DEC 2017
SMCS Codes Dealer Guidebook
Global Dealer Service Operations – Service Standards 501 SW Jefferson Avenue, Peoria, IL 61630 U.S.A.
Rev. 20171312
servicedata.cat.com
SMCS HISTORY We have identified from the SMCS code library and dealer work order history that the SMCS job codes have not been maintained appropriately. We have identified the following:
There is a need for standardized work descriptions leading to a lack of discipline and consistency in SMCS Job code selection and usage.
Too many duplicate or similar meaning Job codes, reducing the effectiveness of the description of the work performed.
Lack of consistency and accuracy from Caterpillar has not enabled our dealers to create consistent and accurate repair options.
Caterpillar has not provided published definitions, adding to the difficulty of utilizing the SMCS Job code library.
Due to the above issues, Caterpillar cannot analyze repair options to provide meaningful dealer efficiency measurements (job cost, labor, parts consumption, etc.) In an effort to help our dealers and enable Caterpillar to provide accurate analytics from dealer work orders, we have completed the following:
Identified low usage job codes
Created a SMCS Job Code Dealer Guidebook
Identified, combined or edited similar meaning job codes
Created job code definitions
Created a cross reference chart for codes identified as obsolete or redundant
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WHAT ARE SMCS CODES? The Service Management Control System (SMCS) is a managed coding structure to describe various service‐related activities; including both repair and management activities. The SMCS Codes provide Caterpillar and dealers uniformity in describing repair activities in internal documents such as:
checklists, work orders, time reporting
work in process (WIP) monitoring
external documents such as “customer facing” quotes and invoices
SMCS Code descriptions can be translated in different languages
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WHERE ARE SMCS CODES USED? SMCS codes are used in many places within Caterpillar and a dealer’s business system to describe repair activities for communication and tracking purposes. Some examples:
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Service Dashboard/Work Order Analysis
Dealer Business System, such as dbs i
Warranty/SIMS Reporting
Equipment Repair Labor Guidelines (ERLG) / Time Requirement Guidelines (TRG)
Repair Options (customer facing)
Standard Jobs (dealer facing)
Quotes/Work Orders
Product Quality Analysis
Variance Tracking/Work Order Analysis
Parts Lists for Repair Activities
Repair Option Builder G3 and Calculator applications
PTOS / OLGA opportunity tracking applications
Service Options Collaborator (SOC) –
future
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AVAILABLE SMCS CODE TYPES There are nine different code types which can combine to describe a repair activity.
Component
Job Condition
Job
Job Location
Modifier
Work Application
Quantity
Cab Type
Product Family
SMCS CODES TYPES Component Code (ex. 5058‐ PISTON MOTOR) ‐ “Iron” that work is to be performed on Job Code (ex. 020‐ RECONDITION) ‐ Type of work performed on a component Modifier Code (ex. ZW‐ SWING) ‐ Further describes work performed, the component or component location, level of work, etc. Quantity Code (ex. E‐ EACH) ‐ Describes how many components are in the repair Job Condition Code (ex. WER‐ WITH ENGINE RUNNING) ‐ Used to describe “something out of the ordinary or different” from the Standard Job* (job condition code only available when using a standard job in dbs) Job Location Code (ex. FRT‐ FRONT, RER‐ REAR) ‐ Used to describe where the job is being performed or the component location where the job is being performed Work Application Code (ex. FRST‐ FORESTRY, 1OHL‐ FIRST OVERHAUL) ‐ Used to describe the product application or level of work Cab Type Code (ex. CO (Cab Over), CV (Conventional)) – Previously used for on‐ highway trucks and describes the type of cab the truck is equipped with, but now is also used as a differentiator for marine applications. Family (ex. 07‐EXCAVATORS) ‐ The family code groups sales models with common characteristics together for reporting and analysis purposes, such as Track‐Type Tractors, Excavators, etc.
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SMCS COMPONENT CODES Component codes consist of 4 digits ( 1000‐9999), making 9000 numbers available for component classification. Component codes are divided into 6 basic categories.
1000 ENGINE component codes (1000‐1999) represent the power source ‐
the engine and its related parts from the fan to the flywheel .
3000 TRANSMISSION & DRIVE LINE component codes (3000‐3999)
represent power transmission units such as torque converters, dividers and transmissions. This group carries power from the engine to the differential and drive axle.
4000 DRIVE TRAIN component codes (4000‐4999) are for power
consumption or propulsion units. They take power from the final drive to the wheels or tracks and include the braking and steering systems.
