Base-Mounted Recirculating Parts Washers{0374, 0599, 0680, 0699, 0700} Caterpillar

Base-Mounted Recirculating Parts Washers{0374, 0599, 0680, 0699, 0700}

Usage:

769C 01X

Caterpillar Products: All

Introduction

Important Safety Information

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Illustration 1	g02139237
Think Safety

European Union Compliant, CE marked

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.

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 Tool Operating Manual.

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" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of 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 warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. 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 and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

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Illustration 2	g02166423
Personal Protection/Important Information

Prohibited Action

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No smoking

Hazard Avoidance

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Crushing hazard (foot)

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Crushing hazard (hand)

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Pinch point

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Fire hazard

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Electrical Shock - Hazard

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Fire hazard

Safety Section

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Personal injury or death can result from escaping fluid under pressure.
Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE

To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills.

General Information

Introduction

The base-mounted recirculating parts washers are designed for indoor use with petroleum-based solvent in service, repair, and/or maintenance shops.

Base-mounted parts washers feature 14 gauge steel construction.
A 74° C (165.2° F) fusible-link closes the fire cover in the event of fire.
Recirculating solvent flexhoses are equipped with flow regulating valves.
A stainless steel drain assembly allows controlled drain-back of solvent.
Included in the optional three-stage filter kit is a polyester filter bag and an in-sink filter sock (for absorbing oil), which extends the life of the solvent.
A deluxe work lamp provides a well-lit work area.
A disposable plastic liner inside the base tank provides a convenient method of sludge removal during the tank cleaning process.

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Illustration 3	g02721699

Base-mounted recirculating parts washers with an optional external filter ensures a supply of clean, fresh solvent. Included in the three-stage filter kit is a polyester filter bag, externally mounted canister filter, and an in-sink filter sock (for absorbing oil), which extends the life of the solvent. The standard filter canister is 15 micron, and a 2 micron filter is also available.

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Illustration 4	g02721700

Base-mounted recirculating parts washers with the optional external filter attachment include: 4C-3874, 4C-3875, 4C-3876, 191-4964, 191-4965, and 191-4968.

Base-mounted recirculating parts washers without the optional external filter attachment include: 194-3988, 194-3989, 194-3990, 194-3991, 194-3992, and 194-3993.

Specifications

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Table 1
Filtered Parts Washer Capacity/Fire Rating
Part No.	Flow Rate	Fusible Link	Tank Capacity
4C-3874	1135 L/min (299.8 US gpm)	74° C (165.2° F)	114 L (30.1 US gal)
4C-3875	1135 L/min (299.8 US gpm)	74° C (165.2° F)	114 L (30.1 US gal)
4C-3876	1135 L/min (299.8 US gpm)	74° C (165.2° F)	132 L (35.1 US gal)
191-4964	1135 L/min (299.8 US gpm)	74° C (165.2° F)	114 L (30.1 US gal)
191-4965	1135 L/min (299.8 US gpm)	74° C (165.2° F)	114 L (30.1 US gal)
191-4968	1135 L/min (299.8 US gpm)	74° C (165.2° F)	132 L (35.1 US gal)

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Table 2
Filtered Parts Washer Electrical/Overall Size
Part No.	Volt	Hz	Size
4C-3874	115	60	81 x 56 x 25 cm (32 x 22 x 10 in)
4C-3875	115	60	122 x 56 x 25 cm (48 x 22 x 10 in)
4C-3876	115	60	122 x 71 x 36 cm (48 x 28 x 14 in)
191-4964	220	50	81 x 56 x 25 cm (32 x 22 x 10 in)
191-4965	220	50	122 x 56 x 25 cm (48 x 22 x 10 in)
191-4968	220	50	122 x 71 x 36 cm (48 x 28 x 14 in)

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Table 3
Unfiltered Parts Washer Capacity/Fire Rating
Part No.	Flow Rate	Fusible Link	Tank Capacity
194-3988	1135 L/min (299.8 US gpm)	74° C (165.2° F)	114 L (30.1 US gal)
194-3989	1135 L/min (299.8 US gpm)	74° C (165.2° F)	114 L (30.1 US gal)
194-3990	1135 L/min (299.8 US gpm)	74° C (165.2° F)	132 L (35.1 US gal)
194-3991	1135 L/min (299.8 US gpm)	74° C (165.2° F)	114 L (30.1 US gal)
194-3992	1135 L/min (299.8 US gpm)	74° C (165.2° F)	114 L (30.1 US gal)
194-3993	1135 L/min (299.8 US gpm)	74° C (165.2° F)	132 L (35.1 US gal)

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Table 4
Unfiltered Parts Washer Electrical/Overall Size
Part No.	Volt	Hz	Size
194-3988	115	60	81 x 56 x 25 cm (32 x 22 x 10 in)
194-3989	115	60	122 x 56 x 25 cm (48 x 22 x 10 in)
194-3990	115	60	122 x 71 x 36 cm (48 x 28 x 14 in)
194-3991	220	50	81 x 56 x 25 cm (32 x 22 x 10 in)
194-3992	220	50	122 x 56 x 25 cm (48 x 22 x 10 in)
194-3993	220	50	122 x 71 x 36 cm (48 x 28 x 14 in)

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

USA: 1-800-542-8665, Option 1International: 1-309-578-7372

Assembly Section

Assembly

After cutting two restraining straps and removing the lid from the shipping crate, inspect the contents.
Note: Contact the freight carrier to report any shipping damage.

