Professional Documents
Culture Documents
2007 C9 ACERT® 2007 Technology TRG
2007 C9 ACERT® 2007 Technology TRG
2007 C9 ACERT® 2007 Technology TRG
Comp. C d e Job Code Mod. Code Qty. Code At the top of each page is the name of the major
(Valve Cover) (MI) (Right) (First One) category for those Component Codes listed on that
page. This major category represents a major
structure or system of the engine installation.
Example 3. SMCS Code For RBI One Valve Cover If the Component Code is not known, the
On Right Side
Alphabetical Index of part names can be used for
If no Modifier Code is used, put a dash I-),
two locating a specific repair segment in the TRG.
blank spaces, and another dash (-1 between the
Job Code and the Quantity Code. (Refer to
Example 4). Standard Time Includes
The repair steps listed under "Standard Time
Includes" are divided under the following possible
su b-headings:
Separate & Connect
Comp. Code .
Job Code No Mad. Qty C d e
* Remove & Install
(Valve Cover) (MI) Code (Set) Disassemble & Assemble
* Remove
Example 4. SMCS Code For R&l Set Of Valve Install
Covers Miscellaneous
Any combination from one to all five of these
NOTICE sub-headings may be listed for a particular repair
When entering SMCS codes in the On-tine Senrice Glaim segment.
System, the dashes (-) between the individual codes are The repair steps listed under each sub-heading are
not used. listed in the approximate order of repair or grouped
with associated pai-tsloperations within each
sub-heading. This makes it easy to follow what a
particualr repair segment includes. It is especially
helpful for repair segments that involve a number of
various components, since all steps associated with
a particular component are listed together under
each sub-heading.
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Time Includes: MC RE SC
2.5 2.4 2.5
Labor Code Code Description
1160-010 Remove & Install Crankshaft Front Seal 1.3 1.2 1.3
1160-030 Test After Repair Crankshaft Front Seal 0.3 0.3 0.3
1160-035 Troubleshoot Crankshaft Front Seal 0.6 0.6 0.6
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Time Includes: MC RE SC
2.5 2.6 2.5
Labor Code Code Description
1256-010 Remove & Install Fuel Transfer Pump 1.1 1.2 1.1
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1256-030 Test After Repair Fuel Transfer Pump 0.5 0.5 0.5
1256-035 Troubleshoot Fuel Transfer Pump 0.6 0.6 0.6
1256-074 Wash Fuel Transfer Pump 0.3 0.3 0.3
Time Includes: MC RE SC
2.5 3.4 2.4
Labor Code Code Description
1302-010 Remove & Install Engine Oil Pan 1.4 2.3 1.3
1302-030 Test After Repair Engine Oil Pan 0.3 0.3 0.3
1302-035 Troubleshoot Engine Oil Pan 0.5 0.5 0.5
1302-074 Wash Engine Oil Pan 0.3 0.3 0.3
Time Includes: MC RE SC
2.2 3.1 2.1
Labor Code Code Description
1302-010 Remove & Install Engine Oil Pan 1.4 2.3 1.3
1302-035 Troubleshoot Engine Oil Pan 0.5 0.5 0.5
1302-074 Wash Engine Oil Pan 0.3 0.3 0.3
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Time Includes: MC RE SC
5.5 5.6 6.1
Labor Code Code Description
1306-010 Remove & Install Eng Oil Filter Hsg/Base 4.4 4.5 5.0
1306-074 Wash Eng Oil Filter Hsg/Base 0.3 0.3 0.3
1306-030 Test After Repair Eng Oil Filter Hsg/Base 0.3 0.3 0.3
1306-035 Troubleshoot Eng Oil Filter Hsg/Base 0.5 0.5 0.5
Time Includes: MC RE SC
5.2 5.3 5.8
Labor Code Code Description
1306-010 Remove & Install Eng Oil Filter Hsg/Base 4.4 4.5 5.0
1306-074 Wash Eng Oil Filter Hsg/Base 0.3 0.3 0.3
1306-035 Troubleshoot Eng Oil Filter Hsg/Base 0.5 0.5 0.5
Time Includes: MC RE SC
2.2 2.2 2.5
Labor Code Code Description
1355-010 Remove & Install Thermostat/Water Temp Reg 0.8 0.8 1.1
1355-030 Test After Repair Thermostat/Water Temp Reg 0.5 0.5 0.5
1355-035 Troubleshoot Thermostat/Water Temp Reg 0.6 0.6 0.6
1355-074 Wash Thermostat/Water Temp Reg 0.3 0.3 0.3
Time Includes: MC RE SC
1.7 1.7 2.0
Labor Code Code Description
1355-010 Remove & Install Thermostat/Water Temp Reg 0.8 0.8 1.1
1355-035 Troubleshoot Thermostat/Water Temp Reg 0.6 0.6 0.6
1355-074 Wash Thermostat/Water Temp Reg 0.3 0.3 0.3
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Time Includes: MC RE SC
3.8 3.6 3.7
Labor Code Code Description
1361-010 Remove & Install Water Pump 2.5 2.3 2.4
1361-030 Test After Repair Water Pump 0.3 0.3 0.3
1361-002 Tfr Components To/From Water Pump 0.2 0.2 0.2
1361-035 Troubleshoot Water Pump 0.5 0.5 0.5
1361-074 Wash Water Pump 0.3 0.3 0.3
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Remove Hood
Separate Steering Pump, Hose(S) N/A
Remove Frame, Bracket
Remove Bumper N/A N/A
Remove Radiator, Bracket N/A N/A
Separate Wiring Harness, Chassis N/A
Separate Windshield Washer, Tank N/A N/A
Remove Eng Electronic Cont Mod, Wiring Harness N/A
Remove Steering Control N/A N/A
Evacuate & Save Refrigerant
Remove Cab, Mounting N/A
Separate Air Conditioner Lines
Remove Cab N/A
Remove Air Inlet, Filter To CGI Valve
Separate Heater Hose/Lines
Remove Air Inlet, Aftercooler To Manifold
Drain Brake Air Tank N/A
Remove Air Inlet, Turbo To Aftercooler
Separate Svc Brake Control Valve, Line(S) N/A
Remove Engine Oil Pan N/A N/A
Separate Flywheel Clutch, Cable N/A
Remove Engine Oil Pump, Tube N/A N/A
