder
Clean 0.1
Clean Counterweight
Install 1.4
Install Counterweight Cylinder
Install Counterweight Cylinder, Pin
Install Counterweight Cylinder, Mounting
Install Counterweight Cylinder, Tube
Remove Counterweight Cylinder, Lift
Connect Counterweight Cylinder, Hose(S), Set (All)
Turn/Reposition Machine
Install Counterweight, Chain
Remove Counterweight, Lift
Raise Counterweight
Lower Counterweight Cylinder
Page 98 of 122
Install Counterweight, Bolt(S), Set (All)

5456 010 E Boom Cylinder, Remove & Install, Each
Notes: z If required, add code (5456-017--E) to Disassemble and Assemble Boom Cylinder, Each.
2.5
Remove 1.3
Turn/Reposition Machine, Boom
Install Boom Cylinder, Lift
Separate Boom Cylinder, Hose(S)
Remove Boom Cylinder, Hose(S)
Separate Grease Lines, Boom Cylinder
Remove Boom Cylinder, Plate
Turn/Reposition Boom Cylinder, Pin
Install Boom Cylinder, Cap(S), Each
Remove Boom Cylinder, Pin
Remove Boom Cylinder
Lift, Block & Lower Boom Cylinder
Remove Boom Cylinder, Lift
Install 1.2
Install Boom Cylinder, Lift
Install Boom Cylinder
Install Boom Cylinder, Pin
Remove Boom Cylinder, Cap(S), Each
Turn/Reposition Boom, Pin, Limited Quantity
Install Boom, Plate
Connect Grease Lines, Boom Cylinder
Install Boom Cylinder, Hose(S)
Connect Boom Cylinder, Hose(S)
Remove Boom Cylinder, Lift
Check Hydraulic Oil

5456 010 O Boom Cylinder, Remove & Install, Both
Notes: None

4.4
Remove 2.0
Install Boom Cylinder, Lift, Both
Separate Boom Cylinder, Hose(S), Both Sides
Remove Boom Cylinder, Hose(S), Both Sides
Separate Grease Lines, Boom Cylinder, Both Sides
Remove Boom Cylinder, Plate, Both Sides
Install Boom Cylinder, Cap(S), Set (All)
Remove Boom Cylinder, Pin, Both Sides
Remove Boom Cylinder, Both
Lift, Block & Lower Boom Cylinder, Both Sides
Page 99 of 122
Remove Boom Cylinder, Lift, Both Sides
Install 2.4
Install Boom Cylinder, Lift, Both Sides
Install Boom Cylinder, Both
Install Boom Cylinder, Pin, Both Sides
Remove Boom Cylinder, Cap(S), Set (All)
Turn/Reposition Boom, Pin
Install Boom, Plate, Both Sides
Connect Grease Lines, Boom Cylinder, Both Sides
Install Boom Cylinder, Hose(S), Both Sides
Connect Boom Cylinder, Hose(S), Both Sides
Remove Boom Cylinder, Lift, Both
Check Hydraulic Oil

5456 017 E Boom Cylinder, Disassemble & Assemble, Each
Notes: None

4.3
Disassemble 1.2
Unpack Boom Cylinder
Identify Boom Cylinder
Remove Boom Cylinder, Tube, Both
Remove Boom Cylinder, Bolt(S), Set (All)
Remove Boom Cylinder, Rod
Remove Boom Cylinder, Nut(S)
Remove Boom Cylinder, Head Assembly
Remove Boom Cylinder, Seal, Set (All)
Remove Boom Cylinder, Seal, Both Sides
Remove Boom Cylinder, Bearing, Both Sides
Clean & Inspect 1.0
Steam Clean Boom Cylinder
Clean Boom Cylinder, Head End
Clean Boom Cylinder, Head Assembly
Clean Boom Cylinder, Barrel
Clean Boom Cylinder, Tube, Both
Inspect Boom Cylinder, Rod
Inspect Boom Cylinder, Barrel
Polish 0.3
Polish Boom Cylinder, Rod
Hone Boom Cylinder, Barrel
Assemble 1.8
Install Boom Cylinder, Seal, Set (All)
Install Boom Cylinder, Head Assembly
Install Boom Cylinder, Nut(S)
Install Boom Cylinder, Rod
Install Boom Cylinder, Bolt(S), Set (All)
Torque Boom Cylinder, Bolt(S), Set (All)
Install Boom Cylinder, Tube, Both
Hydraulic Test Boom Cylinder
Paint Boom Cylinder
Install Boom Cylinder, Bearing, Both Sides
Page 100 of 122

Install Boom Cylinder, Seal, Both Sides

5457 010 Bucket Cylinder, Remove & Install
Notes: z If required, add code (5457-017--E) to Disassemble and Assemble Bucket Cylinder, Each.
2.2
Remove 0.9
Turn/Reposition Stick
Install Bucket Cylinder, Lift
Loosen Bucket Cylinder, Hose(S), Both
Drain Bucket Cylinder, Hose(S), Both
Install Bucket Cylinder, Cap(S), Set (All)
Install Bucket Cylinder, Lift, Each Additional
Remove Bucket Cylinder, Pin, Both
Remove Bucket Cylinder
Lift, Block & Lower Bucket Cylinder
Move Machine, Stick
Clean 0.1
Clean Bucket Cylinder
Install 1.2
Move Machine, Stick
Install Bucket Cylinder, Lift
Install Bucket Cylinder
Install Bucket Cylinder, Pin, Both
Install Bucket Cylinder, Hose(S), Both
Remove Bucket Cylinder, Lift
Check Hydraulic Oil

5457 017 E Bucket Cylinder, Disassemble & Assemble, Each
Notes: None

4.3
Disassemble 1.2
Unpack Bucket Cylinder
Identify Bucket Cylinder
Remove Bucket Cylinder, Tube, Both
Remove Bucket Cylinder, Bolt(S), Set (All)
Remove Bucket Cylinder, Rod
Remove Bucket Cylinder, Nut(S)
Remove Bucket Cylinder, Head Assembly
Remove Bucket Cylinder, Seal, Set (All)
Remove Bucket Cylinder, Seal, Both Sides
Remove Bucket Cylinder, Bearing, Both Sides
Clean & Inspect 1.0
Steam Clean Bucket Cylinder
Clean Bucket Cylinder, Head End
Clean Bucket Cylinder, Head Assembly
Clean Bucket Cylinder, Barrel
Clean Bucket Cylinder, Tube, Both
Page 101 of 122

