Bus002 - SGD - V4 (Cat Lit)

Caterpillar
Literature
BUS002
Student Guide
Caterpillar Service Technician Module
BUS002
Caterpillar Literature
Published by Caterpillar of Australia Pty Ltd.

1 Caterpillar Drive
Tullamarine Victoria Australia 3043
Version 4.0, 2005
Copyright © 2005 Caterpillar of Australia Pty Ltd. Melbourne, Australia.
All rights reserved. Reproduction of any part of this work without the permission of the
copyright owner is unlawful. Requests for permission or further information must be
addressed to the Caterpillar Learning Manager, Australia.
This subject materials is issued by Caterpillar of Australia Pty Ltd. on the understanding that:
Caterpillar of Australia Pty Ltd., its officials, author(s), or any other persons involved in the
preparation of this publication expressly disclaim all or any contractual, tortious, or other form
of liability to any person (purchaser of this publication or not) in respect of the publication and
any consequence arising from its use, including any omission made by any person in reliance
upon the whole or any part of the contents of this publication.
Caterpillar of Australia Pty Ltd. expressly disclaims all and any liability to any person in
respect of anything and of the consequences of anything done or omitted to be done by any
such person in reliance, whether whole or partial, upon the whole or any part of the contents
of this subject material.
Acknowledgements
A special thanks to the Caterpillar Family for their contribution in reviewing the curricula for
this program, in particular:
 Caterpillar engineers and instructors

 Dealer engineers and instructors
 Caterpillar Institutes.
Table of Contents
Included in this Module:
Module Outline Document..........................................1
1
Topic Caterpillar Literature....................................................9
Information Resources................................................................. 10
Media Types................................................................................. 11
Publication Types ........................................................................ 12
Media Form Numbers..................................................................26
Sales, Parts and Service Marketing Literature ...........................28
2
Topic Product Identification................................................39
Introduction...................................................................................40
Caterpillar Product Line Brochure AECQ1042-02....................... 41
Serial Number/Product Identification Number.............................43
Serial/Product Identification Plate................................................ 51
3
Topic Identify Part Numbers................................................53
Introduction...................................................................................54
Identify Parts/Accessories from Parts Book Manual....................54
Part Number Format.....................................................................55
Arrangement Numbers.................................................................56
Group Numbers............................................................................57
Assemblies...................................................................................59
Parts Book Layout........................................................................ 61
Sectioned Drawings.....................................................................66
Retrieval of Parts Information.......................................................67
NPR – Numerical Parts Record...................................................73
C aterpillar L iterature – BUS002

© Caterpillar of Australia P ty Ltd
Module Outline Document
ii
BUS0 02
© C aterpillar of Australia P ty Ltd
Included In This Section:

Learning Outcome Details and Module Information
Caterpillar L iterature – BUS002

CAT Literature
Module Number: BUS002
Module Name: Caterpillar Literature
Objective:
This unit identifies the competence required to correctly identify, state the
application and competently use Caterpillar Service Literature
Prerequisites: Nil
Date: 7 April 2006
Version: 4.0
Recommended Delivery
1. As a minimum, personnel delivering this module must have the status of
a Caterpillar Trainer and Assessor Program (CTAP) Level 1 Facilitator, or
equivalent.
2. Media, demonstration and practical facilitation, given:

• Notebook Computer
• PowerPoint Presentation
• Video Projector
• Whiteboard
• Various tooling, training aids/models or machines
3. Estimated time of delivery – 10 hours
4. Classroom and Workshop Environment
5. Resources:
• Service Manuals (1 per student)
• Guidelines for Reusable Parts
• Parts Manuals (1 per student)
• Operation Maintenance Manual
• One Safe Source
• Shop Product and Tool Guide DVDs
• Previews
• Fuel Settings
• Service Magazines
• Engine News
• Truck Engine News
• Numerical Parts Record
• Technical Information Bulletin
• Service Letter

BUS002
CAT Literature
• Special Publications
• Catalogue
• Special Instructions
• Laptop Computer
• Service Information System (1 per student)
• CD-ROM
• Intranet Access (SIS Web)
• Salesgram
• Product Bulletin
• Competitive Bulletin
• Performance Report
• Promotional Video
• Operator Training Video
• Walk-around Video
• Sales Support Information (CD-ROM)
• Performance Handbook (1 per student)
• Parts Sales Kit
• Information Release Video
• Index Guide
• Serial / Product Identification Plate
• AECQ1042-01 Caterpillar Product Line Brochure
• SEBF9451-23 Caterpillar Serial/Product Identification Number Index
• Current SIS tutorial
6. References:
• BUS002 Facilitator Guide
7. Recommended maximum student/teacher ratio:

• Classroom – 15:1
• Workshop – 8:1
8. Resources for Student:

• BUS002 Student Guide (one for each student)
• BUS002 Activity Workbook (one for each student)
• Relevant manufacturer’s specifications
Revision
• Nil

BUS002
CAT Literature
Assessment
This is an underpinning knowledge module. Learning Outcomes should be assessed
using formative and summative assessments. Evidence of achieving this module’s
learning outcomes, at a knowledge level, is attained by oral and written assessment. The
written assessment is closed book and a minimum standard of 80% is required.
There are no practical assessments for this module. The underpinning knowledge gained
from this module will be used in other modules in the Caterpillar Apprentice Service
Technician Training Program. Transfer of knowledge to skills, at a practical level, will be
assessed during all Service and Repair practical activities. Personnel conducting the
assessment must be qualified as a workplace assessor.

