General Cleaning Methods {1000, 7000} Caterpillar

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Introduction

© 2016 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

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Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you d for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Show/hide table

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

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This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Improving Cleaning Efficiency

There are many ways of increasing cleaning efficiency in a parts cleaning operation. Time can be minimized by designing racks and baskets to use all the space available in a parts washing system. Saving space can include designing and building multiple-level parts baskets. Wash baskets can be used for parts storage reducing handling time.

When cleaning chemicals are worn out or not used at the proper concentration, cleaning time can be greatly increased because you may need to wash the parts multiple cycles.

Design

The size and design of baskets and racks are significant factors when evaluating cleaning efficiency. Using multiple level baskets will increase efficiency by eliminating unused space inside the parts washer.

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Typical rack and basket design. All the baskets have wire mesh sides, bottoms, and tops to allow water to flow through the baskets and onto the piece parts. (1) Single basket (2) Multiple layer basket

The following is an example of how to improve time efficiency:

1. A typical large cabinet washer can have a 1.5 m (5 ft) diameter table with a height limitation of 1.8 mm (72 in).

2. Typical 3500 Engine rebuilds require the use of 12 baskets which are 1.2 x 0.9 x 0.9 m (4.0 x 3.0 x 3.0 ft) to clean all parts. Each basket has a cleaning volume of 0.97 cubic meters (36 cubic feet).

3. Loading and cycle time must also be considered. For this example, a 20 minute wash cycle will be used. Another factor to consider is it takes an extra 5 minutes to load and unload each basket from the parts washer.

4. Loading and unloading the baskets and clean all the parts described in Steps 2 and 3 requires 5 hours.

5. Changing the design of the baskets to have multiple levels will reduce the number of baskets to eight and still clean all the same 3500 parts.

6. Loading and unloading the baskets and cleaning all the parts that are described in Step 5 requires 3.3 hours.

7. This results in a 1.7 hour cleaning time reduction per engine rebuild. It does not take long to pay for the cost of designing and building new wash baskets at this rate of savings.

   Note: The actual rate of savings will vary depending upon the basket design and the size of the components being rebuilt. Cleaning efficiency improvements can also be achieved for power train components, however the basket design will be different.

Wash Baskets and Storage Racks

If wash baskets can also be used as storage racks, double handling of piece parts can be eliminated. Double handling occurs when parts are placed into the wash basket, removed, and then placed into storage racks. The parts are then removed again for assembly.

If the wash baskets are also utilized as storage racks, the intermediate step can be eliminated. Refer to the following example.

1. A typical 3500 Engine rebuild requires the use of eight multiple level baskets to clean all the components.

2. It takes 10 minutes to unload all the components from one basket onto a storage rack.

3. Unloading all the baskets in Steps 1 and 2 takes 80 minutes (1.3 hours).

4. If wash baskets that are also storage racks are used, the 1.3 hours of parts handling time per engine can be eliminated. Only the parts that will require removal from the baskets are the parts that need to have gasket material removed while still hot.

Basket and Rack Unloading

Utilizing baskets and racks during cleaning operations can be a good investment, if the baskets are efficiently designed for the desired operation. However, the baskets will not return full value if not utilized correctly. How baskets are best used can vary with your choice of cleaning process and equipment. The following suggestions will help get the maximum return from the investment:

1. Locate the baskets and racks so that the disassembler can sort parts as the parts are removed from the component. This will help reduce multiple handling of the same piece parts.

2. Parts that are worn out, broken, or unrepairable parts should immediately be put into a scrap tub unless the parts are needed to support a claim or be shown to a customer. If scrap parts need to be saved, then the parts should be placed in a "hold" basket and properly tagged. This will ensure that scrap parts are not being washed which will reduce chemical consumption.

3. Separate aluminum parts from steel, iron, or non-metallic parts.

4. Load baskets and racks loosely so that the cleaning solution can contact all surfaces. Surfaces touching each other in a basket or rack will not be cleaned properly or will not be cleaned at all.

5. If parts are cleaned in a cabinet washer, locate the parts so that the dirtiest side of the part is facing toward the outside of the basket. Parts on the outside of the rack or basket will be closest to the spray orifices and will be flooded with the most cleaning solution.

6. Do not wash all loads for the same length of time. When possible, sort the components into different wash racks or baskets by relative dirtiness ( internal aluminum parts, internal ferrous parts, heavily soiled aluminum parts, and heavily soiled ferrous parts).

7. Wash small parts together with related large components, especially fasteners. Small baskets with lids can be placed inside larger racks and baskets. Avoid large containers of fasteners unless the container is segregated and labeled for fastener location or use. Time can be wasted searching through large fastener baskets for the correct fasteners if the basket is not segregated and labeled.