Remove Transmission, Shifter N/A
Separate Exhaust Pipe, From DPF To CGI N/A
Remove Engine Oil Pump N/A N/A
Separate Engine, Wiring Harness
Separate Exhaust Pipe, From Comb Body To DPF N/A
Separate Ground/Static Strap
Remove Serpentine Belt
Separate Steering Linkage, Shaft N/A
Remove Radiator Hose, Upper
Remove Engine Oil Filter N/A
Remove Radiator Hose, Lower
Separate Radiator, Rod, Set (All) N/A N/A
Remove Fan
Remove Radiator N/A N/A
Separate Air Compressor, Line(S)
Separate Air Compressor Governor N/A N/A
Remove Steering Pump
Separate Air Inlet Heater, Wiring N/A
Separate Fuel, Line(S)
Separate Electric Starting Motor, Wiring Harness
Remove Crankcase Breather N/A N/A
Separate CGI Cooler, Return
Separate Combustion Head, Turbocharger To Exhaust N/A N/A
Separate Exhaust Pipe, Bracket N/A N/A
Remove Radiator Enclosure/Shroud N/A
Separate Engine Mount, Front
Remove Engine Mount, Bolt(S) N/A N/A
Separate Air Compressor Governor, Line(S) N/A
Separate Engine Mount, Rear
Separate Air Compressor, Bracket N/A
Separate Drive Shaft
Remove Air Compressor N/A
Separate Flywheel Clutch, Linkage N/A N/A
Separate Cylinder Block, Heater
Separate Transmission Control
Separate Transmission, Line(S)
Remove Transmission, Wiring Harness
Separate Eng Oil Level Ga/Dipstick, Bracket N/A
Remove Engine & Transmission
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Time Includes: MC RE SC
0.3 0.5 0.3
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Time Includes: MC RE SC
0.9 0.9 0.9
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Time Includes: MC RE SC
1.5 1.5 1.5
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
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Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.4 0.5 0.6
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Time Includes: MC RE SC
0.4 0.4 0.4
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.2 0.2 0.2
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.4 0.4 0.4
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
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Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
0.3 0.3 0.3
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Time Includes: MC RE SC
0.7 0.7 0.7
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.3 0.3 0.3
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Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.9 0.9 0.9
Time Includes: MC RE SC
0.6 0.6 0.6
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Time Includes: MC RE SC
1.0 0.6 1.0
Time Includes: MC RE SC
0.9 0.9 0.9
Time Includes: MC RE SC
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Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
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Remove Exhaust Temperature Sensor Wiring Harness & Exhaust Temp Sensor 0.4 0.7 0.3
Separate Combustion Body, Wiring Harness
Remove Combustion Body, Temperature Sensor & Combustion Head Temperature Sensor
Separate Combustion Body, Element
Install Exhaust Temperature Sensor Wiring Harness & Exhaust Temp Sensor 0.3 1.0 0.3
Install Combustion Body, Temperature Sensor & Combustion Head Temperature Sensor
Connect Combustion Body, Wiring Harness
Connect Combustion Body, Element
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
1.0 1.4 1.0
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
0.4 0.4 0.4
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
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Time Includes: MC RE SC
1.6 1.7 1.5
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
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Time Includes: MC RE SC
0.3 0.3 0.3
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Time Includes: MC RE SC
0.6 0.7 0.7
Time Includes: MC RE SC
0.4 0.4 0.4
Time Includes: MC RE SC
0.2 0.2 0.2
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Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.3 0.3 0.3
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Time Includes: MC RE SC
2.4 1.9 2.1
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Time Includes: MC RE SC
8.3 8.3 8.8
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
1.0 1.0 1.0
Time Includes: MC RE SC
1.2 1.2 1.2
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Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.7 0.7 0.7
Time Includes: MC RE SC
1.4 1.4 1.4
Time Includes: MC RE SC
4.4 3.9 4.1
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Time Includes: MC RE SC
0.3 0.3 0.3
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Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.3 0.3 0.3
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Time Includes: MC RE SC
0.5 0.7 0.7
Time Includes: MC RE SC
0.8 0.6 0.6
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Time Includes: MC RE SC
1.4 1.4 1.4
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.8 0.8 0.8
Time Includes: MC RE SC
1.3 1.2 1.3
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
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Time does not include replacement of any worn clutch parts, which is the customer's labor expense.