Inspect Bucket Cylinder, Rod
Inspect Bucket Cylinder, Barrel
Polish 0.3
Polish Bucket Cylinder, Rod
Hone Bucket Cylinder, Barrel
Assemble 1.8
Install Bucket Cylinder, Seal, Set (All)
Install Bucket Cylinder, Head Assembly
Install Bucket Cylinder, Nut(S)
Install Bucket Cylinder, Rod
Install Bucket Cylinder, Bolt(S), Set (All)
Torque Bucket Cylinder, Bolt(S), Set (All)
Install Bucket Cylinder, Tube, Both
Hydraulic Test Bucket Cylinder
Paint Bucket Cylinder
Install Bucket Cylinder, Bearing, Both Sides
Install Bucket Cylinder, Seal, Both Sides

5458 010 Stick Cylinder, Remove & Install
Notes: z If required, add code (5458-017--E) to Disassemble and Assemble Stick Cylinder, Each.
3.0
Remove 1.1
Install Stick Cylinder, Lift
Separate Grease Lines, Stick Cylinder Bearing
Separate Stick Cylinder, Hose(S), Both
Drain Stick Cylinder, Hose(S), Both
Install Stick Cylinder, Cap(S), Set (All)
Install Stick Cylinder, Lift, Each Additional
Remove Stick Cylinder, Bolt(S), Both
Remove Stick Cylinder, Pin, Both
Lift, Block & Lower Stick Cylinder
Remove Stick Cylinder, Lift
Remove Stick Cylinder, Lift, Each Additional
Clean 0.1
Clean Stick Cylinder
Install 1.8
Install Stick Cylinder
Install Stick Cylinder, Lift, Each Additional
Install Stick Cylinder, Pin, Both
Install Stick Cylinder, Bolt(S), Both
Remove Stick Cylinder, Cap(S), Set (All)
Connect Stick Cylinder, Hose(S), Both
Connect Grease Lines, Stick Cylinder Bearing
Remove Stick Cylinder, Lift, Each Additional
Check Hydraulic Oil

5458 017 E Stick Cylinder, Disassemble & Assemble, Each
Page 102 of 122

Notes: None

4.3
Disassemble 1.2
Unpack Stick Cylinder
Identify Stick Cylinder
Remove Stick Cylinder, Tube, Both
Remove Stick Cylinder, Bolt(S), Set (All)
Remove Stick Cylinder, Rod
Remove Stick Cylinder, Nut(S)
Remove Stick Cylinder, Head Assembly
Remove Stick Cylinder, Seal, Set (All)
Remove Stick Cylinder, Seal, Both Sides
Remove Stick Cylinder, Bearing, Both Sides
Clean & Inspect 1.0
Steam Clean Stick Cylinder
Clean Stick Cylinder, Head End
Clean Stick Cylinder, Head Assembly
Clean Stick Cylinder, Barrel
Clean Stick Cylinder, Tube, Both
Inspect Stick Cylinder, Rod
Inspect Stick Cylinder, Barrel
Polish 0.3
Polish Stick Cylinder, Rod
Hone Stick Cylinder, Barrel
Assemble 1.8
Install Stick Cylinder, Seal, Set (All)
Install Stick Cylinder, Head Assembly
Install Stick Cylinder, Nut(S)
Install Stick Cylinder, Rod
Install Stick Cylinder, Bolt(S), Set (All)
Torque Stick Cylinder, Bolt(S), Set (All)
Install Stick Cylinder, Tube, Both
Hydraulic Test Stick Cylinder
Paint Stick Cylinder
Install Stick Cylinder, Bearing, Both Sides
Install Stick Cylinder, Seal, Both Sides

5459 010 E Swing Drive, Remove & Install, Each
Notes: None

5.4
Remove 2.8
Separate Hydraulic Hoses/Lines, Heavy Duty
Separate Crossover Valve, Hose(S)
Separate Swing Drive Motor, Hose(S), Set (All)
Page 103 of 122

Remove Swing Drive Motor, Bracket, First One
Remove Swing Drive Motor, Bracket, Remaining
Separate Swing Drive Motor, Wiring Harness
Remove Swing Drive Motor, Bolt(S), Set (All)
Install Swing Drive Motor, Eye, Both
Install Swing Drive Motor, Lift
Remove Swing Drive Motor, Each
Remove Swing Drive, Bolt(S), Set (All)
Install Swing Drive, Lift
Remove Swing Drive, Each
Clean 0.1
Clean Swing Drive Motor, Each
Clean Swing Drive Motor, Bolt(S), Each
Install 2.5
Install Swing Drive, Each
Remove Swing Drive, Lift
Install Swing Drive, Bolt(S), Set (All)
Install Swing Drive Motor, Each
Remove Swing Drive Motor, Lift
Remove Swing Drive Motor, Eye, Both
Install Swing Drive Motor, Bolt(S), Set (All)
Connect Swing Drive Motor, Wiring Harness
Install Swing Drive Motor, Bracket, Remaining
Install Swing Drive Motor, Bracket, First One
Connect Swing Drive Motor, Hose(S)
Connect Crossover Valve, Hose(S), Set (All)
Connect Hydraulic Hoses/Lines, Heavy Duty

5459 010 O Swing Drive, Remove & Install, Both
Notes: None

10.5
Remove 5.4
Separate Crossover Valve, Hose(S), Both Sides
Separate Swing Drive Motor, Hose(S), Both Sides
Remove Swing Drive Motor, Bracket, Both Sides
Remove Swing Drive Motor, Bracket, Each Additional
Separate Swing Drive Motor, Wiring Harness, Both Sides
Remove Swing Drive Motor, Bolt(S), Both Sides
Install Swing Drive Motor, Eye, Both Sides
Install Swing Drive Motor, Lift, Both Sides
Remove Swing Drive Motor, Both Sides
Remove Swing Drive, Bolt(S), Both Sides
Install Swing Drive, Lift, Both Sides
Remove Swing Drive, Both Sides
Clean 0.3
Clean Swing Drive Motor, Both Sides
Page 104 of 122