BUS002
CAT Literature
Learning Outcome 1 Identify and use common Caterpillar service literature

to find a correct publication to solve a workplace need
_______________________________
At the completion of this learning outcome, students should be able to:

1.1 Identify Caterpillar media and publication types
Attainment of the performance is confirmed if the student can:
1.1 Identify Caterpillar media and publication types:

1.1.1 Media types
1.1.1.1 Printed matter
1.1.1.2 Mainframe file
1.1.1.3 CD-ROM/DVD
1.1.2 Publication types
1.1.2.1 Service Manuals
1.1.2.2 Fuel Settings
1.1.2.3 Guidelines for Reusable Parts
1.1.2.4 Parts Manuals
1.1.2.5 Operation Maintenance Manual
1.1.2.6 One Safe Source
1.1.2.7 Supplies and Tools DVD
1.1.2.8 Dealer Service Tools DVD
1.1.2.9 Previews
1.1.2.10 Technical Information Bulletin
1.1.2.11 Service Letter
1.1.2.12 Special Publications
1.1.2.13 Catalogue
1.1.2.14 Special Instructions
1.1.2.15 Serial / Product Identification Plate
1.1.2.16 Media Form Numbers
1.1.2.17 Sales, Parts and Service Marketing
− Salesgram
− Product Bulletin
− Competitive Bulletin
− Performance Report
− Promotional and Operator Training Videos
− Walk-around Video
− Sales Support Information (CD-ROM)
− Performance Handbook (1 per student)
− Parts Sales Kit
− Information Release Video
− Index Guide

BUS002
CAT Literature
Learning Outcome 2 Identify the number systems used by Caterpillar for

machines manufactured by the Company
_______________________________
At the completion of this learning outcome, students should be able to:

2.1 Explain terminology used by Caterpillar to identify products
2.2 List the Caterpillar numbering system
2.3 Locate Serial / Product Identification Plate on a machine
2.1 Explain terminology used by Caterpillar to identify products

2.1.1 Product line brochure
2.1.2 Serial / Product Identification Number index
2.2 List the Caterpillar numbering system
2.2.1 List number system
2.2.2 Caterpillar Product line brochure
2.2.3 Serial number/product identification number
2.2.4 Serial number/product identification number by model
2.2.5 Equipment serial/product identification number
2.2.6 Engine identification number
2.2.7 Vehicle engine usage information
2.2.8 Serial/product identification plate
2.3 Locate Serial / Product Identification Plate on a machine

2.3.1 Differing machines

BUS002
CAT Literature
Learning Outcome 3 Use the Caterpillar Parts Identification System to

locate correct parts and service information
_______________________________
At the end of this learning outcome, students should be able to:

3.1 Identify parts/accessories from the Parts Manual
3.2 Access the Service Information System
3.1 Identify parts/accessories from the Parts Manual

3.1.1 Parts Manual
3.1.2 Part number format
3.1.3 Arrangement numbers
3.1.4 Group numbers
3.1.5 Assemblies
3.1.6 Parts manual layout
3.1.7 Sectioned drawings
3.2 Access the Service Information System
3.2.1 Retrieval of parts information
3.2.2 Numerical parts record

BUS002
CAT Literature

BUS002
1 Caterpillar Literature
Topic
Included in this Topic:

Information Resources...........................................................................................................................................10
Media Types......................................................................................................................................................................... 11
Publication Types . .......................................................................................................................................................12
Media Form Numbers. ............................................................................................................................................ 26
Sales, Parts and Service Marketing Literature .................................................................. 28

Student Guide – Topic 1
Information Resources
All Mechanical Service and Maintenance staff will at all times during their
working life need to have access to and read relevant literature. This includes
manuals, service notes, product updates, sales and other reports as well as
other relevant information.
Most Caterpillar literature is now available on Electronic Media and the most
common form of this media is the Service Information System – commonly
referred to as SIS.
Not that long ago a lot of Caterpillar service information was contained
on Microfiche film. This was replaced by a CD-ROM format in the form of
approximately 160 discs released every month. This was again replaced by a
DVD format of approximately six discs every month.
Even though SIS DVDs are still released and commonly used by Field Service
Technicians, the common form for SIS is now on the Caterpillar Intranet Sites in
the form of SIS Web.
This unit is designed to help the participant to identify some of the more
common service literature available, demonstrate simple ways of understanding
service literature, use and identify service literature media types and availability.
It should be noted that whilst much reference is made to Caterpillar literature, all
engine and machine manufacturers develop and support relevant material.
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Media Types
Figure 1
All engine and machine manufacturers produce material in a wide range of

versions. These include the following:
 Printed matter
• Books
• Manuals
• Magazines
 Mainframe data
 CD-ROM/DVD stored matter; Internet and Intranet accessible matter.
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Publication Types
Published matter can deal with any sorts of topics. The service literature is
usually available in four types:
 Basic reference publications
 Service literature
 Periodical publications
 Special publications.
Basic Reference Publications

Basic reference publications contain detailed information about machines,
procedures, methods and equipment.
Types of publications available are:

 Service Manuals
 Fuel Settings
 Guidelines for Reusable Parts
 Parts Manual
 Operation Maintenance Manual (OMM)
 One Safe Source
 Shop Supplies and Tools
 Dealer Service tools.
Periodical Publications
Periodical publications are issued at relatively fixed intervals. They provide
product information of more immediate and specific interest than the basic
reference publications.