If required, add code (1000-010-AO) for R&I Engine Access Cover.
If required, add code (7263-010) for R&I Engine Enclosure.
Time Includes: MC RE SC
5.8 5.8 5.8
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
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Time Includes: MC RE SC
4.6 4.5 4.8
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Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
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Time Includes: MC RE SC
0.3 0.3 0.3
None
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Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
11.9 12.3 12.4
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Time Includes: MC RE SC
20.0 20.5 20.6
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C9 ACERT® 2007
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C9 ACERT® 2007
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C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
1.0 1.0 1.0
Time Includes: MC RE SC
1.2 1.2 1.2
Time Includes: MC RE SC
0.3 0.3 0.3
Page 68 of 170
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C9 ACERT® 2007
Page 69 of 170
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C9 ACERT® 2007
Page 70 of 170
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C9 ACERT® 2007
Page 71 of 170
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C9 ACERT® 2007
Page 72 of 170
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C9 ACERT® 2007
Page 73 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
1.0 1.0 1.0
Page 74 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
1.2 1.2 1.2
Time Includes: MC RE SC
0.5 0.5 0.5
Page 75 of 170
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C9 ACERT® 2007
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C9 ACERT® 2007
Time Includes: MC RE SC
0.5 0.7 0.5
Time Includes: MC RE SC
1.1 1.1 1.1
Page 77 of 170
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C9 ACERT® 2007
Page 78 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
7.7 7.6 7.3
Page 79 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
Page 80 of 170
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C9 ACERT® 2007
Page 81 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
7.8 7.7 7.2
Page 82 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.4 0.4 0.4
Page 83 of 170
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C9 ACERT® 2007
Page 84 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
5.0 4.8 5.3
Page 85 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
7.6 8.3 7.2
Page 86 of 170
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C9 ACERT® 2007
Remove Hood
Separate Refrigerant Condenser
Separate Heater Hose/Lines
Separate Radiator Hose, Lower
Remove Radiator
Separate Serpentine Belt
Remove Crankshaft Damper/Pulley
Separate Air Compressor, Line(S)
Remove Air Compressor, Supply
Separate Air Compressor Governor, Line(S)
Remove Air Compressor, Bracket
Remove Air Compressor
Separate Steering Pump
Remove Fuel, Line(S)
Separate Eng Speed/Timing Sensor
Remove Fuel Filter
Separate Eng Electronic Cont Mod, Connector(S)
Remove Eng Electronic Cont Mod
Remove Cam Rlr Fol/Valve Lifter, Set (All)
Remove Timing Gear Housing Cover
Remove Camshaft
Clean 0.4 0.4 0.4
Clean Timing Gear Housing Cover
Clean & Inspect Cam Rlr Fol/Valve Lifter, Set (All)
Install 4.4 5.0 4.5
Install Camshaft
Install Timing Gear Housing Cover
Install Cam Rlr Fol/Valve Lifter, Set (All)
Install Eng Electronic Cont Mod
Connect Eng Electronic Cont Mod, Connector(S)
Install Fuel Filter
Connect Eng Speed/Timing Sensor
Connect Fuel, Line(S)
Connect Steering Pump
Install Air Compressor
Install Air Compressor, Bracket
Connect Air Compressor Governor, Line(S)
Install Air Compressor, Supply
Connect Air Compressor, Line(S)
Install Crankshaft Damper/Pulley
Connect Serpentine Belt
Install Radiator
Connect Radiator Hose, Lower
Connect Heater Hose/Lines
Connect Refrigerant Condenser
Install Hood
Connect Hood, Wiring Harness
Connect Hood, Cable
Calibrate Eng Speed/Timing Sensor
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C9 ACERT® 2007
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C9 ACERT® 2007
Install Fan
Install Serpentine Belt
Connect Steering Hydraulic Tank
Install Radiator
Connect Radiator, Support
Connect Radiator Hose, Lower
Connect Radiator Hose, Upper
Connect Heater Hose/Lines
Connect Refrigerant Condenser
Install Air Inlet, Turbo To Aftercooler
Install Air Inlet, Aftercooler To Manifold
Install Engine Oil Filter
Refill Engine Oil
Refill Engine Cooling System
Install Hood
Connect Hood, Wiring Harness
Connect Hood, Cable
Install Engine, Access Cover
Install Engine Enclosure
Connect Battery Cable
Prime Fuel System
Calibrate Eng Speed/Timing Sensor
Time Includes: MC RE SC
3.4 3.3 3.6
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C9 ACERT® 2007
Time Includes: MC RE SC
1.0 1.0 1.0
Time Includes: MC RE SC
1.2 1.2 1.2
Time Includes: MC RE SC
0.5 0.5 0.5
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C9 ACERT® 2007
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.4 0.4 0.4
Time Includes: MC RE SC
1.4 1.4 1.4
Time Includes: MC RE SC
0.7 0.7 0.7
Page 91 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Page 92 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