Clean Swing Drive Motor, Bolt(S), Both Sides
Install 4.8
Install Swing Drive, Both Sides
Install Swing Drive, Bolt(S), Both Sides
Remove Swing Drive, Lift, Both Sides
Install Swing Drive Motor, Both Sides
Remove Swing Drive Motor, Lift, Both Sides
Remove Swing Drive Motor, Eye, Both Sides
Install Swing Drive Motor, Bolt(S), Both Sides
Connect Swing Drive Motor, Wiring Harness, Both Sides
Install Swing Drive Motor, Bracket, Each Additional
Install Swing Drive Motor, Bracket, Both Sides
Connect Swing Drive Motor, Hose(S), Both Sides
Connect Crossover Valve, Hose(S), Both Sides

6501 010 KL Boom, Remove & Install, Linkage
Notes: None

13.1
Remove 5.1
Remove Bucket Pin Boss, Cap(S)
Install Bucket, Lift
Remove Bucket Pin, Bolt(S)
Remove Bucket Pin
Remove Bucket Linkage, Bolt(S)
Remove Bucket Linkage, Pin
Remove Bucket, Lift
Raise Machine, Stick
Separate Bucket Cylinder, Hose(S), Both
Turn/Reposition Machine, Stick
Remove Stick Cylinder, Bolt(S)
Remove Stick Cylinder, Pin
Turn/Reposition Stick Cylinder
Fasten Stick Cylinder
Install Stick, Lift
Remove Stick, Pin
Lift, Block & Lower Stick
Move Machine, Boom
Install Boom Cylinder, Lift, Both
Separate Boom Cylinder, Hose(S), Both Sides
Remove Boom Cylinder, Hose(S), Both Sides
Separate Grease Lines, Boom Cylinder, Both Sides
Remove Boom Cylinder, Plate, Both Sides
Install Boom Cylinder, Cap(S), Set (All)
Page 105 of 122

Remove Boom Cylinder, Pin, Both Sides
Remove Boom Cylinder, Both
Remove Boom Cylinder, Lift, Both Sides
Remove Body Panel, Right Front
Remove Ladder/Step
Remove Mirror, Right Front
Separate Wiring Harness, Boom
Separate Boom, Hose(S), Set (All)
Install Boom, Cap(S)
Install Boom, Lift
Remove Boom, Bolt(S)
Remove Boom, Pin
Move Machine
Lift, Block & Lower Boom
Clean 0.1
Clean Boom, Linkage
Clean Stick, Bore, Both
Clean Stick Cylinder, Pin, Both
Install 7.9
Install Boom, Lift
Raise Boom
Install Boom
Install Boom, Pin
Install Boom, Bolt(S)
Remove Boom, Lift
Connect Wiring Harness, Boom
Install Mirror, Right Front
Install Ladder/Step
Install Body Panel, Right Front
Connect Boom, Hose(S), Set (All)
Install Boom Cylinder, Lift, Both Sides
Install Boom Cylinder, Both
Install Boom Cylinder, Pin, Both Sides
Remove Boom Cylinder, Cap(S), Set (All)
Turn/Reposition Boom, Pin
Install Boom, Plate, Both Sides
Connect Grease Lines, Boom Cylinder, Both Sides
Install Boom Cylinder, Hose(S), Both Sides
Connect Boom Cylinder, Hose(S), Both Sides
Remove Boom Cylinder, Lift, Both
Install Stick, Pin
Install Stick Cylinder, Pin
Remove Bucket Cylinder, Cap(S), Set (All)
Connect Bucket Cylinder, Hose(S), Both
Move Bucket
Install Bucket, Seal, Both
Install Bucket Pin
Align Bucket Linkage, Pin
Install Bucket Pin, Seal, Both
Install Bucket Linkage, Pin
Install Bucket Pin, Bolt(S), Both
Install Bucket Pin Boss, Cap(S)
Page 106 of 122

Install Grease/Oils/Lub/Fluids, Bucket Bearing
Remove Bucket, Lift
Check Hydraulic Oil

6502 010 KL Stick, Remove & Install, Linkage
Notes: None

3.8
Remove 1.4
Remove Bucket Pin
Remove Bucket, Lift
Raise Machine, Stick
Separate Bucket Cylinder, Hose(S), Both
Remove Stick Cylinder, Bolt(S)
Remove Stick Cylinder, Pin
Turn/Reposition Stick Cylinder
Fasten Stick Cylinder
Install Stick, Lift
Remove Stick, Pin
Lift, Block & Lower Stick
Clean 0.1
Clean Stick Cylinder, Pin, Both
Clean Stick, Bore, Both
Install 2.3
Install Stick, Pin
Install Stick Cylinder, Pin
Remove Bucket Cylinder, Cap(S), Set (All)
Connect Bucket Cylinder, Hose(S), Both
Move Bucket
Install Bucket Pin
Page 107 of 122

Remove Bucket, Lift
Check Hydraulic Oil

6513 010 Bucket Linkage, Remove & Install
Notes: z If required, add code (6513-017--) to Disassemble and Assemble Bucket Linkage.
3.3
Remove 1.4
Remove Bucket Pin
Remove Bucket, Lift
Install Lifting Devices
Install Bucket Linkage, Lift
Remove Bucket Linkage, Bolt(S), Both
Remove Bucket Linkage, Link, Both Sides
Remove Bucket Linkage, Pin, Both
Remove Bucket Linkage
Clean 0.1
Clean Bucket Linkage
Install 1.8
Install Lifting Devices
Install Bucket Linkage
Install Bucket Linkage, Pin, Both
Install Bucket Linkage, Link, Both Sides
Install Bucket Linkage, Bolt(S), Both
Move Bucket
Install Bucket Pin
Install Grease/Oils/Lub/Fluids, Linkage
Remove Bucket, Lift

6513 017 Bucket Linkage, Disassemble & Assemble
Notes: None

1.0
Disassemble 0.4
Remove Bucket Linkage, Bearing, Set (All)
Clean 0.1
Page 108 of 122

Clean Bucket Linkage, Internal Component(S)
Assemble 0.5
Install Bucket Linkage, Bearing, Set (All)