5000 IMPLEMENT CONTROLS component codes (5000‐5999) are for
implement controls to operate dozers or rippers, etc. Hydraulic controls convey power from the engine through valves, pumps, lines, hoses and cylinders to operate implements.
6000 IMPLEMENTS component codes (6000‐6999) represent implements ‐
bulldozers, rippers, buckets, etc
7000 MACHINE component codes (7000‐7999) are for structural framework
or body. This provides the base and enclosure for the other components.
Component Codes (2000‐2999) and (8000‐8999) are reserved for future expansion.
Component Codes (9000‐9999) can be used for non‐Caterpillar products at the discretion of the dealer.
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Component code categories (ex 1000 ENGINE ) are divided into sub‐groups (ex 1250 FUEL SYSTEM). The SMCS basic categories and sub groups can be used to
describe a repair as long as there is also a specific component code (ex 1290 UNIT INJECTOR) used for the part causing failure.
Component categories and sub‐groups codes can be used to describe certain activities, but the recommedation is to be as specific as possible.
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COMPONENT CODES BASIC STRUCTURE
0000 (BLANK) 1000
ENGINE
1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1700 1800 1900
AIR INDUCTION & EXHAUST SYSTEM CYLINDER HEAD ASSEMBLY FRONT & REAR COVERS SHORT BLOCK FUEL SYSTEM LUBRICATION SYSTEM ENGINE COOLING SYSTEM ELECTRIC SYSTEM STARTING SYSTEM GASOLINE STARTING/AUXILIARY ENGINE IGNITION SYSTEM ELECTRIC DRIVE & CONTROL FUEL SYSTEM (CONTINUATION OF CATEGORY 1250) OTHER ENGINE COMPONENTS ENGINE ELECTRONIC CONTROL SYSTEM
3000
TRANSMISSION & DRIVE LINE
3050 3100 3150 3200 3250 3300 3400
CLUTCH & TRANSMISSION TORQUE CONVERTER, TORQUE DIVIDER, RETARDER POWER SHIFT TRANSMISSION (SUBSTITUTE WITH CODE 3030) HYDROSTATIC TRANSMISSION (SUBSTITUTE WITH CODE 3030) DRIVE LINE/DRIVE AXLE MARINE GEAR COUNTERSHAFT TRANSMISSION (SUBSTITUTE WITH CODE 3030)
4000
DRIVE TRAIN
4050 4100 4150 4200 4250 4300 4350 4450 4800
FINAL DRIVE STEERING CLUTCH & BRAKE UNDERCARRIAGE WHEEL & TIRE BRAKING SYSTEM STEERING SYSTEM HYDROSTATIC DRIVE ELECTRIC POWER GENERATOR DRIVE TRAIN ELECTRONIC CONTROL
5000
IMPLEMENT CONTROLS
5050 5100 5150 5200 5300 5350 5400 5450 5500 5550 5600 5700 5800 5900
HYDRAULIC SYSTEM LIFT, TILT, TIP & OTHER CONTROLS CABLE & WINCH CONTROLS MOTOR GRADER & OTHER IMPLEMENT CONTROLS SCRAPER & OTHER CONTROLS RIPPER, TOOL BAR & OTHER CONTROLS PIPELAYER, COUNTERWEIGHT & OTHER CONTROLS EXCAVATOR/BACKHOE/FRONT SHOVEL/SURFACE EXTRACTION & OTHER CONTROLS AIR CONTROL SYSTEM LOGGER & SKIDDER CONTROLS PAVING EQUIPMENT CONTROLS IMPLEMENT ELECTRONIC CONTROLS OTHER CONTROLS COMBINE CONTROLS
6000 IMPLEMENTS 6050 6100 6150 6200 6300 6400 6500 6600 6700 6800 6900
BULLDOZER LOADING IMPLEMENTS MOTOR GRADER IMPLEMENTS SCRAPER OTHER IMPLEMENTS MATERIAL HANDLING ATTACHMENTS EXCAVATOR/BACKHOE/FRONT SHOVEL/SURFACE EXTRACTION IMPLEMENTS PAVING IMPLEMENTS WORK TOOL GROUND ENGAGING TOOLS (GET) COMBINE
7000 MACHINE 7050 7100 7150 7200 7250
FRAME HITCH GUARD SUSPENSION BODY
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7300 7400 7450 7500 7550 7600 7700 7850 7900 7950
79C0 79D0 79E0 79L0 79S0 79T0
OPERATOR STATION PROTECTION DEVICES, ALARMS & INDICATORS GAUGES & INDICATORS MAINTENANCE COMMON SUBJECTS MACHINE ELECTRONIC CONTROLS & DATA MANAGEMENT SYSTEMS SERVICE CLAIM CATEGORIES GAUGES & INDICATORS (CONTINUATION OF CATEGORY 7450) SERVICE CLAIM CATEGORIES (CONTINUATION OF CATEGORY 7700) MISCELLANEOUS MINING PRODUCT/DRAGLINE MINING PRODUCT/DRILLS MINING PRODUCT/ELECTRIC ROPE SHOVELS MINING PRODUCT/LONGWALL MINING PRODUCT/HIGH WALL MINER MINING PRODUCT/ROOM & PILLAR
2000 - 2999 RESERVED FOR EXPANSION 8000 - 8999 RESERVED FOR EXPANSION 9000 - 9999 RESERVED FOR DEALER NON-CATERPILLAR USE
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Example: 1290‐513—S (Unit injector replace with Reman Set (All) is a recommended choice. 1250‐023 (Fuel system repair) is not recommended.
