Escolar Documentos
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Table of Contents
Repair Limitations of Maintenance TRG Format . . . . . . . . . . . . . . . . . . . . . . . .E
Service Dealers . . . . . . . . . . . . . . . . . . . . . B
How to Use the Segmented Repair Times .H
Types of Cab Configurations . . . . . . . . . . B
List of All Available TRG’s . . . . . . . . . . . . . I
Heavy-Duty Cab Type Classifications . . . . C
Claim Example . . . . . . . . . . . . . . . . . . . . .. .J
What the Published Labor Times Include . D
Introduction
Time Requirement Guides (TRG) are used as removed in the process of repair are to be
a basis for warranty allowance for service reinstalled as-is unless the user authorizes
operations performed on Caterpillar engines the additional expense. The intent is to
and generators. The guides list allowable repair/replace the warranted parts and restore
labor hours for various normal warranty the rest of the component to its operating
repairs. The intent of Time Requirement condition just prior to the warrantable failure.
Guides is to provide reasonable and It is not the intent to restore the product to
obtainable times. like-new condition.
TRG Format
The various repair times contained in TRG’s components which are part of or directly
are listed by a coding system called Service associated with the Cylinder Head Assembly.
Management Control System (SMCS). The
SMCS Codes provide company and dealer Job Codes
uniformity in describing job operations.
The Job (JOB) Code is a three-digit numeric
An SMCS Code is divided into two, three, or code that identifies the type of repair
four separate codes. All SMCS Codes have at operation performed on the component.
least two separate codes which are :
Typical Job Codes:
! Component Code
! Job Code 010 = Remove & Install
020 = Recondition
In addition, some SMCS Codes will have one 038 = Diagnostic Test
or both of the following:
The Component Code is followed by a dash
! Modifier Code, and/or (-) and the three digit Job Code.
! Quantity Code
Component Codes
Comp. Code Job Code
The Component (COMP) Code is a four-digit (Valve Cover) (R&I)
number that identifies the name of the
component or part. The Component Code is
the first four digits of the SMCS Code.
Examples of major categories: Example 1: SMCS Code for R&I Valve Cover
Example: FR = Front
P1 = PAR
1100 = Cylinder Head Assembly HG = Housing
1101 = Cylinder Head Casting
1102 = Rocker Shaft Assembly Not all SMCS Codes have a Modifier Code. If
1105 = Valve the SMCS Code has a Modifier Code, the
1107 = Valve Cover Modifier Code will directly follow the Job Code
with a dash between the Job Code and
In the above example, all Component Codes Modifier Code.
from 1101 through 1149 are parts and/or
F
F = First One
A = Each Additional Booklet of All SMCS Codes
S = Set All
A booklet of all SMCS Codes for Engine
If the SMCS Code has both a Modifier Code Division Products (Form SEBD3437) is
and a Quantity Code, then the Quantity Code included in the TRG Binder Manual and the
follows the Modifier Code with a dash (-) Service Warranty Guide. This booklet lists the
between the Modifier and Quantity Codes. Component Codes, Job Codes, Modifier
____________________________________ Codes, and Quantity Codes that are available.
The SMCS Code Booklet should be used
1107-010-RI-F when developing an SMCS Code for a repair
segment that is not included in the TRG.
____________________________________
_
Example 3: SMCS Code for R&I One Valve
Cover On Right Side
G
TRG Times Listed by SMCS Code NOTE Section
All repair segments included in segmented A NOTE section, when applicable, may be
TRG’s are listed by the SMCS Code, in included at the beginning of each repair
numerical order of the Component Code. In segment in the TRG. The NOTE section is
addition, within each Component Code the designed to help dealer personnel by:
various repair segments for a particular code
are listed in numerical order of the Job Code.
• Clarifying or further defining the repair
time.
At the top of each page is the name of the
• Stating when a particular repair time
major category for those Component Codes
should be used.
listed on that page. This major category
represents a major structure or system of the • Reminding dealers of additional codes
engine installation. that can be claimed.
If the Component Code is not known, the The NOTE section, when applicable, is
Alphabetical Index of part names can be used located directly below the code description at
for locating a specific repair segment in the the beginning of a published repair segment.
TRG. An example of a NOTE is shown in the
following illustration.