If necessary, move the shipping crate to an open area to allow for unpacking and assembly of the parts washer.

Read the Operating Manual, NEHS0952, "Tool Operating Manual" to become familiar with components and assembly procedures.

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Illustration 5	g02721701
NEHS0952 Tool Operating Manual

Note: Report any missing parts or concealed damage to Dealer Service Tools.

Open the smaller cardboard container and remove base tank (3a) from the shipping crate.
Note: The base tank is heavy. Assistance will be required to remove it from the cardboard container.

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Illustration 6	g02721702
(3a) Base Tank.

Place the base tank on the floor, with room to work around it, in the location where it will be used. The front of the base tank is the side with the single hinge pin sleeve, as indicated by the arrow.
Note: If desired, install optional 4C-3898 Caster Set on the base tank.

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Illustration 7	g02721704

Open the large cardboard container and open the hinged fire cover on the tub weldment. Remove the small cartons from inside the tub weldment and close the hinged fire cover.
Note: If the parts washer is equipped with the optional filter kit, there will be two small cartons inside the tub. One carton will contain the standard hardware, and the other will contain the optional external filter parts (except the in-sink filter sock, which is packaged inside the tub weldment).

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Illustration 8	g02721705

Use a lifting device and slings with adequate capacity to lift the tub weldment from the cardboard container.

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NOTICE

The tub weldment is heavy. To prevent damage, make sure the lifting device and slings are capable of supporting the weight of the tub weldment and accessories.

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Illustration 9	g02721708

Set the tub weldment on two support stands capable of supporting the weight of the tub weldment and accessories.

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NOTICE

The tub weldment is heavy. To prevent damage, make sure that the support stands are capable of securely supporting the weight of the tub weldment and accessories.

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Illustration 10	g02721712

Open the small cardboard cartons and inspect the contents. Verify that the cardboard cartons contain all the required parts.
Note: Report any missing parts or concealed damage to Dealer Service Tools.

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Illustration 11	g02721714

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Illustration 12	g02721715
Hardware Parts Kit (included with all parts washers).

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Illustration 13	g02721716
Filter Kit (included only with parts washers having optional external filtration) Not included is the in-sink filter sock which is contained in the tub weldment.

Install lamp pole (5a) into the threaded hole at the rear of hinged fire cover (2). Tighten the lamp pole so the welded "W" faces forward.
Note: Make sure the "W" on the pole points forward and lines up with the keyhole in hinged fire cover (2) .

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Illustration 14	g02721748
(2) Hinged Fire Cover. (5a) Lamp Pole.

Open the hinged fire cover, and securely engage the fusible link in the keyhole in the center of the hinged fire cover.

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Illustration 15	g02721759

Install drain assembly (13) in the tub weldment.
1. Separate drain screen (12) and insert upper bowl (13a) into the bottom opening from inside the tub weldment.
1. From underneath the tub weldment, install rubber gasket (13b) and lower bowl (13c) over upper bowl (13a) .
  Note: Make sure rubber gasket (13b) is installed on the underside of the tub.
1. Hold lower bowl (13c) in place and install large nut (13d) to secure the lower bowl and rubber gasket in place. Tighten the large nut securely.
1. Install nylon gasket (13e) into the flanged opening of drain pipe (13f). Slide small nut (13g) over the drain pipe and install it onto the threaded portion of upper bowl (13a), as shown. Tighten the small nut securely.

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Illustration 20	g02721793

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Illustration 21	g02721799
(13a) Upper Bowl. (13e) Plastic Gasket. (13f) Drain Pipe. (13g) Nut (Small).

Install the optional polyester filter bag.
1. Remove and discard the tag from inside polyester filter bag (15). Install worm gear clamp (14) over the open end of the filter bag.
1. Slide the open end of the polyester filter bag over the drain pipe. Position the worm gear clamp so it is over the exposed threads above the small nut. Tighten the worm gear clamp securely.