 Preview
 Service Magazines (SM)
 Engine News (EN)
 Truck Engine News (TEN)
 Numerical Parts Record (NPR).
Special Publications
These publications contain important service information about urgent product
improvements, warranty, safety, and parts inspections, parts return and other
matters. This literature is published as the information becomes available.

 Technical Information Bulletin (TIB)
 Service Letter
 Special Publications
 Catalogue
 Special Instructions.
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Service Manual
Figure 2
The service manual (Figure 2) is the basic reference source for:

 Diagnostic work
 Troubleshooting
 Assembly and disassembly
 System operation
 Testing and adjusting
 Machine system specifications.
Service Manuals are published soon after the first new machine is shipped.
Service Manuals are broken into sections:

 Power Train
 Engine
 Lubrication and Maintenance
 Electrical System.
Service Manuals are available in the following media:
 Printed
 CD-ROM/ DVD (Service Information System or SIS)
 Intranet (SIS Web).
Fuel Setting
Fuel setting and related information library is composed of five libraries separated
according to engine application.
Fuel setting information for non-current models can be found in the fuel setting
microfiche.
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Adjustment data available:

 Fuel Settings
 High and Low Idle Speeds
 Full Load Speeds
 Fuel Ratio Control Settings
 Turbocharger Boost Pressures
 Corrected Specific Fuel Consumption
 Other Fuel System Settings.
Figure 3
Fuel Settings are available in the following media:

 Intranet (TMI Web)
 SIS Web (Figure 3).
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Guidelines for Reusable Parts
Figure 4
Each guideline (Figure 4) is published on a single subject and includes detailed

photographs depicting both reusable and non-reusable parts.
Information about cleaning, measuring and reconditioning parts is also included.
Guidelines for Reusable Parts are available in the following media:

 Printed (Booklet)
 SIS Web
The form number for the ‘Index of Publication on Reusability or Salvage of Used
Parts’ is SEBF 8029.
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Parts Manuals
Figure 5
Parts Manuals (Figure 5) are issued for all products and are used as a parts
ordering reference. Books are provided in paper form for users and accompany
each machine shipped. These books are revised and reissued periodically and
announced in preview.
Information that Parts Manuals provide:

 Provide part numbers
 Part names
 Locations on machines
 Quantities used.
Part Books are available in the following media:
 CD-ROM/SIS DVD
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Operation Maintenance Manuals
Figure 6
The operation and maintenance manual (Figure 6) describes operation and

maintenance of a prime product and may include information on components.
It covers the basic procedures that are done every day during the operation and
maintenance of that particular product, it does not include repair work.
The operation and maintenance is shipped with every product as the targeted
audience is the operator or person responsible for the maintenance and
servicing of the product.
Information that the Operation Maintenance Manual provides:

 Procedures for checking, starting and stopping
 Operating techniques
 Lubrication and Maintenance schedules.
Operation Maintenance Manuals are available in the following media:
 Printed
 CD-ROM/SIS DVD
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Tool Guides
Tool Guides are broken up into two sections:
Figure 7
1. Dealer Service Tool Catalogue (Figure 7), includes information on specialist

tooling for:
 Diagnostics
 Air conditioning
 Engine
 Power Train
 Hose assembly
 Undercarriage
 Vehicle systems
 Major equipment
 Cleaning equipment
 Tool repair
 Hydraulic/mechanical/pullers/drivers
 Lifting/blocking/clamping
 Lubrication equipment
 Pneumatics
 General shop tools.
This product is available on SIS Web or in DVD format (NENG2550)
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Figure 8
2. Shop Supplies and Hand Tools (Figure 8) includes information on warranty,

hand tools, shop supplies and shop equipment, specifically:
 Hand tools
 Torque wrenches
 Pneumatic tools
 Electric tools
 Tool boxes
 Consumables (abrasives / chemicals / caps and plugs / paints / material han-
dling etc)
 Shop equipment (vices / lubricating equipment / battery
service equipment etc).
This information is available also in SIS Web and available in DVD format
(PERJ0048).
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One Safe Source
Figure 9
One Safe Source (Figure 9) lists genuine Caterpillar service parts.
One Safe Source is available in the following media:

 Printed
 DVD.
Previews
Figure 10
Preview (Figure 10) is a monthly publication that announces new or revised

product support, marketing, training and promotion materials.
The memorandum-style newsletter is broken into different market segments and

these segments are identified by colour:
Blue: Service Information
Red: Engine Marketing
Green: Parts and Service Marketing
Yellow: Machine Marketing
Previews are available in the following media:

 Printed.
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Service Magazines
Figure 11
A Service magazine is a newsletter type publication for news and tips, which is
published weekly. It is a quick and easy way to alert dealers to new and better
procedures, parts, and ideas.
Service Magazines provide information on:

