Procedures for Using the 120-9143 Cylinder Washer Tank Group {0374, 0602, 0680, 0738} Caterpillar

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Introduction

Important Safety Information

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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.

General Information Section

Introduction

This Tool Operating Manual discusses how to use the 120-9143 Cylinder Washer Tank Group to clean the bores of honed or contaminated cylinder tubes.

While honing is an important reconditioning step, honing introduces an enormous quantity of abrasive particles into the cylinder tube. Because hydraulic systems are becoming increasingly sensitive to contamination, thoroughly clean all cylinder components before assembly or installation. Particles as small as 30 microns (1 micron = 1,000,000th of a meter) in hydraulic oil act as a fine grinding paste. Particles prematurely wear out parts, resulting in loss of efficiency and performance of hydraulic systems.

As designed, the washer is a companion tool to the 5P-8595 Honing Tool Group , 9U-6463 Hone Group , or similar cylinder hones. The filter paper used in the washer will remove particles larger than 25 microns in size. The washer should also be used on any cylinder that has been disassembled or overhauled.

Illustration 2	g02799199
Locate The Cylinder Tube Washer at The End Of The Cylinder Hone

The washer brush is used in a horizontal position at the end of a cylinder hone. Position the washer tank so there is enough space at the end of a cylinder hones barrel cradle stand to stroke the full length of a long cylinder tube.

Additional Contact Information

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

Tooling for Complete Cleaning System

The 120-9143 Cylinder Washer Tank Group consists of a cleaning solution holding tank and an air powered pump. To create a complete cylinder tube cleaning system, a dealer must have the parts listed in Table 1.

Illustration 3	g02799200

Illustration 4	g02799201

Brush and Rotating Arbor (Tube) Assembly

Illustration 5	g02799205
Arbor (Tube) and Brush Nomenclature (3a) Brush Head (3b) Nozzle (3c) Retaining Ring (4) Brush (5) Arbor Tube

Illustration 6	g02799206
Arbor and Union Assembly Nomenclature (2a) Pipe Coupling (2b) Union (2c) Pipe (2d) ON/OFF Valve (2e) Quick-Disconnect Coupling (2f) Quick-Disconnect Nipple (5) Arbor Tube (6) Pneumatic Drill

1. From Table 1, select brushes (4) that exceed the cylinder bore size by more than 50 mm (2.0 inch). If brush size is not available, use shears or a utility knife to trim the bristles to fit the inside diameter of the cylinder tube.

2. Assemble six brushes (4) onto brush head (3a) using retaining rings (3c) at both ends.

   Note: If the brushes do not slide easily into the slotted head, check to see if slots are tapered.

3. Make sure that six nozzles (3b) are screwed tightly into the brush head.

4. Thread assembled brush head onto one of the listed arbor tubes (5) .

5. Thread the other end of arbor tube (5) into pipe coupling (2a) .

6. Thread the assembled arbor onto the male pipe adapter on union (2b) .

7. Assemble the short length of pipe (2c), the ON/OFF Valve (2d), and the Quick-Disconnect Nipple/Coupling (2e), (2f) into the union assembly.

8. Select a drive motor to rotate the brush head, such as a 171-5688 Pneumatic Drill . This drill is an extra heavy-duty, variable speed unit with a 13 mm (0.5 inch) Jacobs® chuck. The drill runs at 500 rpm using a 1/2 hp high-torque motor. Many other types of air drills will work as well in this application.

If Using Hand Brushes

If optional hand brushes are used to clean a cylinder bore, a 135-7643 Nozzle Adapter (1) is required to attach the brushes to the arbor tube. The nozzle adapter installed in place of the 120-9146 Brush Assembly . Select the appropriately sized brush, based on the cylinder bore size, from Table 2. When using this method, set the pressure regulator between 68 to 103 kPa (9.9 to 14.9 psi) (do not run at higher pressures).

Note: The diameter of a hand brush should not exceed the bore diameter of the cylinder by more than 50 mm (2.0 inch).

Illustration 7	g02799210

1. To use the 135-7643 Nozzle Adapter , cut the twisted wire handle off bottle brush (2). Allow approximately 50 mm (2.0 inch) of wire handle to remain.