In the example above, component code 1290 UNIT INJECTOR is part of the sub‐ group 1250 Fuel System. 1250 Fuel System is part of the category 1000 ENGINE. 1000
ENGINE
1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1700 1800 1900
AIR INDUCTION & EXHAUST SYSTEM CYLINDER HEAD ASSEMBLY FRONT & REAR COVERS SHORT BLOCK FUEL SYSTEM LUBRICATION SYSTEM ENGINE COOLING SYSTEM ELECTRIC SYSTEM STARTING SYSTEM GASOLINE STARTING/AUXILIARY ENGINE IGNITION SYSTEM ELECTRIC DRIVE & CONTROL FUEL SYSTEM (CONTINUATION OF CATEGORY 1250) OTHER ENGINE COMPONENTS ENGINE ELECTRONIC CONTROL SYSTEM
********************************************
1250 FUEL SYSTEM 1251 1252 1253 1254 1255 1256 1257 1258 1259 125H 1260 1261 1262 1263 1264 1265 1266 1267 1268 1269 126D 1270 1271 1272 1273 1274 1275 1276 1277 1278 1279 127A 1280 1281 1282 1283 1284 1285 1286 1287 1288 1289 1290 1292 1293 1294 1295 1296 1298 1299
FUEL INJECTION PUMP FUEL INJECTION LINES FUEL INJECTION PUMP HOUSING FUEL INJECTION VALVE/NOZZLE FUEL TRANSFER PUMP HOUSING FUEL TRANSFER PUMP TORQUE CONTROL/FUEL RACK FUEL PRIMING PUMP FUEL SHUTOFF SOLENOID HIGH PRESSURE FUEL PUMP PRIMARY FUEL FILTER FUEL FILTER FUEL FILTER HOUSING/BASE WATER SEPARATOR GOVERNOR GOVERNOR CONTROL LINKAGE CARBURETOR LPG CONVERSION SPEED/HORSEPOWER LIMITER THROTTLE DUPLEX FUEL FILTER GAS PRESSURE REGULATOR LPG VAPORIZER TIMING ADVANCE FUEL TANK FUEL SUPPLY/RETURN LINES GOVERNOR AIR CONTROL VALVE DECELERATOR/ACCELERATOR LINE PRESSURE REGULATOR (B) FUEL RATIO CONTROL FUEL TANK VALVE FUEL RAIL FUEL FUEL INJECTION PUMP LIFTER LPG FUELOCK VALVE LPG CONVERTER/REGULATOR LPG TANK LPG LINES/HOSES GOVERNOR & FUEL INJECTION PUMP GOVERNOR HOUSING FUEL PUMP/GOVERNOR DRIVE PUMP DRIVE HYDRAULIC/HYDRA-MECHANICAL GOVERNOR UNIT INJECTOR CAMSHAFT (FUEL SYSTEM) DUAL FUEL SYSTEM CHOKE CABLE AUXILIARY FUEL TRANSFER PUMP FUEL HEATER UNIT INJECTOR CONTROL LINKAGE HYDRAULIC TIMING ADVANCE(SUBSTITUTE WITH CODE 1272)
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HOW TO CHOOSE THE CORRECT SMCS CODE 1. The work order should contain multiple segments for even a single repair. The lowest level part being repaired should be used to determine the correct SMCS component code for a simple repair. Work involving multiple repairs should be segmented correctly to capture the individual job operations. Each segment should have its own SMCS component code to the lowest level that makes sense. 2. Use the SMCS code search feature at servicedata.cat.com to help you choose an accurate SMCS code of any type.