SMCS CODE
COMP JOB MOD QTY CODE DESCRIPTION
1166 010 TIMING GEAR ASSEMBLY
REMOVE & INSTALL -- (IN-FRAME)
NOTE: - USE THIS CODE FOR ACCESS TO TIMING GEARS, DO NOT USE THIS CODE FOR R&I TIMING
GEAR HOUSING, USE INSTEAD CODE (1162-010)
- IF REQUIRED, ADD CODE (1166-010-S1) TO R&I TIMING GEAR COVER SOUND SUPPRESSION
PANEL.
SC MC CV CO
STANDARD TIMES (HRS) 7.6 7.6 7.2 8.2
TIME INCLUDES:
SEPARATE & CONNECT
HOOD - TILT SUPPORT CABLES N/A
Illustration: Shows NOTE Section and notation for Not Applicable “N/A”
Standard Time Includes The repair steps listed under each sub-
heading are listed in the approximate order of
The repair steps listed under “Standard Time repair or grouped with associated
Include” are divided under the following parts/operations within each sub-heading.
possible sub-headings: This makes it easy to follow what a particular
repair segment includes. It is especially
• Separate and Connect helpful for repair segments that involve a
• Remove and Install number of various components, since all
• Disassemble and Assemble steps associated with a particular component
are listed together under each sub-heading.
• Remove
• Install
Some vehicle model configurations may not
• Miscellaneous
require certain repair steps that are listed
under the “Standard Time Includes”. To
Any combination from one to all five of these
indicate which repair steps listed are not
sub-headings may be listed for a particular
included for a certain cab/model configuration,
repair segment.
an “N/A” (not applicable) will appear to the
right of that step in the column(s) under the
appropriate cab/model configuration. See
illustration above.
H
The following list of tasks are not part of other Glass Bead Pistons
component repair times listed in this TRG. If required, add Code 1214-020.
These tasks, when applicable, are separate
repair segments that must be listed separately R&I Fuel Injector Sleeves
when establishing the total labor hours that If required, add Code 1713-010.
can be claimed for a particular warranty
repair. 500 Job Codes
R&I Power Take-Off Units Explanation in Service Report: Could not use
If required, add appropriate code using overhead hoist because truck had a non-
“actual reasonable time”. Code 1165-010. removable car hauler rack. Required two men
and forklift with a boom to R&I cylinder head.
I
These TRG’s are available through the Caterpillar Literature Distribution System.
Claim Example
J
Developing the Total Claimable Labor Breakdown from the Service
Labor Time Report
SMCS Description Hours
Since segmented repair times are broken
into individual tasks or repair segments, we 1202-074 Wash Crank 0.5
must review how these individual segments 7006-552 Maneuver Stalled 0.6
are used to establish the total allowable Truck
warranty repair time. 1202-038 Diagnose 1.0
Problem
The following example illustrates taking the 1000-010 R&I Engine 12.3
information in the Service Report and listing
the various repair segments to determine the 1202-010-WX R&I Crank with 16.4
total labor hours allowed for a warranty Damage
repair. For clarity, the labor breakdown 1304-001 D&A Oil Pump 0.7
should be listed in the approximate order that 1119-010-ES-S R&I Jake Brake 0.5
the work was performed, as illustrated in the
following labor breakdown chart. 1216-082-LJ-S Measure Liner 0.7
Projection
Example: 1000-031-CS Dyno Test After 0.9
Repair
Cab Type: Cab-Over Freightliner with 3406E Total Labor 33.6
Hours
Service Report: Truck was towed in. Driver
heard knocking noise and noticed loss of
power. Steam cleaned engine and towed
truck into shop. Dropped oil pan and found
No. 4 rod bearing spun. The spun bearing
damaged the crank, con-rod, and piston of
No. 4 cylinder. Inspected No. 3 and 5 main
bearings which showed no damage thus
indicating the lube system was not
contaminated. Removed engine from truck,
replaced crankshaft, and replaced No. 4
cylinder pack. Left remaining five piston &
liners in cylinder block. Disassembled oil
pump & liners in cylinder block.
Disassembled oil pump & inspected gears.
Oil pump was O.K. Assembled engine and
checked liner projection. Engine was
equipped with Jake brake. Re-installed
engine in truck and chassis dyno tested
engine