8. If a component with many right and left side parts is being disassembled, keep the parts from the two sides separate. Keeping the parts separate will avoid confusion and wasted time sorting parts later.

9. Wash all components that need repairs together. After cleaning the parts can be shipped to the appropriate repair area immediately.

   Note: Inspect baskets, lifting devices, storage racks, and all other related equipment for damage and repair before use.

Cleaning Solutions

Using the correct chemical concentration is an important factor in controlling the cleaning efficiency of a cabinet washer or any other cleaning process that uses a chemical to clean parts. Refer to the following example:

A 3500 Engine rebuild requires the use of eight multiple level baskets to clean all the components. The cleaning cycle time of the cabinet washer is 20 minutes. An extra 5 minutes is needed to load and unload each basket from the cabinet washer. The cabinet washer has the correct amount of cleaning agent as specified by the chemical and equipment manufacturers. To load, unload, and clean all the baskets , takes 200 minutes (3.3 hours).

Now consider the following two inefficient scenarios

Scenario #1

• Multiple level parts baskets are used and the washing procedure has consumed or has an insufficient amount of cleaning agent.

• When the cabinet washer is opened after cycling, the parts are not clean.

• The operator cycles the cabinet washer again because the parts were not clean after one cycle.

• Two wash cycles per basket to clean the components.

• Loading and unloading the baskets and cleaning all the parts described above takes 360 minutes (6.0 hours).

• Cleaning takes longer with the multiple level baskets than it did with the single baskets. This example was used to demonstrate the need to manage the cleaning equipment even after new cleaning baskets are purchased or fabricated.

Scenario #2

• The multiple level baskets are not used and 12 baskets are needed to clean all the 3500 Engine components.

• The cleaning times and chemical condition remains the same from Scenario #1.

• Loading and unloading the baskets and cleaning all the parts described above would take 540 minutes (9.0 hours).

The result of insufficient cleaning solution in either scenario is more time spent washing parts, resulting in decreased dealer profits.

Manual Cleaning Solution Alternatives (Solvent Cleaning)

Check with your local governing bodies before using any of the following parts washing alternatives.

The following parts washing systems are adequate alternatives. The employee health and safety, cost, and environmental requirements of each should be considered before making a selection.

Solvent cleaning may result in hazardous waste due to flash points or contaminants. Refer to all local, state, federal, and other applicable environmental laws and regulations.

Note: Use all Personal Protective Equipment (PPE) and controls to ensure employee health and safety. Refer to all local, state, federal, and other applicable safety laws and regulations.

Solvents may also be recycled using a Finish Thompson solvent recycler (vacuum distillation). Contact the Caterpillar Service Technology Group for more information about vacuum distillation and Finish Thompson solvent recyclers. Regardless of the method, solvents must be separated from waste water discharge.

Note: For a complete list of suppliers, telephone numbers, and addresses refer to Reuse and Salvage Guidelines, SEBF8356, "Introduction to the Cleaning Guide".

Before Paint Cleaning

The following are cleaning alternatives for equipment and components before painting. Each method should be evaluated for cost and environmental requirements before selecting a method.

1. Remove only dirt and oils

   1. Manual clean. Refer to Shop Review, SEBF8358, "Initial Cleaning Area"

2. Remove paint and rust.

   1. Shot blast with sand grit

   2. Shot blast with steel grit

   3. Use Armex Blast Cabinet which can be operated wet or dry. For further information contact Caterpillar Service Technology Group.

   4. Use dry ice blasting system. Dry ice evaporates quickly, reducing waste materials and leaving behind only paint and rust flakes. Also, bearing and seals are not contaminated with an abrasive grit.

Note: Used steel grit can be sold or given to asphalt companies to be used as filler material, reducing the volume of disposable waste.

Miscellaneous Cleaning Methods

Asphalt Removal

1. Presoak with diesel fuel or Hydrosolv 4165. Clean the component with a high-pressure wand washer. All of the run off must be contained and collected.

2. Dry blast the area with the Armex Blast Cabinet (for more information, contact Caterpillar Service Technology Group.

Decal Removal

1. Steam or hot air gun.

2. 3M decal remover disk.

3. Use a spray-type paint and decal remover and hand scrape.

Concrete Removal

1. Presoak with mild acid cleaner, then clean with a high-pressure wand washer.

2. Wet or dry sand blast the component.

3. Dry blast the area with the Armex Blast Cabinet (for more information, contact Caterpillar Service Technology Group).