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EXAMPLE OF USING SMCS CODES
The Component + Job codes are the minimum SMCS code types required to define a Service Repair Option or Job Operation
Follow the format below for repair options and descriptions:
Component + Job + Modifier + Quantity + Job Location + Work Application + Job Condition
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WHY ARE SMCS CODES IMPORTANT?
Consistency and Uniformity in Parts, Labor, Miscellaneous Quoting and Invoicing
Important in determining exact type of repairs for analysis for future opportunity with regards to service or in cases of quality issues, in resolving them rapidly.
Selection of Standard Job within a dealer’s business system.
Variance Analysis and Work Order Analysis
Supports the before failure repair strategy
Promotes Parts Sales Growth
Promotes Customer Support Agreement (CSA) development
Promotes Customer Satisfaction
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SMCS EXAMPLES AND RECOMMENDATIONS: The Job and Component codes are the minimum SMCS code types required to define a Repair Option or Job Operation
High level component codes such as machine 7000 and engine 1000 should only be used with certain job codes. High level component codes should not be used with generic job operations such as 023 repair, 020 recondition, etc. Examples are provided below. Acceptable Category component code Examples
(7000‐070) Machine Clean
(1000‐072) Engine Paint
(7000‐055) Machine Load/Unload
(5050‐016) Hydraulic System Flush
Unacceptable Category code examples:
(1000‐023) Engine repair
(7000‐023) Machine repair
(7950‐023) Miscellaneous Repair
(7000‐035) Machine Troubleshoot The example above is not specific, was the hydraulic system being troubleshot? (5050‐035) Hydraulic System Troubleshoot would be the more appropriate SMCS component and job combination for a troubleshooting activity.
(5050‐013) Hydraulic System Replace with Dealer Exchange The above example is not specific to the component. What component was replaced with exchange? (5084‐013) Implement Pump Replace with Dealer Exchange would be the more appropriate SMCS component and job combination
(1000‐527) Engine Tighten/Torque
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The above example does not describe the component that was needing the action. What specific component on the engine needed to be tightened? (1120‐527) Valve cover Base Tighten/Torque would be the more appropriate SMCS component and job combination. An engine has a complaint of excess smoke from the exhaust pipe. Troubleshooting determines that the turbocharger is leaking oil past the turbine shaft seals. You replace the turbocharger cartridge with a Cat Reman part. Unacceptable
(1000‐023) Engine‐Repair (7000‐023) Machine‐Repair (7950‐023) Miscellaneous‐Repair (7000‐035) Machine‐Troubleshoot Acceptable
(1000‐035) Engine‐Troubleshoot (1053‐513) Turbocharger Cartridge‐Replace With Cat Reman Acceptable Job code Examples
(125H‐513) High Pressure Fuel Pump‐Replace with Reman (125H‐014) High Pressure Fuel Pump‐Replace Gasket / Seal (1100‐012) Cylinder Head Assembly‐Install (1397‐042) Serpentine Belt‐Inspect & Maintain Unacceptable Job code examples:
(125H‐023) High Pressure Fuel Pump‐Repair (125H‐‐‐‐‐‐) High Pressure Fuel Pump‐“null” (1100‐042) Cylinder Head Assembly‐Inspect & Maintain (1397‐020) Serpentine Belt‐Recondition
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MODIFIER CODES Modifier codes are available to offer additional detail about work performed, the component or component location, level of work, etc. If a machine has duplicate components, the modifier code can be used to describe the component location, such as front driveshaft, or left final drive. Further identifying repairs with a modifier code will increase service documentation effectiveness. Having the work order coded with a modifier describing the component location allows efficient work order review, without the need to look at the notes to determine the component location. Clear work order documentation can reduce customer and service personnel confusion. The use of a modifier is provided in the example below. (4050‐02B‐RR) Final Drive‐Recondition W/Lvl 2 Prts‐Right Rear
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REPAIR OPTION STRUCTURE: Caterpillar is working towards offering new standard repair options for each major component. Below are the standard repair options jobs each major component may have when working from the future Service Options Collaborator (SOC). Updates for new Caterpillar standard repair options will be added as completed.