7000 074 Machine, Wash
Notes: z This time is for a complete exterior wash of the machine, as necessary, prior to a major repair.
1.0
Wash 1.0
Wash Machine

7000 074 MN Machine, Wash, Minor
Notes: z This time is for a localized washing around an individual component to prevent contamination.
0.6
Wash 0.6
Wash Machine, Minor

7000 552 Machine, Tow
Notes: z Claim actual reasonable time to manuever inoperative machine into shop
0.0
Tow 0.0
Tow Machine

7056 010 QCH Counterweight, Remove & Install, Quick Change
Notes: None

1.4
Remove 0.9
Raise Counterweight Cylinder
Remove Counterweight, Bolt(S), Set (All)
Lower Counterweight
Separate Counterweight, Chain
Move Machine
Clean 0.1
Clean Counterweight
Install 0.4
Connect Counterweight, Chain
Raise Counterweight
Lower Counterweight Cylinder
Page 109 of 122

Install Counterweight, Bolt(S), Set (All)

7251 010 CE Hood, Remove & Install, Center
Notes: None

0.7
Remove 0.3
Open Hood, Center
Install Hood, Lift, First One
Separate Hood, Arms & Braces
Remove Hood, Bolt(S), First One
Remove Hood, Center
Install 0.4
Install Hood, Center
Install Hood, Bolt(S), First One
Connect Hood, Arms & Braces
Close Hood

7251 010 QS Hood, Remove & Install, Right Side
Notes: None

1.1
Remove 0.5
Open Hood
Install Hood, Lift
Install 0.6
Close Hood

7251 010 ZL Hood, Remove & Install, Left Side
Notes:
None
Page 110 of 122

1.3
Remove 0.5
Open Hood, Center
Install Hood, Lift
Install 0.8
Remove Hood, Lift
Open Hood, Center

7268 010 Storage Rack/Box, Remove & Install
Notes: None

0.6
Remove 0.3
Turn/Reposition Seat Assembly
Remove Storage Rack/Box, Cab Mounted
Install 0.3
Install Storage Rack/Box, Cab Mounted

7304 010 KO Cab Heater, Remove & Install, Core
Notes: None

5.1
Remove 2.2
Open Hood, Center
Page 111 of 122

Remove Bottom Guard, Left Side
Separate Evaporator Coil, Hose(S), Both
Separate Cab Heater, Hose(S), Both
Separate Heater & Air Conditioner, Wiring Harness, Set (All)
Turn/Reposition Wiring Harness, Cab Mounted
Separate Heater & Air Conditioner, Duct, Set (All)
Remove Heater & Air Conditioner, Bolt(S), Set (All)
Remove Heater & Air Conditioner, Assembled
Separate Cab Air Pressurizer, Wiring Harness, Set (All)
Separate Heater & Air Conditioner
Separate Cab Heater, Temperature Sensor
Remove Heater & Air Conditioner, Cover, Remaining
Separate Heater & Air Conditioner, Actuator, Both
Remove Cab Heater, Core
Install 2.9
Install Cab Heater, Core
Connect Heater & Air Conditioner, Actuator, Both
Install Heater & Air Conditioner, Cover
Connect Cab Heater, Temperature Sensor
Connect Heater & Air Conditioner
Connect Cab Air Pressurizer, Wiring Harness, Set (All)
Install Heater & Air Conditioner, Assembled
Install Heater & Air Conditioner, Bolt(S), Set (All)
Install Heater & Air Conditioner, Duct, Set (All)
Install Wiring Harness, Cab Mounted
Connect Heater & Air Conditioner, Wiring Harness, Set (All)
Connect Cab Heater, Hose(S), Both
Connect Evaporator Coil, Hose(S), Both
Install Bottom Guard, Left Side
Vacuum Refrigerant
Charge Refrigerant
Close Hood

7309 010 AS Heater & Air Conditioner, Remove & Install, Assembled
Notes: None

3.9
Remove 1.8
Open Hood, Center
Page 112 of 122

Install 2.1
Vacuum Refrigerant
Charge Refrigerant
Close Hood

7309 010 BW Heater & Air Conditioner, Remove & Install, Blower
Notes: None

1.3
Remove 0.6
Remove Cab Air Pressurizer, Cover
Separate Cab Air Pressurizer, Wiring Harness
Remove Heater & Air Conditioner, Blower
Install 0.7
Install Heater & Air Conditioner, Blower
Connect Cab Air Pressurizer, Wiring Harness
Install Cab Air Pressurizer, Cover

7312 010 Seat Assembly, Remove & Install
Page 113 of 122

Notes: None

0.4
Remove 0.2
Separate Seat Assembly, Wiring Harness
Remove Seat Assembly, Bolt(S), Set (All)
Remove Seat Assembly
Install 0.2
Install Seat Assembly
Install Seat Assembly, Bolt(S), Set (All)
Connect Seat Assembly, Wiring Harness

7312 010 BA Seat Assembly, Remove & Install, Base
Notes: None

1.0
Remove 0.4
Remove Seat Assembly, Bolt(S), Both Sides
Separate Seat Assembly, Wiring Harness, Set (All)
Remove Seat Assembly, Bolt(S)
Remove Seat Assembly
Separate Seat Assembly, Wiring Harness
Remove Seat Assembly, Base
Install 0.6
Install Seat Assembly, Base
Connect Seat Assembly, Wiring Harness
Install Seat Assembly
Install Seat Assembly, Bolt(S)
Connect Seat Assembly, Wiring Harness, Set (All)
Install Seat Assembly, Bolt(S), Both Sides

7322 010 A/C Receiver/Dryer, Remove & Install
Notes: None

1.7
Remove 0.7
Open Hood, Center
Separate A/C Receiver/Dryer, Hose(S), Both
Page 114 of 122

Remove A/C Receiver/Dryer
Install 1.0
Install A/C Receiver/Dryer
Connect A/C Receiver/Dryer, Hose(S), Both
Vacuum Refrigerant
Charge Refrigerant
Close Hood