 Self-training for service personnel
 Helpful tips for operators and dealer personnel
 New or improved parts
 New or improved products
 New tooling
 New or improved service procedures
 Corrections made to other service manuals
 Permanent fixes for field problems
 Safety
 New parts for old parts replacements
 Announce new Special Instructions for installing parts.
Service Magazines are available in the following media:
 Printed
 SIS DVD (Figure 11)
 SIS Web.
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Engine News/Truck Engine News
Figure 12
Engine News is a customer publication that provides current service information

on all marine and industrial engines (except natural gas), marine gear and
generator sets.
A similar publication called Truck Engine News (Figure 12) is available for
owners of on-highway truck engines.
Both publications include information about:

 Engine improvements
 Maintenance
 Special tools
 Customer news
 New product hints
 Troubleshooting
 Safety notes.
Articles in Engine News and Truck Engine News may have been published
previously in other publications.
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Engine News/Truck Engine News are available in the following media:

 Printed
 SIS DVD
 Internet (SIS Web).
Numerical Parts Records
Figure 13
Complete list of Caterpillar part numbers (Figure 13) with current information
about each number. Includes part numbers, part names and service part/
replacement part number numerical parts records.
These are available in the following media:

 SIS DVD
 SIS Web.
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Technical Information Bulletins

The purpose of the Technical Information Bulletin (TIB) is to inform the dealer
technical communicators on a confidential basis of any product related
problems, and the necessary corrective actions as quickly as possible.
Technical Information Bulletins provide information on:

 Temporary solutions to problems that have not been completely validated
 Changes or corrections for dealer to perform prior to product delivery to cus-
tomers
 Parts return for engineering analysis (not warranty parts)
 Non-traditional troubleshooting procedures to try that cannot be referenced in
any other publication.
Technical Information Bulletins are available in the following media:
 Printed
 SIS DVD
 SIS Web – under New Information.
Service Letters
Service letter contains important information about:
 Urgent product improvements
 Warranty
 Safety
 Part inspections
 Parts return.
All service letters have SMCS code and a program number located beneath the
title.
There are two types of programs:

 Product Improvement (PI), mandatory action required:
• Safety letters
• Priority letters, identifies service letters concerning urgent non-safety
rework programs that can involve considerable expense to all parties if
not completed promptly.
 Product Support (PS), at dealer discretion:
• After failure
• Before/After failure.
Service letter supplements, cancellations or extensions are sent out to update
the information on existing service letters.
Service Letters are available in the following media:

 Printed
 SIS DVD
 SIS Web.
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Special Publications
Special publications can contain information on how to analyse a component or
machine.
They provide standards for inspecting failed parts and the procedures used to
determine the cause of failure. Special publications can also be promotional
literature encouraging dealers or users to take specific action.
Special Publications are published as special parts or service information

becomes available.
Special Publications are available in the following media:

 Printed
 SIS DVD
 SIS Web.
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Media Form Numbers

What is a Form Number?
A Form Number defines originating area, and is a device designed specifically
by Caterpillar, for reference and use by Caterpillar. It involves a particular
language, medium, coding and alpha-numeric assignment that assist in the
exact identification of the specific type of support material, be it CD, A/V tape,
written work or other.
There are five main categories:
1. Originator Cod
2. Language Code
3. Media Code
4. Section Identification
5. Numeric Identification.
Examples of Caterpillar Codes

Originator Code
A Sales promotion
K Sales
L Engine Division
M CofA
S Service
T Sales Development
Language Code
E English
F French
G German
M Multilingual
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Media Code
B Book, Slide / Text Reference
C Catalogue
G Course / Technical Instruction
R Computer Disk
S Service Training Meeting Guide
V Video Tape
Industrial Code
D Dealer Publication
Identifying Form Numbers

S E S V 1234
Language Section Numeric

Originating Media Code
Code I.D. I.D.
Sales Book, slide/ Service
A E English B V
Promotion Text Reference Training
K Sales F French C Catalogue
Course,
Engine
L G German G Technical
Division
Module
M CofA M Multilingual R Computer Disk
Service
S Service P Portuguese S Training
Meeting Guide
Sales
T S Spanish V Video Tape
Development
Table 1
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Sales, Parts and Service Marketing Literature
Figure 14
This section covers various types of Caterpillar sales marketing literature, and
their purpose and contents.
The literature available is:
Salesgrams Sales Support Information CD
Product Bulletins Preview
Competitive Bulletins Performance Handbook
Performance Report Parts Sales Kit
Promotional Videos Information Release Memo
Operator Training Videos Catalogues
Walk-Around Videos
Table 2
Media Types
Media involves a very wide range of different ways of presenting information.
These include the following:
 Printed word
 DVD
 Intranet.
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Salesgrams
Figure 15
Salesgrams (Figure 15) are time sensitive information that updates sales people
on product improvements, changes, corrections, competitive situations, and
up‑coming product introductions.
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Product Bulletins
Figure 16
Product bulletins (Figure 16) are detailed reviews of new/improved products.