0.4 0.4 0.4
Page 93 of 170
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C9 ACERT® 2007
Page 94 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
2.0 2.0 2.0
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C9 ACERT® 2007
Time Includes: MC RE SC
3.0 3.0 3.0
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.3 0.3 0.3
None
Page 96 of 170
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C9 ACERT® 2007
Time Includes: MC RE SC
1.2 1.2 1.2
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
0.9 0.9 0.9
Page 97 of 170
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C9 ACERT® 2007
Page 98 of 170
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C9 ACERT® 2007
Page 99 of 170
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C9 ACERT® 2007
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
7.0 6.6 7.4
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
9.7 9.4 10.1
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
1.0 1.0 1.0
Time Includes: MC RE SC
1.2 1.2 1.2
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.6 0.6 0.6
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
2.7 3.7 2.6
Time Includes: MC RE SC
5.3 6.4 5.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
4.1 4.4 4.4
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
1.1 1.2 1.1
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.8 0.6 0.8
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Notes: None
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.3 0.3 0.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.3 0.3 0.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.7 0.7 0.7
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.2 0.2 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.7 0.7 0.7
Time Includes: MC RE SC
1.4 2.3 1.3
Time Includes: MC RE SC
0.4 0.4 0.4
None
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
2.0 3.0 1.9
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.8 0.7 0.8
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
4.4 4.5 5.0
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.1 0.2 0.1
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.3 0.3 0.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Notes: None
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.4 0.3 0.4
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.9 0.9 0.9
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.3 0.3 0.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.2 0.2 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
2.2 2.0 2.1
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.7 0.7 0.7
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.8 0.8 1.1
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
2.2 2.3 2.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Notes: None
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.3 0.3 0.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Notes: None
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
1.2 0.6 1.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
1.3 1.3 1.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
4.4 4.5 5.0
Time Includes: MC RE SC
0.5 0.5 0.5
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.2 0.2 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.2 0.2 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.1 0.1 0.1
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.4 0.4 0.4
Time Includes: MC RE SC
1.0 1.0 1.0
Time Includes: MC RE SC
0.9 0.9 0.9
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
0.2 0.2 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
1.1 1.1 0.9
Time Includes: MC RE SC
5.7 5.8 5.6
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.5 0.5 0.5
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.7 0.7 0.7
None
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.9 0.9 0.9
Time Includes: MC RE SC
3.5 3.5 3.5
Time Includes: MC RE SC
0.4 0.4 0.4
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
1.7 1.7 1.7
Time Includes: MC RE SC
0.2 0.2 0.2
Time Includes: MC RE SC
0.9 0.9 0.9
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.6 0.6 0.6
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.2 0.3 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.8 0.5 0.8
Time Includes: MC RE SC
0.9 0.6 0.9
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
1.4 1.4 1.4
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.6 0.6 0.6
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
2.5 3.0 2.3
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
1.2 1.2 1.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.4 0.4 0.4
Time Includes: MC RE SC
1.1 1.2 1.2
Time Includes: MC RE SC
0.3 0.3 0.3
None
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.6 0.6 0.6
Time Includes: MC RE SC
0.3 0.3 0.3
Time Includes: MC RE SC
0.7 0.4 0.7
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.2 0.2 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.2 0.4 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
2.9 2.9 2.9
Time Includes: MC RE SC
0.4 0.4 0.4
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Notes: Use this code in conjunction with repair time codes that include R&I transmission when they must be removed for access.