7325 010 ROPS/FOPS Cab, Remove & Install
Notes: None

8.4
Remove 4.2
Open Hood, Center
Remove Cab, Plate
Remove Cab, Cover, Limited Quantity
Remove Cab, Bolt(S), Limited Quantity
Remove Bottom Guard, Left Front
Separate Cab, Wiring Harness, Set (All)
Separate Ground/Static Strap
Separate Hydraulic Pilot Lines, Cab Mounted, Limited Quantity
Separate Brake Shuttle Valve, Hose(S), Set (All)
Separate Hydraulic Pilot Lines, Cab Mounted, Remaining
Remove Mach Elec Cont&Data Mgmt, Bolt(S), Set (All)
Turn/Reposition Mach Elec Cont&Data Mgmt
Turn/Reposition Windshield Washer, Tank
Separate Product Link System, Wiring Harness
Separate Windshield Washer, Hose(S)
Install Cab, Eye, Set (All)
Install Cab, Lift
Remove Cab, Bolt(S), Remaining
Remove Cab
Clean 0.1
Clean ROPS/FOPS Cab
Install 4.1
Install Cab
Install Cab, Bolt(S), Remaining
Tighten Cab, Bolt(S), Remaining
Remove Cab, Lift
Remove Cab, Eye, Set (All)
Connect Windshield Washer, Hose(S)
Connect Product Link System, Wiring Harness
Install Windshield Washer, Tank
Install Mach Elec Cont&Data Mgmt
Install Mach Elec Cont&Data Mgmt, Bolt(S), Set (All)
Page 115 of 122

Connect Hydraulic Pilot Lines, Hose(S), Remaining
Connect Brake Shuttle Valve, Cab Mounted
Connect Hydraulic Pilot Lines, Cab Mounted, Limited Quantity
Connect Ground/Static Strap
Connect Wiring Harness, Cab Mounted
Install Bottom Guard, Left Front
Install Cab, Bolt(S), Limited Quantity
Install Cab, Cover, Limited Quantity
Install Cab, Plate
Vacuum Refrigerant
Charge Refrigerant

7343 010 Evaporator Coil, Remove & Install
Notes: None

4.8
Remove 2.1
Open Hood, Center
Separate Cab Air Pressurizer, Wiring Harness, Set (All)
Separate Heater & Air Conditioner
Separate Evaporator Coil, Temperature Sensor
Remove Evaporator Coil
Install 2.7
Install Evaporator Coil
Install Evaporator Coil, Temperature Sensor
Connect Heater & Air Conditioner
Connect Cab Air Pressurizer, Wiring Harness, Set (All)
Page 116 of 122

Vacuum Refrigerant
Charge Refrigerant
Close Hood

7490 038 Electronic Mon Sys/Panel, Diagnostic Test
Notes: None

0.2
Diagnostic Test 0.2

Diagnostic Test Electronic Mon Sys/Panel

7600 010 CMO Mach Elec Cont&Data Mgmt, Remove & Install, Control Module
Notes: None

0.6
Remove 0.2
Separate Mach Elec Cont&Data Mgmt, Wiring Harness, Both
Remove Mach Elec Cont&Data Mgmt, Bolt(S), Set (All)
Remove Mach Elec Cont&Data Mgmt, Control Module
Install 0.4
Install Mach Elec Cont&Data Mgmt, Control Module
Install Mach Elec Cont&Data Mgmt, Bolt(S), Set (All)
Connect Mach Elec Cont&Data Mgmt, Wiring Harness, Both

79PA 010 E Swing Drive Motor, Remove & Install, Each
Notes: None

4.3
Remove 2.1
Page 117 of 122

Separate Crossover Valve, Hose(S)
Separate Swing Drive Motor, Hose(S), Set (All)
Remove Swing Drive Motor, Bracket, First One
Remove Swing Drive Motor, Bracket, Remaining
Separate Swing Drive Motor, Wiring Harness
Remove Swing Drive Motor, Bolt(S), Set (All)
Install Swing Drive Motor, Eye, Both
Install Swing Drive Motor, Lift
Remove Swing Drive Motor, Each
Clean 0.1
Clean Swing Drive Motor, Each
Clean Swing Drive Motor, Bolt(S), Each
Install 2.1
Install Swing Drive Motor, Each
Remove Swing Drive Motor, Lift
Remove Swing Drive Motor, Eye, Both
Install Swing Drive Motor, Bolt(S), Set (All)
Connect Swing Drive Motor, Wiring Harness
Install Swing Drive Motor, Bracket, Remaining
Install Swing Drive Motor, Bracket, First One
Connect Swing Drive Motor, Hose(S)
Connect Crossover Valve, Hose(S), Set (All)

79PA 010 O Swing Drive Motor, Remove & Install, Both
Notes: None

8.1
Remove 3.7
Separate Crossover Valve, Hose(S), Both Sides
Separate Swing Drive Motor, Hose(S), Both Sides
Remove Swing Drive Motor, Bracket, Both Sides
Remove Swing Drive Motor, Bracket, Each Additional
Separate Swing Drive Motor, Wiring Harness, Both Sides
Remove Swing Drive Motor, Bolt(S), Both Sides
Install Swing Drive Motor, Eye, Both Sides
Install Swing Drive Motor, Lift, Both Sides
Remove Swing Drive Motor, Both
Clean 0.3
Clean Swing Drive Motor, Both
Clean Swing Drive Motor, Bolt(S), Both
Install 4.1
Install Swing Drive Motor, Both
Remove Swing Drive Motor, Lift, Both Sides
Remove Swing Drive Motor, Eye, Both Sides
Install Swing Drive Motor, Bolt(S), Both Sides
Connect Swing Drive Motor, Wiring Harness, Both Sides
Page 118 of 122

Install Swing Drive Motor, Bracket, Each Additional
Install Swing Drive Motor, Bracket, Both Sides
Connect Swing Drive Motor, Hose(S), Both Sides
Connect Crossover Valve, Hose(S), Both Sides
Page 119 of 122

Index of Repair Times
Part or Component Failure Page Part or Component Failure Page
A Crankshaft Rear Seal-Wash 28