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Illustration 23	g02721804

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Illustration 24	g02721805

Inspect the optional in-sink filter sock (part of the three-stage optional filter), and position it inside the filter sock housing bracket. If excess dust from in-sink filter sock (21) has accumulated in tub weldment (1) during shipping, a shop vacuum may be used to remove the dust, or it can be allowed to wash into the base tank when the unit is filled with a cleaning solution.

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Illustration 25	g02721808
(1) Tub Weldment. (21) In-Sink Filter Sock.

Solvent Pump Installation

There are two procedures to install the solvent pump, depending if the parts washer has an optional external filter. If the parts washer does not have an optional external filter, use the following procedure, Solvent Pump Installation Without Optional Filter. If the parts washer has an optional external filter, use the Solvent Pump Installation With Optional Filter procedure.

Solvent Pump Installation Without Optional Filter

Insert solvent pump (8) hanger into the bracket located on the bottom rear edge of tub weldment (1). Make sure the intake screen on the solvent pump faces in.
Note: The polyester filter bag is removed from the drain pipe for photographic clarity.

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Illustration 26	g02721810
(1) Tub Weldment. (8) Solvent Pump.

Install hose barb fitting (11) into the threaded opening next to the solvent pump hanger bracket and tighten securely.

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Illustration 27	g02721812
(11) Hose Barb Fitting.

Slide ear clamp (10) over solvent pump connector hose (9). Install the hose over hose barb fitting (11). Crimp the ear clamp to secure the hose to the fitting.

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Illustration 28	g02721814
(9) Pump Connector Hose. (10) Ear Clamp. (11) Hose Barb Fitting.

Route the solvent pump power cord to electrical box (27) on the side of tub weldment (1), and plug it into the lower outlet.

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Illustration 29	g02721816
(1) Tub Weldment. (27) Electrical Box.

Solvent Pump Installation With Optional Filter

Remove and discard ear clamp (10) and connector hose (9) from the hose barb fitting on solvent pump (8) .
Note: Do not damage the hose barb fitting on the solvent pump. The fitting will be reused.

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Illustration 30	g02721818
(8) Solvent Pump. (9) Pump Connector Hose. (10) Ear Clamp.

Install hose barb fitting (11) into the threaded opening next to the solvent pump hanger bracket and tighten securely.

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Illustration 31	g02721823
(11) Hose Barb Fitting.

Install the external filter connector hoses.
1. Slide ear clamp (10) over the end of filter supply connector hose (24a). Install the connector hose onto the solvent pump hose barb fitting. Crimp ear clamp (10) to secure the hose onto the pump fitting.
1. Slide ear clamp (10) over the end of filter return connector hose (24b). Install the filter return connector hose on the hose barb fitting installed in the bottom of tub weldment (1). Crimp the ear clamp to secure the hose onto the tub fitting.
1. Insert solvent pump (8) hanger into the bracket located on the bottom rear edge of the tub. Make sure the intake screen on the solvent pump faces in.

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Illustration 32	g02721826
(1) Tub Weldment. (8) Solvent Pump. (24a) Filter Supply Connector Hose. (24b) Filter Return Connector Hose. (10) Ear Clamp.

Loosen the bolt in the filter bracket indicated by the arrow. Install the filter bracket over the top edge of tub weldment (1) on the same end as the electrical box. Tighten the bracket bolt and locknut to secure the filter bracket onto the tub weldment.
Note: Do not completely tighten the bracket bolt. It will be tightened in a later step.

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Illustration 33	g02721829
(1) Tub Weldment.

Install the connector hoses on the filter head.
Note: First, make sure both swivel O-ring fittings are tight (completely seated) in the filter housing.
1. Slide ear clamp (10) over the end of filter supply connector hose (24a) and install it on filter head (23) inlet fitting, as shown. Crimp the ear clamp to secure the hose onto the fitting.
1. Slide ear clamp (10) over the end of filter return connector hose (24b) and install it on filter head (23) outlet fitting, as shown. Crimp the ear clamp to secure the hose onto the fitting.

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Illustration 35	g02721836
(10) Ear Clamp. (24b) Filter Return Connector Hose. (A) Inlet. (B) Outlet.

Install filter (25) onto filter head (23). Lightly lubricate the filter gasket with clean oil and tighten it.

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Illustration 36	g02721845
(23) Filter Head. (25) Filter.

Route the solvent pump power cord to electrical box (27) on the side of tub weldment (1), and plug it into the lower outlet.

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Illustration 37	g02721846
(1) Tub Weldment. (27) Electrical Box.

Fill the Base Tank

Insert plastic liner (4) into base tank (3a) so it conforms to the inside of the base tank. Fold the excess plastic liner over the top edge of the base tank.
Note: The front of the base tank has the single hinge pin sleeve. Position the base tank in the location where the parts washer will be used. Once the base tank is filled, it is very heavy and can be difficult to move. When positioning the base tank, allow room for access to the rear of the parts washer, once assembled.