Time Includes: MC RE SC
1.0 1.0 1.0
Time Includes: MC RE SC
0.8 0.8 0.8
Time Includes: MC RE SC
0.8 0.8 0.8
Time Includes: MC RE SC
1.5 1.5 1.5
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.7 0.7 0.7
Time Includes: MC RE SC
0.5 0.5 0.5
Time Includes: MC RE SC
0.2 0.2 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.5 0.5 0.5
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.7 0.5 0.5
Time Includes: MC RE SC
0.4 0.3 0.4
Time Includes: MC RE SC
1.0 0.6 1.0
Time Includes: MC RE SC
0.4 0.3 0.4
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.1 0.1 0.1
Time Includes: MC RE SC
2.1 0.0 2.5
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
C9 ACERT® 2007
Time Includes: MC RE SC
0.2 0.2 0.2
https://webwasqwn1.ecorp.cat.com:8144/TRG_Authoring/servlet/cat.dcs.ssd.trg.booklet.se... 11/3/2010
CHECKLIST FOR WARRANTY REPAIRS
DEALER CODE WORK ORDER DATE ENGINE MODEL ENGINE S/N CAB TYPE MILES/HR KM
CYLINDER CUTOUT TEST REQUIRES 2 PRINTOUTS (before & after repair) 1290-038-I3-S claim 2 times
COMMENTS______________________________________________________________________________________
A C
AFTERCOOLER CAB
Crack/Leak Test – (Air To Air)...…..........................…….. 26 Lift, Block & Lower………..………...…………………….. 162
AFTERCOOLER CORE Remove & Install…………………………………………... 162
Flush – (Air To Air)........................................…….........… 27 CAMSHAFT
Remove & Install – (Air To Air)……………...…………..... 26 Combined Repair Time……………................................. 8
AIR CLEANER Combined Repair Time - (Includes R&I Some Comp).… 8
Remove & Install………………...………...……………….. 18 Remove & Install………………...………...…………….... 84
AIR COMPRESSOR Remove & Install – (Engine Out of Frame)..................… 85
Combined Repair Time……………..........................…..... 11 Remove & Install – (Excludes Some R & I)………...…… 86
Combined Repair Time - (Gasket).…………………...…… 11 Remove & Install – (Includes R&I Some Comp)……...… 87
Remove & Install ……………………………………..……. 149 Remove & Install – (Out F/Out Hull/Off Site)..........….... 89
Remove & Install – (Pressure Control Valve)……………. 150 Test After Repair………………………………………..... 90
Test After Repair......................................................….... 150 Troubleshoot………………………………………..…....... 90
Transfer Components To/From.........................…....….... 149 Wash………………………………………………….……. 90
Troubleshoot........................................................…......... 150 CAMSHAFT BEARING
Wash....................................................................……..... 151 Remove & Install – (Set [All])...............................…....... 90
AIR CONTROL VALVE CAMSHAFT GEAR
Remove & Install………………...………...……………...... 27 Remove & Install...................................................…...... 90
Test After Repair………………………………….…...…... 27 CAMSHAFT ROLLER FOLLOWER/VALVE LIFTER
Troubleshoot……………………………………….…...….. 28 Disassemble & Assemble - (Each)…………………….. 83
Wash……………………………………………………...… 28 Disassemble & Assemble - (Set)…………………...….. 83
AIR DRYER Remove & Install – (Each Additional)..........……............ 77
Clean - (In Frame/In Hull/On Site)…………………….….… 159 Remove & Install – (Set [All]).....................................…. 77
Recondition……………………………………...…………. 158 Remove & Install – (Center)……………...………...…... 79
Remove, Clean & Install………………...………...………… 158 Remove & Install – (Front)……………...…………..…... 80
Remove & Install………………………………..………...… 158 Remove & Install – (Rear)……………...……………...... 82
AIR INDUCTION & EXHAUST SYSTEM CGI COOLER (CLEAN GAS INDUCTION COOLER)
Crack/Leak Test…………………………………………..... 17 Remove & Install……………………………………..….… 30
Inspect……………………………………………………..... 18 Test After Repair………………………………….…..…... 30
AIR INLET HEATER Troubleshoot……………………………………….…..….. 30
Remove & Install...………………………………………..... 37 Wash…………………………………………………..…… 31
Remove & Install – (Switch[s])……...…………….……...… 38 CLEAN GAS INDUCTION VALVE (CGI MIXER)
ALTERNATOR Remove & Install..............................................……....... 34
Remove & Install...………………………………………..... 138 Remove & Install - (Air Control Valve) …………..……… 35
Remove & Install – (Bracket[s])……...…………….…….… 138 Remove & Install – (Solenoid).................... 35
ATMOSPHERIC PRESSURE SENSOR Remove & Install – (Temperature Sensor)..................... 35
Remove & Install…………………………………...……… 155 Test After Repair………………………………….……..... 36
B Transfer Components To/From - (Air Control Valve)...... 34
BATTERY Troubleshoot……………………………………….…….. 36
Diagnostic Test – (Using Battery Load Test)………......... 137 Wash……………………………………………………… 36
BATTERY CABLE COMBUSTION BODY (ARD)
Separate & Connect………………………………….…..… 138 Remove & Install..................................................……... 28
BELT TIGHTENER Test After Repair………………………………….….…... 29
Remove & Install………………………………………….... 131 Transfer Components To/From.........................….......... 28
BRAKE AIR TANK Troubleshoot……………………………………….…….. 29
Flush – (Each)…………………………………...………..... 158 Wash……………………………………………………… 30
Remove & Install………………………...……………..…… 157 COMBUSTION BODY SENSOR (TEMPERATURE)
BUMPER Remove & Install.....................................................…… 29
Install……………………………………...………………..... 160 COMBUSTION FUEL ENABLE SOLENOID