They highlight product features, product improvements, competitive situation
analyses and up-coming product introductions.
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Competitive Bulletins
Figure 17
Competitive Bulletins (Figure 17) are produced most frequently with a new
product introduction or in response to competitive products. They provide
detailed comparison of the Caterpillar machines with those of the competitors.
The emphasis is placed on information that will inform sales people and
customers about Caterpillar machines’ differentiating features and resulting
benefits.
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Performance Reports
Figure 18
Performance Reports (Figure 18) are usually produced with new product
introductions and are the result of production studies.
The tests are set up to replicate actual applications.
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Promotional Video / DVD
Figure 19
Promotional videos (Figure 19) are produced in conjunction with new product
introductions.
Provides information in a very promotional manner with an overview of product

features and how they will benefit customers.
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Operator Training Videos

Provide information in a very informative, educational manner with a step by step
demonstration of new controls and operating techniques.
Safety operating procedures are highlighted.
Sales Support Information DVD
Figure 20
Sales Support Information DVD (Figure 20) are a form of video presentation
that are computer based. These contain detailed product information as well as
electronic versions of associated printed materials.
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Performance Handbooks
Figure 21
The performance handbook (Figure 21) includes data for comparing or

estimating machine performance and guidelines for estimating owning and
operating cost.
The performance and productivity data take into account factors such as weight
to horsepower ratio, capacity, transmission and climate.
Tables and curves throughout the book show expected cycle times and hourly
production figures for Caterpillar machines in certain conditions.
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Parts Sales Kits
Figure 22
At Caterpillar, parts sales kits (Figure 22) are published for four Product Families:
1. Ground Engaging Tools

2. Hydraulics
3. Undercarriage
4. Power Train/Maintenance Products.
This quick reference tool provides access to a wealth of information including
part numbers and product information as well as features and benefits for
selected parts and service commodities.
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Information Release Memos

Information release memos provide information on new or changed attachments
or replacement parts.
The product area that Information Release Memo’s relate to are identified in the
top right corner with the following codes:
REM: Reman
MISC: Miscellaneous
DT: Drive Train
SPG: Shop Product Guide
ENG: Engine
Fil: Filters
UC: Under Carriage
BAT: Battery
HYD: Hydraulics
GET: Ground Engaging Tools.
CofA: Caterpillar of Australia Ltd.
What is a Form Number
Figure 23
All Caterpillar literature has form numbers (Figure 23), these form numbers are
used to identify and order literature.
The ability to recognise the most commonly used alphanumeric digits will be
helpful when selecting and identifying literature types and markets.
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2 Product Identification
Topic

Introduction.......................................................................................................................................................................... 40
Caterpillar Product Line Brochure AECQ1042-02................................................................41
Serial Number/Product Identification Number..................................................................... 43
Serial/Product Identification Plate........................................................................................................51

Cterpillar Literature
Introduction
Student reference materials are Caterpillar product line brochure No.
AECQ1042-01 and Caterpillar Serial/Product identification Number Index
SEBF9451-23.
All manufacturers of major products (such as plant, machinery, motor cars etc.)
use identification numbers or letters or a mixture of both to identify their different
products. These products will usually have two forms of identification. One is a
sales model number, which is used as a top level number to identify a product
for use in discussion with customers and in general discussion with employees.
The other number is a serial number or product identification number. The serial
number or product identification number usually is a combination of two sets of
numbers or letters. It has a prefix, which identifies a model family and a suffix,
which is a unique number to identify a specific machine.
In this topic, the discussion will cover the numbering systems used by Caterpillar
for the machines which are manufactured by the company.
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Caterpillar Product Line Brochure AECQ1042-02
Figure 24
The Caterpillar Product Line brochure, AECQ1042-02 shows the sales model
numbers which are used to identify the various models manufactured by the
company. Note how the numbering system is used to separate the various
families of machine, and how different numbering conventions are used.
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Figure 25
For example, the Track-Type Tractor family is identified with the letter D in front
of a number. The D shows that the machine is a Track-Type Tractor. The number
gives an indication of the size of the machine, i.e. the smaller the number the
smaller the machine and the letter at the end of the sequence changes each
time there is a major update to the model.
A different numbering convention is used for wheel and track loaders. This family
is the 900 series where the first digit–9 is for a loader, the second two digits are
used for the different size machines, small number smaller machine. If the last
number is an even number, it is indicating a Wheel Loader. If the last number is
an uneven number, it is indicating a Track Loader. The letter at the end of the
sequence changes when the particular machine model is updated.
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Serial Number/Product Identification Number
Figure 26
Figure 26 shows the front page of the 793C parts manual to demonstrate the
use of PIN and Serial Number usage. Traditionally, as with most manufacturers,
Caterpillar has used Serial Number Identification for their product. Recently,
Caterpillar has made a small change to the way the terminology of serial number
and product identification numbers are used.
Presently, the Product Identification Number (PIN) is used to identify the

primary machine and Serial Number is used to identify major components in the
machine. For example, a 793C (Sales Model Number) Off Highway Truck has
a PIN with a prefix of ATY followed by a unique number for each machine built.
All 793C's built have the prefix ATY and each machine has a different number
(suffix) following the prefix. This numbering system therefore gives each machine
a unique number.
The 793C also contains an engine. The engine has a Serial Number prefix of
7TR. Each engine has a suffix, which is also a unique number. Similarly the
transmission in the 793C has 4GX for a prefix and the torque converter has a
serial number prefix of 3KT.
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Figure 27
Caterpillar produces an index guide (Figure 2) to show the Serial/Product

Identification numbers of all products manufactured from the start of production.
This guide is updated frequently. The same information is also available
electronically.
The book contains five indexes, which are shown on the front page. From these
indexes it is possible to identify specific information related to all products.
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Index Section A:
Serial/Product Identification Number
Figure 258
Index Section A shown in Figure 28 provides a listing by serial number prefix.