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Illustration 38	g02721848
(3a) Base Tank. (4) Plastic Liner.

Fill the base tank with the required amount of solvent. Fill the base tank so the solvent pump will be completely submersed, once the tub weldment is installed.

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NOTICE

Running the solvent pump without fluid can result in damage to the pump. Make sure that the base tank is filled so the solvent pump will be completely submersed in the fluid during operation.

Install the Tub Weldment On the Base Tank

Use a lifting device and sling with adequate capacity to carefully lift the tub weldment assembly off the support stands and position it over the base tank.

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Illustration 39	g02721851

Note: If equipped with an external filter, it may be necessary to slide the filter head to the center to allow the sling to be secured under each corner of the tub weldment.

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Illustration 40	g02721852

Carefully lower the tub weldment assembly toward the base tank.

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Illustration 41	g02721857

Position the solvent pump's power cord into the small notch at the rear of the base tank. If equipped with an external filter, position the connector hoses into the notches at the rear of the base tank. Lower the tub weldment assembly into position.
Note: Make sure that the pump connector hoses are not pinched or twisted, which would restrict the flow of solvent.

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Illustration 42	g02721860

Align the hinge pin sleeves and install two rear and one front hinge pins (28) to secure the tub weldment to the base tank.

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Illustration 43	g02721862

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Illustration 44	g02721867
(28) Hinge Pin.

Remove the slings and lifting device. If equipped with an external filter, slide filter head (23) back into position near the rear corner of the tub weldment. Completely tighten the filter head bolt and locknut.

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Illustration 45	g02721871
(23) Filter Head.

Install Work Lamp Assembly

Remove the guard from the work lamp and install a 100 watt maximum, type A, bulb. Replace the guard.

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Illustration 46	g02721873

Note: The work lamp has a top mounted ON/OFF switch. This switch may be left in the ON position so that the lamp is ON whenever the pump is operating.

Install work lamp assembly (7) onto work lamp mounting stud (5b). Pull up on the black collar of the work lamp base while inserting it over the mounting stud. Release the collar to lock the lamp into position.
Note: Make sure the collar fully releases into the original position to lock the lamp onto the mounting stud.

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Illustration 47	g02721876
(5b) Work Lamp Mounting Stud. (7) Work Lamp Assembly.

Route the work lamp assembly electrical power cord to electrical box (27) and plug it into the upper outlet.

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Illustration 48	g02721878
(27) Electrical Box.

Final Assembly

Use plastic ties (not included) to neatly bundle and secure all the hoses and electrical cords to prevent chaffing and/or damage during use.

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Illustration 49	g02721879

Plug the electrical assembly power cord into a grounded power supply with the correct Voltage rating.

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Illustration 50	g02721880

Insert drain screen (12) into drain assembly (13a) .

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Illustration 51	g02721881
(12) Drain Screen. (13a) Drain Assembly.

Note: The drain screen allows solvent to flow through the drain assembly while helping to prevent large debris from entering the base tank.

Operation Section

Operation

Open hinged fire cover (2) and engage the fusible link attached to lamp pole (5a) into the keyhole in the fire cover.

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Illustration 52	g02721884

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Illustration 53	g02721886
(2) Hinged Fire Cover. (5a) Lamp Pole.

With the flex hoses directed into the tub weldment, open the flow regulating valves. Push the power switch to the ON position. The solvent should flow through the flex hoses. The unit is now ready for use.

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Illustration 54	g02721887

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Illustration 55	g02721889
(I) ON. (O) OFF.

Note: If the unit is equipped with an optional three-stage filter system, a filter sock is included to extend solvent life. To use this option, open the flow regulating valve for the filter sock while the solvent pump is running.

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Illustration 56	g02721890

Maintenance Section

Maintenance

Note: Fluid and filter replacement intervals depend on the amount of use. Proper replacement intervals will need to be identified for each base-mounted recirculating parts washer application. Use these guidelines as a starting point for a maintenance program.

Check the solvent level in the base tank frequently. Maintain the solvent level so the solvent pump is completely submersed.

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NOTICE

Running the solvent pump without solvent can result in damage to the pump. Make sure that the base tank is filled so the solvent pump will be completely submersed in the fluid during operation.

It is recommended the filter sock be replaced a minimum of once every six months, or more often if reduced solvent flow through the filter sock is apparent.

It is recommended the spin-on filter element (if equipped) be replaced a minimum of once every three months, or more often if reduced solvent flow through the flex hoses is apparent.

Replace the solvent at regular intervals, or when the solvent is contaminated and no longer effective. When replacing the solvent, always replace the polyester filter bag and base tank plastic liner.

Note: Always dispose of all fluids, solid waste, and filters in accordance with local, state, and federal regulations.

Parts Section