Remove & Install…………………….........………...……... 160 Remove & Install - (Main)...........................…………...... 147
Remove & Install - (Pilot).............................……………. 148
D ENGINE MOUNT(S)
DIESEL PARTICULATE FILTER (DPF) Separate & Connect – (Front)........................................ 48
Disassemble & Assemble……………………………..….. 31 Separate & Connect – (Rear)......................................... 48
Regenerate …………………………………………...….... 32 ENGINE OIL
Remove & Install…………………………………..…..…… 31 Drain & Refill..........................................................…..... 126
Remove & Install – (Sensor)........................………......... 31 Measure – (Pressure[s])......................................…....... 126
Test After Repair............................................…...…........ 32 Take & Analyze S O S From – (Sample)........................ 126
Troubleshoot.....................................................……..….. 32 ENGINE OIL COOLER
Wash.................................................................……........ 32 Crack/Leak Test....................................................…….. 136
DRIVE AXLE Remove & Install...................................................…...... 134
Install................................................................……..…... 157 Test After Repair.................................................…........ 135
DRIVE SHAFT Troubleshoot...................................................….…....... 136
Install...................................................................……….. 157 Wash..............................................................…............. 136
E ENGINE OIL FILLER
ELECTRIC STARTING MOTOR Remove & Install - (Tube)..........................…................. 123
Remove & Install.................................................….…..... 140 Test After Repair..................................................…....... 124
ELECTRIC SYSTEM Troubleshoot........................................................…....... 124
Diagnostic Test – (Using Voltmeter)...................……...... 137 Wash........................................................................…... 124
ENGINE ENGINE OIL FILTER HOUSING/BASE
Dynamometer Test – (Chassis)........................….....…... 15 Combined Repair Time …………..…………….…...…… 10
Dynamometer Test – (Out F/Out Hull/ Off Site)....…........ 15 Combined Repair Time – (Gasket)…………….…...…… 10
Dynamometer Test – (PAR)...................................…...... 16 Remove & Install.............................................……........ 121
Dynamometer Test – (PAR After Repair).............…........ 16 Test After Repair..............................................…….…... 122
Dynamometer Test – (PAR After Repair And Unhook)… 16 Transfer Components To/From..............….....…............ 120
Dynamometer Test – (PAR Preliminary Inspect)............. 16 Troubleshoot...............................................……......…... 122
Paint.......................................................................……... 17 Wash............................................................……......….. 122
Paint – (Minor).......................................................……... 17 ENGINE OIL FILTER
Remove & Install...................................................…….... 12 Cut & Analyze.................................................…......…... 123
Remove & Install – (Access Cover)………………...……. 15 Remove & Install..............................................….…...... 123
Road Test.................…………………………………….... 17 Remove & Install – (Spin-On Type)....................…........ 123
Transfer Components To/From.........................…........... 12 ENGINE OIL & FILTER
Wash – (Minor).................................................……........ 17 Remove & Install..................................................……... 125
ENGINE COOLANT ENGINE OIL LEVEL GAUGE/DIPSTICK
Drain & Refill......................................................…........... 136 Adjust....................................................................…...... 126
Measure – (Temperature[s])..............................…........... 137 Remove & Install..................................................…....... 125
Test.......................................................................…….... 137 ENGINE OIL LINES
ENGINE COOLING SYSTEM Test After Repair..............................................…...….... 122
Crack/Leak Test......................................................……… 127 Troubleshoot...................................................…....….... 122
Diagnostic Test – (Using Bottle Test).....................…….. 127 Wash...................................................................…….... 122
Flush........................................................................……… 127 ENGINE OIL PAN
Flush – (Excludes Some R & I)...........................……...... 127 Combined Repair Time…………………………...……… 9
ENGINE ELECTRONIC CONTROL MODULE Combined Repair Time – (Gasket)……………...……… 9
Adjust – (Full Load/Torque Setting)....................….......... 151 Remove & Install..................................................…….... 118