Aftercooler-Crack/Leak Test-Air To Ai 17 Cylinder Block-Measure, Pressure(s 30
Aftercooler-Remove & Instal 16 Cylinder Block-Replace Gasket/Reseal, Plug(s)-Eac 30
Aftercooler Core-Crack/Leak Test-Air To Ai 17 Cylinder Block-Test After Repai 30
Aftercooler Core-Flush-Air To Air 17 Cylinder Block- Troubleshoot 30
Air Cleaner-Remove & Install, Housing 10 Cylinder Block Cylinder-Inspect, Using Borescope-Set (All) 38
Air Conditioner Receiver/Dryer-Remove & Install 114 Cylinder Block Cylinder-Measure, Each 38
Air Induction & Exhaust System-Crack/Leak Test 10 Cylinder Head (Bare)-Crack/Leak Test 18
Air Induction & Exhaust System-Inspect 10 Cylinder Head (Bare)-Inspect-Crack(s) 19
Alternator-Remove & Install 71 Cylinder Head (Bare)-Machine/Grind/Mill 19
Atmospheric Press Sensor-Remove & Install 81 Cylinder Head (Bare)-Ream/Bore/Drill 19
B Cylinder Head Assembly-Test After Repair 18
Battery-Diagnostic Test-Using Battery Load Test 70 Cylinder Head Assembly-Troubleshoot 18
Battery-Remove & Install-Set (All) 70 Cylinder Head Assembly-Wash 18
Belt Tensioner-Troubleshoot 60 Cylinder Liner-Clean & Inspect, Set (All) 36
Boom- Remove & Install, Linkage 105 Cylinder Liner-Measure, Liner Projection-Set (All) 36
Boom Cyliinder- Disassemble & Assemble, Each 100 Cylinder Liner-Recondition, Flex Hone (Each) 34
Boom Cylinder- Remove & Install, Both 99 Cylinder Liner-Recondition, Flex Hone-Set (All) 35
Boom Cylinder- Remove & Install, Each 99 Cylinder Liner-Recondition, Hard Hone (Each) 35
Boost Pressure Sensor-Remove & Install 80 Cylinder Liner-Recondition, Hard Hone-Set (All) 35
Boost Pressure Sensor-Test 80 Cylinder Pack-Recondition, Each 38
Bucket Cylinder- Disassemble & Assemble, Each 101 Cylinder Pack-Recondition, Set (All) 39
Bucket Cylinder- Remove & Install 101 Cylinder Pack-Recondition, Test After Repair 39
Bucket Linkage- Disassemble & Assemble 108 Cylinder Pack-Recondition, Troubleshoot 39
Bucket Linkage- Remove & Install 108 Cylinder Pack-Recondition, Wash 39
C E
Cab Heater-Remove & Install, Core 111 Electric Starting Motor-Remove & Install 73
Camshaft-Remove & Install, Position Sensor 32 Electric System-Diagnostic Test-Using Voltmeter 70
Camshaft-Test After Repair 32 Electronic Monitoring System/Panel-Diagnostic Test 117
Camshaft-Troubleshoot 32 Engine-Dynamometer Test-Out Of Frame/Out Of Hull/Off Site 8
Camshaft-Wash 33 Engine-Dynamometer Test-Par 9
Camshaft Gear-Adjust 33 Engine-Dynamometer Test-Par After Repair 9
Camshaft Gear-Test After Repair 33 Engine-Dynamometer Test-Par After Repair & Unhook 9
Camshaft Gear-Troubleshoot 33 Engine-Dynamometer Test-Par Preliminary Inspection 9
Camshaft Gear-Wash 33 Engine-Paint 9
Camshaft Roller Follower/Valve Lifter-Wash 32 Engine-Paint-Minor 9
Carrier Roller- Disassemble & Assemble, Each 87 Engine-Remove & Install 6
Carrier Roller- Remove & Install, Each 87 Engine-Wash 10
Connecting Rod-Measure, Each Additional 37 Engine-Wash-Minor 10
Connecting Rod-Measure, First One 37 Engine Coolant-Drain & Refill 69
Connecting Rod-Measure, Set (All) 38 Engine Coolant-Measure-Temperature(s) 69
Connecting Rod-Recondition-Major, Each Additional 36 Engine Coolant-Test 69
Connecting Rod-Recondition-Major, First One 36 Engine Cooling System-Crack/Leak Test 54
Connecting Rod-Recondition-Major, Set (All) 36 Engine Cooling System-Diagnostic Test-Using Bottle Test 54
Connecting Rod-Recondition-Minor, Each Additional 37 Engine Cooling System-Flush 54
Connecting Rod-Recondition-Minor, First One 37 Engine Cooling System-Flush-Excludes Some R&I 54
Connecting Rod-Recondition-Minor, Set (All) 37 Engine Cooling System-Flush-With Dynamometer Test 54
Counterweight-Remove & Install, Quick Change 109 Engine Electronic Control Module-Adjust-Full Load/Torque Setting 77
Counterweight Cylinder- Remove & Install 98 Engine Electronic Control Module-Obtain-Password(s) 78
Crankcase Breather-Remove & Install 51 Engine Electronic Control Module-Remove & Install 76
Crankcase Breather-Test After Repair 52 Engine Electronic Control Module-Reprogram 78
Crankcase Breather-Troubleshoot 52 Engine Electronic Control Module-Test After Repair 77
Crankcase Breather-Wash 52 Engine Electronic Control Module-Test-Using Test Ecm 78
Crankshaft-Remove & Install, Position Sensor 31 Engine Electronic Control Module-Troubleshoot 77
Crankshaft-Test After Repair 31 Engine Electronic Control Module-Wash 78
Crankshaft-Troubleshoot 31 Engine Oil- Measure, Pressure(s) 53
Crankshaft-Wash 31 Engine Oil- Take & Analyze S-O-S From, Sample 53
Crankshaft Front Seal-Test After Repair 27 Engine Oil Cooler-Combined Repair Time (Warranty) 5
Crankshaft Front Seal-Troubleshoot 27 Engine Oil Cooler-Crack/Leak Test 67
Crankshaft Front Seal-Wash 27 Engine Oil Cooler-Remove & Install 66
Crankshaft Rear Seal-Test After Repair 27 Engine Oil Cooler-Test After Repair 66
Crankshaft Rear Seal-Troubleshoot 27
Page 120 of 122