The sequence of the listing is not obvious. This is based on the third digit which
is always a letter, (with the exception of a few machines of very old production
which are listed first on pages 1A and 2A of the listing).
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Therefore all of the serial numbers which have the letter A as the third letter
appear first all the way through to the machines which have the letter Z as the
third letter.
The second part of the sequence uses the first digit, which is usually a number
until recent machines which have a letter as the first digit. The second part of the
sequence commences with 0 all the way up to 9. In cases where the first digit is
a letter, these will follow after 9 starting with A.
The third part of the sequence is on the second digit and the order is the same
as just discussed.
The listing provides the beginning number (machines do not always start at
number 1), Sales Model Number and description, country of manufacture and
year first shipped.
NOTE:
Only prime product serial / product identification numbers are listed in the index.
Component serial numbers are not listed.
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Index Section B:
Serial/Product Identification Number by Model
Figure 29
The section B index shown in Figure 29 is a listing by Sales Model Number.

If the sales model number of the machine is known, then the various serial
/ product identification number can be found. There may be many different
prefixes used for the same Sale models. If the model is manufactured in two
different countries, then there will be a different serial / product identification
number for each.
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Index Section C:
Equivalent Serial/Product Identification Number
Figure 30
This listing shows all the equivalent serial numbers for a particular sales model.
The listing covers all the serial / product numbers which have the same basic
design.
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Index Section D:
Engine Identification Information
Figure 31
The listing shows the serial number prefix of the engines which are used in the
primary product.
The listing is organised by each product family.
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Index Section E:
Vehicle Engine Usage Information
Figure 32
This index is the reverse of index section D. It lists the engine model for all the
machines the engine is used in.
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Serial/Product Identification Plate
Figure 33
INSTRUCTOR NOTE:
Take the student to the used equipment yard. Ask each individual student to
locate a Product Identification Number plate on a machine and show the sales
model number and serial / product identification number. If possible, also review
how other manufacturers identify their product.
A Caterpillar product Identification plate is in Figure 33 for reference.
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3 Identify Part Numbers
Topic

Introduction.......................................................................................................................................................................... 48
Identify Parts/Accessories from Parts Book Manual. ................................................. 48
Part Number Format.................................................................................................................................................. 49
Arrangement Numbers.......................................................................................................................................... 50
Group Numbers................................................................................................................................................................51
Assemblies............................................................................................................................................................................ 53
Parts Book Layout........................................................................................................................................................ 55
Sectioned Drawings................................................................................................................................................. 60
Retrieval of Parts Information. .....................................................................................................................61
NPR – Numerical Parts Record. ................................................................................................................ 67

Introduction
This learning outcome will introduce the students to the various methods,
which are used in industry to identify the correct part numbers of the parts or
accessories.
It will cover the hard copy parts manual and electronic means of identification of
parts. Also included is a section on the use and maintenance of the microfiche
viewer.
The parts identification systems in use by Caterpillar will be used for completion
of this unit.
Identify Parts/Accessories from Parts Book

Manual
The following graphics are taken from a Caterpillar 793C parts manual. The
format used in the graphics is the current computer generated format, which
will apply to all future parts manual. The previous parts manuals have the same
content however, the format is slightly different.
Figure 34
The front cover of the parts manual (Figure 34) provides essential top level
information. To review, 793C is the sales model number. ATY-1 up is the Product
Identification Number 7TR830-up is the Serial Number of the engine, 4GX1-up is
the Serial Number of the transmission, and 3KT1-up is the Serial Number of the
Torque Converter.
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A review of the Serial/Product Identification Numbers will show that for example
7TR is the prefix, and 830 is the number of a specific engine. Because the
number starts at 830, this means that there were significant engineering
changes made to the engine and engine number 830 was the first engine to
contain the changes.
Part Number Format

There are many different formats used by manufacturers for part numbers and
they will not all be discussed totally in this topic.
The early part number format for parts used in the Caterpillar system were as
follows:
 4X-5467
The part numbers in this sequence all had the same format. That is, the first digit
is always a number, the second digit is always a letter, there is always a hyphen
after the letter and there are always four numbers following the hyphen. The
first number in the sequence is 0A-0001 and the last number in the sequence is
9Z-9999. A single part number is only ever used once to identify a specific part.
Even when the part is discontinued, the part number is also scrapped.
Unfortunately, Caterpillar used all of the different combinations in this simple and
consistent system and as a result had to develop a new format.
The new format is 125-5678. There are always three numbers followed by a
hyphen, which is followed by four numbers.
Therefore, as the parts book is examined, both conventions will be seen. Unlike
some manufacturers, the part number formats used by Caterpillar have no
other use other than to identify parts. In other words, it is not possible to tell
from the part number which component a part belongs to or where the part is
manufactured.
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Arrangement Numbers
Machine Arrangement
170-3613 Chassis AR
Pin ATY1-UP
Part of 170-3593 Common AR-Truck
Figure 35
Arrangement Numbers
Underneath the Product Identification Number, there is an order of seniority for
the terms.
An arrangement number is a top level description for a machine or major

component. The arrangement number has the same format as the part number
and an arrangement usually contains a collection of groups and sometimes
other arrangements.
An example of an arrangement is chassis arrangement, which in the case of the