Combined Repair Time.......................................….......... 11 Remove & Install – (Out F/Out Hull/Off Site)..........…...… 118
Obtain – (Password[s]).......................................….......... 152 Test After Repair............................................……......... 118
Remove & Install...............................................……........ 151 Troubleshoot..................................................……......... 119
Reprogram.......................................................………….. 153 Wash………………………………………………………. 119
Test – (Using Test ECM).....................................…...….… 152 ENGINE OIL PUMP
Test After Repair…………………………………….……… 152 Disassemble & Assemble...................…................…..... 120
Troubleshoot………………………………………….…….. 152 Remove & Install………………………………………...… 119
Wash....................................................................……..... 152 Test After Repair.......................................…..........….... 120
ENGINE ENCLOSURE Troubleshoot..............................................…….......…... 120
Remove & Install.................................................……...... 162 Wash..........................................................……........….. 120
ENGINE OIL PRESSURE SENSOR
Remove & Install………………………………………...... 156
P T
PISTON THERMOSTAT/WATER TEMPERATURE REGULATOR
Recondition – (Each Additional)............................…….... 91 Combined Repair Time.......................................…….... 10
Recondition – (First One)......................................…….... 91 Combined Repair Time – (Gasket)………………...….… 10
Recondition – (Set [All])......................................……...... 91 Diagnostic Test....................................................…….... 131
PISTON & CONNECTING ROD Remove & Install..................................................……... 129
Remove & Install – (Each Additional)............……........... 97 Remove & Install – (Housing)............................……...... 130
Remove & Install – (First One).......................……........... 97 Test After Repair...............................................……...... 130
Remove & Install – (Set [All])..........................…….......... 100 Transfer Components To/From.........................….......... 129
Remove & Install – (Out Of Frame) – (Each Additional… 103 Troubleshoot.......................................................…….... 131
Remove & Install – (Out Of Frame) – (First One)....……. 103 Wash................................................................……....... 131
Remove & Install – (Out Of Frame) – (Set [All]).....……... 105 THROTTLE POSITION SENSOR
Test After Repair………………………………………….. 106 Remove & Install.....................................................…… 154
Troubleshoot……………………………………….…..…. 106 TIMING GEAR HOUSING
Wash………………………………………………………. 106 Combined Repair Time.....................................……...... 6
PISTON COOLING JET Combined Repair Time – (Gasket).....………………...... 6
Test – (Set [All])................................................………..… 126 Combined Repair Time – (Includes R&I Some Comp)… 6
R Remove & Install..................................................……... 57
RADIATOR Remove & Install – (Includes R&I Some Comp)………… 58
Flush – (Out Of Frame)........................................……..... 129 Remove & Install – (Out F/Out Hull/Off Site).........…..... 60
Remove & Install....................................................……... 128 Test After Repair....................................................……. 61
Remove & Install – (Support)…………………………...… 128 Troubleshoot........................................................……... 61
RADIATOR CAP Wash....................................................................……... 61
Crack/Leak Test......................................................……… 136 TIMING GEAR HOUSING COVER
REFRIGERANT COMPRESSOR Remove & Install...............................................….…..... 62
Charge – (Excludes Some R&I)……………………….….. 149 Test After Repair…………………………………………. 62
Remove & Install..................................................………. 148 Troubleshoot……………………………………………… 62
Separate & Connect………………………………...…….. 148 Wash……………………………………………………… 63
REFRIGERANT CONDENSER TORQUE CONVERTER / TRANS OIL COOLER
Separate & Connect...........................................……....... 151 Remove & Install – (Lines).....................………...…...... 134
ROCKER SHAFT TRANSMISSION
Remove & Install …………..………………………..…….. 44 Drain & Refill - (Automatic)............................................ 157
Test After Repair………………………………….…........ 44 Remove & Install – (Automatic)..........................…..….. 156
Troubleshoot……………………………………….…..…. 45 Remove & Install – (Control Cable)..........................…. 156
Wash……………………………………………………..... 45 Remove & Install – (Manual)..........................…..…….. 156
S TRUCK
SERPENTINE BELT Lift & Block..............................................................…… 159
Remove & Install ………….............................….............. 137 Tow.......................................................................……... 160
SHORT BLOCK TURBOCHARGER
Transfer Components To/From....................…...….......... 63 Combined Repair Time ……………...……………..…… 4