Engine Oil Cooler-Troubleshoot 67 Fuel Filter Housing/Base-Troubleshoot 44

Engine Oil Cooler-Wash 67 Fuel Filter Housing/Base-Wash 44
Engine Oil Filler-Troubleshoot 51 Fuel Priming Pump- Inspect, Check Valve 42
Engine Oil Filler-Wash 51 Fuel Priming Pump- Test After Repair 41
Engine Oil Filter-Cut & Analyze 51 Fuel Priming Pump- Troubleshoot 42
Engine Oil Filter Housing/Base- Comb Repair Time (Warranty) 4 Fuel Priming Pump- Wash 42
Engine Oil Filter Hsg/Base- Comb Repair Time (Wrnt), Gasket Only 4 Fuel Supply/Return Lines-Inspect & Maintain 45
Engine Oil Filter Housing/Base-Remove & Install 49 Fuel Supply/Return Lines-Test After Repair 45
Engine Oil Filter Housing/Base-Test After Repair 50 Fuel Supply/Return Lines-Troubleshoot 45
Engine Oil Filter Housing/Base-Troubleshoot 50 Fuel Supply/Return Lines-Wash 45
Engine Oil Filter Housing/Base-Wash 50 Fuel System-Check 40
Engine Oil Level Gauge/Dipstick-Adjust 52 Fuel System-Flush 40
Engine Oil Level Gauge/Dipstick-Test After Repair 52 Fuel System-Measure-Pressure(s) 40
Engine Oil Level Gauge/Dipstick-Troubleshoot 53 Fuel Tank-Remove & Install 44
Engine Oil Level Gauge/Dipstick-Wash 53 Fuel Temperature Sensor-Remove & Insta 81
Engine Oil Pan- Combined Repair Time (Warranty) 3 Fuel Transfer Pump-Combined Repair Time (Warranty) 3
Engine Oil Pan- Combined Repair Time (Wrnt), Gasket Only 4 Fuel Transfer Pump-Combined Repair Time (Wrnt), Gasket Only 3
Engine Oil Pan-Ream/Bore/Drill 48 Fuel Transfer Pump-Remove & Install 40
Engine Oil Pan-Remove & Install 47 Fuel Transfer Pump-Test After Repair 41
Engine Oil Pan-Test After Repair 48 Fuel Transfer Pump-Troubleshoot 41
Engine Oil Pan-Troubleshoot 48 Fuel Transfer Pump-Wash 41
Engine Oil Pan-Wash 48 Fuel Transfer & Priming Pump-Test After Repair 74
Engine Oil Pressure Sensor-Remove & Install 82 Fuel Transfer & Priming Pump-Troubleshoot 75
Engine Oil Pump-Inspect 49 Fuel Transfer & Priming Pump-Wash 75
Engine Oil Pump-Test After Repair 49 H
Engine Oil Pump-Transfer Components To/From 48 Heater & Air Conditioner-Remove & Install, Assembled 112
Engine Oil Pump-Troubleshoo 49 Heater & Air Conditioner-Remove & Install, Blowe 113
Engine Oil Pump-Wash 49 Hood-Remove & Install, Center 110
Engine Output Drive Assembly/Coupling-Remove & Install 82 Hood-Remove & Install, Left Side 110
Engine Speed Timing Sensor-Adjust 79 Hood-Remove & Install, Right Side 110
Engine Speed Timing Sensor-Calibrate 80 Hydraulic Control Valve-Remove & Install, Main 94
Engine Speed/Timing Sensor-Test After Repair 79 Hydraulic Fan Motor-Remove & Install 67
Engine Speed/Timing Sensor-Troubleshoot 79 Hydraulic Fan Pump-Remove & Install 68
Engine Speed/Timing Sensor-Wash 79 Hydraulic Oil-Drain & Refill 98
Ether Starting Aid-Remove & Install 73 Hydraulic Oil Cooler-Remove & Install 64
Evaporator Coil-Remove & Install 116 Hydraulic Propel/Drive Motor- Remove & Install, Each 93
Exhaust Combustion Lines-Test After Repair 18 Hydraulic Tank-Remove & Install 95
Exhaust Manifold-Combined Repair Time (Warranty) 3 I
Exhaust Manifold-Combined Repair Time (Wrnt), Gasket Only 3 Idler/Idler Wheel- Disassemble & Assemble, Each 90
Exhaust Manifold-Remove & Install 14 Idler/Idler Wheel- Remove & Install, Each 89
Exhaust Manifold-Test After Repair 15 Inlet Air Temp Sensor-Remove & Install 81
Exhaust Manifold-Troubleshoot 15 Inlet/Exhaust Valve-Recondition-Each 20
Exhaust Manifold-Wash 15 Inlet/Exhaust Valve-Recondition-Set (All) 21
F Inlet/Exhaust Valve-Test After Repair 21
Fan-Measure, Speed 60 Inlet/Exhaust Valve-Troubleshoot 21
Fan-Remove & Install 59 Inlet/Exhaust Valve-Wash 21
Fan Drive-Remove & Install 61 Inlet Manifold-Combined Repair Time (Warranty) 2
Final Drive-Disassemble & Assemble, Each 84 Inlet Manifold-Combined Repair Time (Wrnt), Gasket Only 2
Final Drive-Remove & Install, Each 83 Inlet Manifold-Measure Pressure(s) 14
Final Drive Hub-Clean & Inspect, New-Each 86 Inlet Manifold-Remove & Install 13
Final Dr Plane Carriers Hub & Ring Gear-D&A, Gear-Ea Section 86 Inlet Manifold-Test After Repair 14
Final Dr Plane Carriers Hub & Ring Gear-D&A, Gear-Set (All) 86 Inlet Manifold-Troubleshoot 14
Flywheel-Remove & Install 24 Inlet Manifold-Wash 14
Flywheel-Wash 26 M
Flywheel Housing-Test After Repair 26 Machine-Tow 109
Flywheel Housing-Troubleshoot 26 Machine-Wash 109
Flywheel Housing-Wash 26 Machine-Wash-Minor 109
Fuel-Diagnostic Test, Pressure(s) 46 Machine Elec Cont&Data Mgmt-Remove & Install, Control Module 117
Fuel-Measure 46 Muffler-Remove & Install 16
Fuel Cooler-Remove & Install 74
Fuel Filter Housing/Base-Remove & Install, Primary 42
Fuel Filter Housing/Base-Remove & Install, Secondary 43
Fuel Filter Housing/Base-Test After Repair 43
Page 121 of 122