2. Slide the twisted wire handle into nozzle adapter (1) .

3. Use two 4B-9808 Setscrews (3) [1/4-20 x 12 mm (0.47 inch) long] to hold the brush in place.

Startup Preparation

1. Raise the screen assembly and fill the tank with 40 to 46 cm (15.80 to 18.1 inch) of clean water. Add a water-based cleaning solution to the water to aid in the cleaning performance of the washer.

2. Slide the 6V-1986 Support Tube through a roll of 120-9150 Filter Element (paper) and put into brackets on the tank.

3. Pull a length of paper across the steel paper support tray. Position the paper so all of the cleaning solution will filter through the paper before draining back into the tank.

4. Lower the screen assembly and position the cylinder tube washer at the end of the cylinder hone.

Operation

1. After the cylinder has been finish honed, rotate end-for-end on the rear of the barrel cradle stand.

2. Cap the port at the closed end of the tube with heavy-duty tape, bolt-on plate, threaded plug, or similar method.

3. After cleaning, use a V-bock from the barrel cradle stand, or a block of steel or wood to elevate the closed end of the cylinder. Elevating will make sure the cleaning solution easily drains from the cylinder .

4. Secure the cylinder in place using nylon straps to prevent the cylinder barrel from rotating. Position the cylinder to extend over the end of the stand 150 to 300 mm (5.9 to 11.8 inch).

5. Position the washer tank against the end of the stand and lock the casters in place.

6. Position the splash shield over the end of the barrel.

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NOTICE
The pump on the tank washer is wired for 110 V. Using any other voltage without changing the motors wiring, will result in motor damage. Refer to Section ""Wiring" " in this manual for detailed instructions on converting the motor to 220 V.

7. Plug the tank power cord into a suitable 110 V outlet. Refer to ""Wiring" " Section, in this manual for wiring variations between the United States and other locations.

   Note: The correct draw of the motor will require a 30 Amp breaker in the circuit.

8. Make sure that valve (2d) is in the "OFF" position.

9. Insert the brush head into the cylinder. Turn the pump ON to start the flow of solution.

10. Open valve (2d). Start the air drill and adjust the speed so the brush head runs smoothly. Stroke the brush through the entire length of the cylinder.

11. Cleaning will be accomplished in 1-2 minutes, if the brushes are the correct size and the solution is the correct concentration.

12. Turn OFF the drill and the pump. Remove the brush head from the cylinder.

13. After the solution has drained from the cylinder, use a white cloth or paper towel to wipe across the surface of the bore. The cylinder is "clean" when the towel is not discolored after being wiped through the bore. Repeat washing and brushing the cylinder until a clean towel is not discolored.

Wiring

Cylinder washers sold in the United States are for operation with 110 V. Cylinder Washers are equipped with ground fault interrupters (GFI) to minimize the chance of electrical shock.

Depending on Voltage requirements, the motor that powers the pump can be rewired to 220 V. Currently available GFIs cannot operate on 220 V. The GFI must be removed from the circuit on any 120-9143 Cylinder Washer Tank Group wired for 220 V operation.

To change the Voltage requirement of the motor, refer to the wiring diagram on the outside of the motor and the following illustrations. The GFI must be removed before the motor is rewired for the higher Voltage.

Also, installation of a ground strap installed between the motor case and washer tank is recommended. Refer to the ""Ground Strap" " Section, in this manual.

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Illustration 8	g02799215
Wiring For 110 V Systems With Ground Fault Interrupters (GFI)

1. Unplug the cylinder tube washer, remove the cover from the electrical box, and place a lockout device on the electrical supply source.

2. Remove the two wires leading from the GFI to terminals L1 and L3 on the ON/OFF switch.

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Illustration 9	g02799217
The ON/OFF Switch Has Been Rewired For 220 V Operation And The GFI Has Been Removed

3. Remove the two black wires from the GFI and reconnect to the T1 and T3 terminals on the ON/OFF switch.

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Illustration 10	g02799220
Remove Cover and Change Wiring For 220 V Operation

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Illustration 11	g02799222
Wiring Diagram For The Motor On The Cylinder Tube Washer

4. Remove the motor cover plate and charge the wiring for 220 V operation by following the wiring diagram in Figure 11

Ground Strap

1. Unplug the cylinder tube washer, place a lockout device on the electrical supply source.

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Illustration 12	g02799227

2. Install a ground strap or cable between the motor case and a convenient location on the washer tank. Make sure that the connections are clean and free of paint.