SPARK PLUG Combined Repair Time – (Gasket)......................…....... 4
Remove & Install..........................................……...…...... 141 Disassemble & Assemble....................................…….... 20
STEERING PUMP Inspect.............................................................…...…..... 20
Remove & Install........................................……........…... 159 Measure..........................................................…...…..... 21
Separate & Connect..................................…...........…..... 159 Remove & Install ……………………............................... 18
STEERING SYSTEM Remove & Install – (Line[s])............................……........ 19
Separate & Connect..................................….........…....... 159 Remove & Install – (Out F/Out Hull/Off Site).................. 20
Remove & Install – (Sensor)...............................…….... 19
Test After Repair …………………………………………. 20
Troubleshoot ……………………………………………… 20
Wash ………………………………………………………. 21
TURBOCHARGER CARTRIDGE W
Test After Repair …………………………………………. 21 WARNING HORN
Troubleshoot ……………………………………………… 21 Remove & Install………………………………..………… 162
Wash ………………………………………………………. 21 WATER PUMP
U Combined Repair Time............................…................... 10
UNIT INJECTOR Combined Repair Time – (Gasket)..………………......... 11
Combined Repair Time – (First One)..............…….........… 9 Check – (Pressure[s])...................................……........... 134
Combined Repair Time – (Set [All])................….............. 9 Remove & Install.........................................……............ 133
Diagnostic Test – (Using Cyl. Cut-out Test) – (Set)……. 117 Test After Repair........................................……............. 133
Remove & Install – (Each Additional)..................…......... 114 Transfer Components To/From.........................….......... 132
Remove & Install – (First One).........................…............ 114 Troubleshoot....................................……....................... 134
Remove & Install – (Set [All])..………………………….. 115 Wash...................................................…….................... 134
Remove & Install – (Tube - Each Additional)................... 115 WATER TEMPERATURE SENSOR
Remove & Install – (Tube - First One)............................. 116 Remove & Install..................................................……... 153
Remove & Install – (Tube - Set [All])..……………….….. 116 Test After Repair.................................................…….... 153
Reprogram – (Set [All])..………………………………..... 118 Troubleshoot.......................................................…….... 153
Test – (Solenoid) – (Set [All])...........................……......... 117 Wash................................................................……....... 154
Test After Repair..............................................……......... 117 WIRING HARNESS
Troubleshoot.....................................................……........ 117 Remove & Install …………………………….………….… 138
Wash.................................................................……........ 117 Remove & Install – (12-pin Connector).............………… 139
UNIT INJECTOR SLEEVE Remove & Install – (40-pin Connector).........…………... 139
Recondition – (Each)................………………………....... 144 Remove & Install – (70-pin Connector)........………….... 139
Recondition – (Set [All])...................…………….............. 144 Replace – (3-pin Connector)...........................……........ 140
Recondition – (Out F/Out Hull/Off Site) – (Each)............. 145 Replace – (Seal[s])..........................................……........ 140
Recondition – (Out F/Out Hull/Off Site)– (Set [All]).......... 145 Separate & Connect – (Chassis).................................... 139
Remove & Install – (Each Additional).................……...... 143 Test After Repair.............................................……........ 140
Remove & Install – (First One).........................……......... 143 Troubleshoot....................................................……....... 140
Remove & Install – (Set [All])............................……........ 143
Remove & Install – (Out F/Out Hull/Off Site) - Ea Addl.... 143
Remove & Install – (Out F/Out Hull/Off Site) - First One.. 144
Remove & Install – (Out F/Out Hull/Off Site) - Set........... 144
Test After Repair................................................……....... 145
Troubleshoot......................................................……....... 145
Wash.................................................................……........ 145
V
VALVE COVER
Remove & Install..................................................………. 46
Test After Repair…………………………………………. 47
Troubleshoot……………………………………………… 47
Wash……………………………………………………… 47
VALVE COVER BASE
Remove & Install..................................................……..... 47
VALVE GUIDE
Remove & Install – (Each)..............….....................…..... 45
VALVE SEAT/INSERT(S)
Remove & Install – (Each)..................…...............…....... 45
Machine/Grind/Mill………………………………………. 45
VENTURI
Remove & Install............................................….....…...... 36
Test After Repair …………………………………………. 36
Troubleshoot ……………………………………………… 37
Wash ………………………………………………………. 37