793C, is part of the host Common arrangement – truck.
Optional attachments can be arrangements or groups. Example, the 793C has

a different chassis arrangement to meet the standards of the European market.
The desired consist of a particular machine is ordered originally by the selling
dealer and is normally recorded by the servicing dealer if this is a different
company. In any case, the consist of a machine, including all attachments needs
to be known, before the correct parts can be supplied.
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Group Numbers
Power Train
7T-4887 Screen GP-Magnetic-Transmission
S/N 4GX1-UP
Part of 9U-9822 Transmission AR
Figure 36
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Group Numbers
A group is a collection of individual parts or assemblies, which make a
component. The group is usually the component. A machine is built from a
collection of groups, which can also be attachments.
All group numbers have the same identification format as parts and it is not
possible to determine whether the item is a group or a part from the actual
number.
Examples of groups are:

 Steering pump
 Engine alternator
 Engine cylinder head
 Hoses for the transmission or hydraulic system which are called lines groups
 Access ladder for the machine, the electrical wiring which are wiring groups
or lighting groups.
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Assemblies
Hydraulic System
118-5081 Actuator GP-Pilot Control-Hoist
PIN ATY1-UP
Part of 147-0997 Valve GP-Control
Figure 37
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Assemblies
Assemblies are at a lower level than groups and always contain more than one
part. The assembly could be serviced as a complete item or the parts within an
assembly could be serviced separately.
Note from the graphic of the actuator group. This contains a 122-5874 Solenoid
assembly.
The complete 122-5874 Solenoid assembly is serviced, however if required,

the user can purchase the individual parts which are indented. These are the
serviced parts which are part of the solenoid.
Examples of assemblies are:

 housing, which contains a pressed in bearing, is an assembly, and is called
A
‘housing as’
 A plate which contains nuts welded to it on is called a ‘plate as’
 A valve which contains a wiring connecter is called a ‘valve as’.
Part Number
The part number is the lowest level and is usually a single item. A part can be
large or small, for example a bolt or nut will each have a different part number,
and a very large gear or housing will also have a part number.
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Parts Book Layout
Table of Contents
Figure 38
The table of contents (Figure 38) is at the front of the book. The table of contents
lists the groups under the various system headings and the page number for the
group.
When searching for a part number, and the group description is known, then
using the table of contents is the easiest way to find the page number for the
group which contains the part number.
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Maintenance Parts
Figure 39
The parts book contains a separate list of maintenance parts (Figure 39) as
these parts are normally high usage items and frequently requested.
The maintenance items are listed under the system where they are used, the
group they are used in, and show quantities in the group and the page number.
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Part Number Index
Figure 40
The parts book also contains a part number index, which is located at the rear of
the book.
If the part number is known, then the page numbers, which contain the part
number, can be identified.
Note from Figure 40, that a single part number can be used in many different
groups.
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Lubrication System
106-9873 Pump GP-Engine Oil

S/N 7TR830-UP
Two Section Gear
Part of 175-5293, 187-4593, 187-4594, 187-4595 Engine Air Attachment
Figure 41
The page layout of the parts book is shown. The system which contains the
group is shown at the top of the page. In this case the system is the lubrication
system, the group is the 106-9873 Pump Group – Engine Oil, the serial number
of the engine is shown underneath, and the arrangement number which contain
the pump group are also shown.
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The SMCS code numbers in the box are part of the service management control
system which is a classification system for components.
There is various information available in the part number list.
The first column is for any note codes, which relate directly to the individual
parts. The description of the note code is listed underneath the column. In cases
where the parts list for a group number contains another group, note Y is listed
and the page number, which shows the list of parts in this group is shown in the
column at the far right hand side under the heading ‘see page’.
The second column shows the reference number of the part on the drawing
which is either underneath the parts list or in the case of large parts lists, on a
separate page. The third column contains the number of the graphic reference
where the part is shown.
The fourth, fifth and sixth columns contain the part number, the quantity of the
part used in the group, and the part name.
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Sectioned Drawings
Fuel System
8X-2570 Fastner GP-Fuel Tank-3790L (1000GAL)
PIN ATY1-UP Part of 131-7953 Tank and Filter AR-Fuel
An Attachment
Figure 42
Some group illustrations show sectioned drawings or alternate views in the

group to improve clarity. When a section or alternate view is shown, designations
such as VIEW OF AREA A or VIEW B-B are used.
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The graphic shows such an instance. VIEW B-B is a view of the fuel tank
mounting looking at the right hand side of the fuel tank and from the right
hand direction. VIEW C-C is a sectioned view of another part of the fuel tank
mounting. VIEW OF AREA A is a close up view of the mud flap around the fast
fill nozzle.
Retrieval of Parts Information

Many manufacturers use electronic options for identification and retrieval of
part number information. There are also numerous software suppliers who will
convert a parts book for access by computer. Caterpillar uses SIS (Service
Information System), which is available either through the Caterpillar Internal
Intranet System or via DVDs, which are updated every month.
For this section, the intranet system is used.
To access the Caterpillar SIS, a computer with an SIS-compatible browser (i.e.