P Turbocharger-Inspect 12
Piston-Recondition, Each Additional 34 Turbocharger-Measure 13
Piston-Recondition, First One 34 Turbocharger-Remove & Install 11
Piston-Recondition, Set (All) 34 Turbocharger-Test After Repair 12
Piston & Gear Pump- Remove & Install, Main 96 Turbocharger-Transfer Components To/From 11
Piston Cooling Jet-Test, Set (All) 53 Turbocharger-Troubleshoot 12
R Turbocharger-Wash 13
Radiator-Remove & Install 56 U
Radiator & Oil Cooler-Remove & Install, Package 55 Undercarriage-Inspect 87
Radiator Cap-Crack/Leak Test 67 Unit Injector-Diagnostic Test-Using Cyl Cut-Out Test-Each Addl 46
Recoil Spring, Remove & Install 89 Unit Injector-Diagnostic Test-Using Cyl Cut-Out Test-Set (All) 46
Refrigerant Compressor-Remove & Install 75 Unit Injector-Test After Repair 46
Refrigerant Condenser-Remove & Install 76 Unit Injector-Test-Solenoid-Set (All) 47
Refrigerant-Evacuate & Charge 76 Unit Injector-Troubleshoot 46
Rocker Arm-Test After Repair 23 Unit Injector-Wash 47
Rocker Arm-Troubleshoot 23 V
Rocker Arm-Wash 23 Valve Actuator-Test After Repair 24
Rocker Shaft Assembly-Test After Repair 19 Valve Actuator-Troubleshoot 24
Rocker Shaft Assembly-Troubleshoot 20 Valve Actuator-Wash 24
Rocker Shaft Assembly-Wash 20 Valve Cover-Remove & Install 21
ROPS/FOPS Cab-Remove & Install 115 Valve Cover-Test After Repair 22
S Valve Cover-Troubleshoot 22
Seat Assembly-Remove & Install 113 Valve Cover-Wash 22
Seat Assembly-Remove & Install, Base 114 Valve Cover Base-Test After Repair 22
Serpentine Belt-Adjust 70 Valve Cover Base-Troubleshoot 23
Sprocket Assembly- Remove & Install, Each 91 Valve Cover Base-Wash 23
Steering Counterbalance Valve, Remove & Install, Each 93 Valve Seat/Insert-Machine/Grind/Mill-Each 20
Stick- Remove & Install, Linkage 107 W
Stick Cylinder- Disassemble & Assemble, Each 102 Water Pump-Combined Repair Time (Warranty) 5
Stick Cylinder- Remove & Install 102 Water Pump-Combined Repair Time (Wrnt), Gasket Only 5
Storage Rack/Box-Remove & Install 111 Water Pump-Check-Pressure(s) 64
Swing Drive-Remove & Install, Both 104 Water Pump-Remove & Instal 62
Swing Drive- Remove & Install, Each 103 Water Pump-Test After Repair 63
Swing Drive Motor- Remove & Install, Both 118 Water Pump-Troubleshoot 63
Swing Drive Motor- Remove & Install, Each 117 Water Pump-Wash 64
Swivel- Disassemble & Assemble 96 Water Temperature Sensor-Remove & Install 78
Swivel- Remove & Install 95 Wiring Harness-Check-Short 73
T Wiring Harness-Remove & Install-Seal 71
Thermostat/Water Temp Reg-Comb Repair Time (Wrnt) 4 Wiring Harness-Replace-3-Pin Connector 72
Thermostat/Water Temp Reg-Comb Rep Time (Wrnt), Gasket Only 5 Wiring Harness-Replace-12-Pin Connector 72
Thermostat/Water Temperature Regulator-Diagnostic Test 59 Wiring Harness-Replace-40-Pin Connector 72
Thermostat/Water Temperature Regulator-Remove & Install 58 Wiring Harness-Replace-70-Pin Connector 72
Thermostat/Water Temperature Regulator-Test After Repair 58 Wiring Harness-Replace, Seal 72
Thermostat/Water Temperature Regulator-Troubleshoot 58 Wiring Harness-Test After Repair 71
Thermostat/Water Temperature Regulator-Wash 59 Wiring Harness-Troubleshoot 71
Timing Gear Housing-Test After Repair 28
Timing Gear Housing-Troubleshoot 28
Timing Gear Housing-Wash 28
Timing Gear Housing Cover-Test After Repair 29
Timing Gear Housing Cover-Troubleshoot 29
Timing Gear Housing Cover-Wash 30
Timing Gear Housing Plate-Test After Repair 29
Timing Gear Housing Plate-Troubleshoot 29
Timing Gear Housing Plate-Wash 29
Track Adjuster- Disassemble & Assemble, Each 88
Track Adjuster- Remove & Install, Each 88
Track Assembly- Remove & Install, One Side 91
Track Guide/Guard- Remove & Install 92
Track Roller- Disassemble & Assemble, Single Flange 92
Track Roller- Remove & Install, Each 92
Turbocharger-Combined Repair Time (Warranty) 2
Turbocharger-Combined Repair Time (Warranty), Gasket Only 2
Turbocharger-Disassemble & Assemble 12
Page 122 of 122

Repair Labor Guidelines: 345D and 349D EXCAVATORS

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Repair Labor Guidelines: 345D and 349D EXCAVATORS

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October 2012

Repair Labor Guidelines

COMP JOB MOD QTY Code Description

COMP JOB MOD QTY Code Description

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Time Includes: 349D L

COMP JOB MOD QTY Code Description

Dynamometer Test 5.0

COMP JOB MOD QTY Code Description

Dynamometer Test 0.9

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Dynamometer Test 2.8

COMP JOB MOD QTY Code Description

Dynamometer Test 0.8

COMP JOB MOD QTY Code Description

Dynamometer Test 2.4

COMP JOB MOD QTY Code Description

COMP JOB MOD QTY Code Description

COMP JOB MOD QTY Code Description

COMP JOB MOD QTY Code Description

COMP JOB MOD QTY Code Description

Time Includes: 349D L

Crack/Leak Test 0.2

COMP JOB MOD QTY Code Description

COMP JOB MOD QTY Code Description

Time Includes: 349D L

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Tfr Components To/From 0.1

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