010
REMOVE & INSTALL
014
REPLACE GASKET / SEAL
020
RECONDITION
007
RECONDITION AFTER FAILURE (quoting only)
019
RECONDITN BEFORE FAILURE (quoting only)
013
REPLACE WITH DLR EXCHNGE
513
REPLACE WITH CAT REMAN
511
REPLACE WITH NEW
02A
RECONDITION W/ LVL 1 PRTS
02B
RECONDITION W/ LVL 2 PRTS
02C
RECONDITION W/ LVL 3 PRTS
02D
RECONDITN W/CAT CERT RBLD
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STANDARD REPAIR OPTIONS BUILD RULES (010 REMOVE AND INSTALL) It is suggested that 010 REMOVE AND INSTALL should not be used as a REPAIR OPTION when using a “REPLACE” job such as 013, 513, or 511. Caterpillar is working towards including remove and install job parts. 010 Remove and Install job operation build rule will be the following: “REMOVE AND INSTALL” Job parts are defined as: One time use parts that are disturbed while removing and installing a component and directly contact the component being removed; R&I job parts do not take into consideration the removal of other parts/components for access. The entire parts group for the R&I parts will be added to the job operation. Only the one time use parts will have a 100% replacement percentage. Example Turbocharger R&I will contain the oil lines group. Only the O‐rings, seals and gaskets will be at 100% replacement; the oil lines themselves will be at 0% replacement.”
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SMCS Warranty Use the appropriate specific SMCS job code.
Example, use 511 REPLACE WITH NEW or 014 REPLACE GASKET / SEAL instead of 010 REMOVE & INSTALL etc.
Notes:
(001 REPAIR FOR WARRANTY) This was developed for Service Letter use only.
(501 TRG OVERTIME) should not be used, instead use a more specific SMCS job code and then explain in the claim story details about why the labor exceeded the labor guidelines.
(000 COMBINED REPAIR TIME WARRANTY) is only used with On‐Hwy Truck engine claims if listed in the TRG document.
SMCS Reference Use only the short SMCS description. The short description has a maximum of 25 characters. Any database tables that are used with dbs, dbs i (or other ERP systems) or Builder G3 may need updating. If the long version has been used in the past, it gets truncated and not properly abbreviated. Do not use the long description unless your ERP supports the longer field description ‐ up to a maximum of 69 characters. Follow the format below for repair options and descriptions:
Component + Job + Modifier + Quantity + Job Location + Work Application + Job Condition
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SMCS CODE RANGES
SMCS CODE TYPE
CATERPILLAR RANGE
DEALER RANGE
Component
0000‐8999
9000‐9999
(4‐position)
A000‐Z999
AAAA‐ZZZZ
AAA0‐ZZZ9 AA00‐ZZ99 A00A‐Z99Z A0AA‐Z9ZZ 000A‐999Z 00AA‐99ZZ 0AAA‐9ZZZ 0A00‐9Z99 0AA0‐9ZZ9 00A0‐99Z9 Job
000‐089
090‐499
(3‐position)
500‐899
900‐999
0AA‐9ZZ AAA‐ZZZ AA0‐ZZ9 A00‐Z99 0A0‐9Z9 00A‐99Z Modifier
AA‐ZZ
00‐99
(3‐position)
A0‐Z9
0A‐9Z
AAA‐ZZZ
000‐999
A00‐Z99
00A‐99Z
AA0‐ZZ9 0AA‐9ZZ 0A0‐9Z9 A‐Z
0‐9
Job Location
AAA‐ZZZ
000‐999
(3‐position)
AA0‐ZZ9
00A‐99Z
0AA‐9ZZ
A00‐Z99
Quantity
(1‐position)
0A0‐9Z9
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Work Application
0000‐9999
000(space)‐999(space)
(4‐position)
AAAA‐ZZZZ
AAA(space)‐ZZZ(space)
AAA0‐ZZZ9 AA00‐ZZ99 A000‐Z999 A00A‐Z99Z A0AA‐Z9ZZ 000A‐999Z 00A0‐99Z9 0A00‐9Z99 00AA‐99ZZ 0AAA‐9ZZZ 0AA0‐9ZZ9 Job Condition
AAA‐ZZZ
000‐999
(3‐position)
A00‐Z99
00A‐99Z
AA0‐ZZ9 0AA‐9ZZ 0A0‐9Z9 Cab Type
AA‐ZZ
00‐99
(2‐position)
A0‐Z9
0A‐9Z
Product Family
00‐49
50‐99
(2‐position)
A0‐Z9
0A‐9Z
AA‐ZZ
For additional questions please contact
[email protected] ,
[email protected]
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