supports the https (hypertext transfer protocol – secure) protocol), an SIS login
ID and password are required.
Figure 43
Figure 43 shows the entry screen to the SIS Web system. The system has many
uses but only the system for finding parts is discussed in this lesson. Two basic
methods of retrieving parts information will be discussed.
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The first method requires that the serial number prefix of the primary product is
known and is entered into the serial number box. (This serial number is in fact
the product identification number as discussed in Topic 1).
Having entered the serial number (PIN) prefix, then the parts search field can
be used to search. If the number of the part required is known, then this can be
keyed directly into the field. If the part number required is not known but some
information about the part is known, then a keyword search can be completed.
In the example above, what is known is that the part required is a water pump
somewhere on the machine, which has a serial number prefix of ATY.
When the search key is pressed, the next screen is visible.
Figure 44
All of the pump groups which are listed for the 793C sales model machine,
with PIN of ATY are listed. To progress further the user needs to know which
particular pump group the required part belongs to.
By clicking on the required pump group, the parts list is then displayed as
shown. In this instance the 152-1029 Drive GP-Auxiliary has been selected.
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Figure 45
This list on the screen normally has the picture of the group above the list of
parts. The parts list is the complete list of parts which are contained in the group
which has been selected. The size of the pictures can be selected by clicking
and dragging the line between the graphic and the parts list.
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BUS002
Figure 46
Similarly, when searching for the parts book illustration when the part number is
known, enter the part number in the field and enter the PIN for the machine in
the serial number field.
Figure 47
The part number selected is used in more than one group. The search will show
all of the groups, which contains the part number selected under the system
headings for the groups. The required group can then be selected.
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Figure 48
It is also possible to search for part number information by doing a document

structure search. Click the Document Sutructure button and the next screen
appears.
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Figure 49
Then click on the Parts Identification and search in the appropriate areas in the
right section of the screen.
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NPR – Numerical Parts Record

The electronic parts book page shows an indicator NPR next to the empty box
which is next to the item number.
The Caterpillar Numerical Parts Record is a separate master database, which

relates to part numbers.
Figure 49
The database contains both essential and useful information. For example, the
weight of the part is shown, along with the engineering change number. There
are also three columns of information in a table.
The first column shows the part name. The part number listed underneath the
part name, is the part number of a previous part, which has been replaced by
the new one. Any earlier part numbers, for the same product, will appear in this
column.
 he second column shows the part number or numbers which are used to
T
service the item required. Sometimes, a group or part will appear in the parts
book and this is not serviced. The serviced part number is shown in this
column. Sometimes a part number is released initially and later serviced by
two different part numbers or the number may change. This column will also
show the reference to any service related information about the part when
this exists.
 The third column shows the group numbers, which the particular part number
is used in.
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Caterpillar

Published by Caterpillar of Australia Pty Ltd.

Version 4.0, 2005

Copyright © 2005 Caterpillar of Australia Pty Ltd. Melbourne, Australia.

 Caterpillar engineers and instructors

C aterpillar L iterature – BUS002

Included In This Section:

Caterpillar L iterature – BUS002

Module Number: BUS002

Module Name: Caterpillar Literature

2. Media, demonstration and practical facilitation, given:

3. Estimated time of delivery – 10 hours

4. Classroom and Workshop Environment

7. Recommended maximum student/teacher ratio:

8. Resources for Student:

Learning Outcome 1 Identify and use common Caterpillar service literature

At the completion of this learning outcome, students should be able to:

Attainment of the performance is confirmed if the student can:

1.1 Identify Caterpillar media and publication types:

Learning Outcome 2 Identify the number systems used by Caterpillar for

At the completion of this learning outcome, students should be able to:

Attainment of the performance is confirmed if the student can:

2.1 Explain terminology used by Caterpillar to identify products

2.3 Locate Serial / Product Identification Plate on a machine

Learning Outcome 3 Use the Caterpillar Parts Identification System to

At the end of this learning outcome, students should be able to:

Attainment of the performance is confirmed if the student can:

3.1 Identify parts/accessories from the Parts Manual

Included in this Topic:

Caterpillar L iterature – BUS002

All engine and machine manufacturers produce material in a wide range of

Basic Reference Publications

Types of publications available are:

Types of publications available are:

Types of publications available are:

The service manual (Figure 2) is the basic reference source for:

Service Manuals are broken into sections:

Adjustment data available:

Fuel Settings are available in the following media:

Guidelines for Reusable Parts

Each guideline (Figure 4) is published on a single subject and includes detailed

Information about cleaning, measuring and reconditioning parts is also included.

Guidelines for Reusable Parts are available in the following media:

Information that Parts Manuals provide:

Operation Maintenance Manuals

The operation and maintenance manual (Figure 6) describes operation and

Information that the Operation Maintenance Manual provides:

1. Dealer Service Tool Catalogue (Figure 7), includes information on specialist

2. Shop Supplies and Hand Tools (Figure 8) includes information on warranty,

One Safe Source

One Safe Source (Figure 9) lists genuine Caterpillar service parts.

One Safe Source is available in the following media:

Preview (Figure 10) is a monthly publication that announces new or revised

The memorandum-style newsletter is broken into different market segments and

Blue: Service Information

Red: Engine Marketing

Green: Parts and Service Marketing

Yellow: Machine Marketing

Previews are available in the following media: