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

Caterpillar Products

All

Engine Generator Set

3500 Series

Introduction

European Union Compliant, CE Marked

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

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.

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

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 is responsible for ensuring that the procedures used are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

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Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understand the operation lubrication, maintenance, and repair information.

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

Whenever a question arises regarding your service tool or this publication, contact the Global Dealer Solutions Networkhotline at:

Safety Information

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. The operator should also have the necessary training, skills, and tools to perform these functions properly.

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

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Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Safety Signal Words

The following safety signal words can be found throughout this publication. Review the image below to understand the severity of bodily harm that can occur during certain operational steps. Refer to "ANSI Z535.1-2002 - American National Standard For Safety Color Code" and "ANSI Z535.6-2011- American National Standard - Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials"for more information.

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Tool Image

There are specific safety messages on this tool. The exact location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety messages.

Make sure that all the safety messages are legible. Clean the safety messages or replace the safety messages if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to fall.

Replace any safety message that is damaged, or missing. If a safety message is attached to a part that is replaced, install a safety message on the replacement part. Any Catdealer can provide new safety messages.

Do Not Operate

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Warning - Do not operate or work on this machine unless you have read and understand the instruction and warning in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact and Cat dealer for replacement manuals. Proper care is your responsibility.

Crush -Hand

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Warning - Crush Point/Stay Clear

Mandatory Action and Personal Protection Identification

The personal protective equipment symbols shown in this section are all not used with this tool. Read and understand the manual fully to know which personal protective equipment should be used during tool operation. Always use the appropriate personal protective equipment when operating the tool.

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Product Safety Information

General Safety Hazards

• Read and understand this and all other manuals before installing, operating, repairing, maintaining, or working near the machine.

• Only trained operators should install, adjust, or use this tool. Do not allow unauthorized personnel to operate tool.

• It is your responsibility to make this information available to others that will operate this product.

• The warnings given in this manual are for identified hazards that are foreseeable in the general use of this tool.

• Never use a tool that has been damaged or is malfunctioning.

• Do not modify the tool, safety devices, and accessories. Doing so will increase hazards to the operator and others.

• Perform preventative maintenance on the tool regularly. Keep tool clean of fluids, grease, dust, and debris found around the workspace.

• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment.

Crushing and Cutting Hazard

• The work tool can become unstable if not stabilized properly when bumped.

• Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks.

• Moving parts are found on this tool, keep hands, fingers, and loose clothing away when tool parts are in motion.

• Use of the tool can expose the operator hands to hazards, including crushing, impacts, cuts, abrasions, and heat. Wear suitable gloves to protect your hands.

• Personal injury or death can result from improper use of this tool and from improperly supporting and bracing of the load.

• Do not work under any supported load.

• Stand a safe distance back when lifting load.

General Safety Rules

1. Follow all safety codes, and the Occupational Safety and Health Act (OSHA).

2. Stand on a dry surface when operating the parts washer.

3. Make sure that your power source is a standard 12 Volt DC. If a new circuit is required, installation should be done by a licensed professional. A grounded two-wire system is required.

4. Always wear eye, face, and hand protection when working with cleaning solutions. Use only recommended solutions.

5. Do not use solvents or liquids which have a flash point. DANGER! Using these may cause a fire or explosion.

6. Do not operate the machine without the fusible link intact.

7. Keep cover down when not in use.

8. Do not attempt to modify any part or function of the unit or to circumvent any of the safety features. Altering the equipment will effectively invalidate the warranty and could cause serious injury to the operator.

9. Read the entire assembly, set up, operation and maintenance guide before putting equipment into service.

10. Read all safety and warning labels on the machine exterior before beginning operation.

11. Dispose of spent sludge/solution only in methods approved by all local state and federal codes.

Introduction

The environmentally responsible Parts Washer (Part No 482-9831),(482-9832 - 220 Volt), (482-9830 - 12 Volt), uses a cleaning solution that is as effective as solvent-based chemicals. This minimizes maintenance effort and provides a satisfying experience and pleasant working environment.

The Parts Washer is easy to maintain and operate. This model has a reservoir of aqueous based solution. The solution is contained in the reservoir. As the pump circulates solution to the work area, it flows through the side-mounted filter. This filter will remove oil and debris. The filter bowl is clear to allow user to see when the filter element is dirty and needs replaced.

Solvent Based Parts Washer

General Information-Introduction

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

• Base-mounted parts washers feature 16 gauge steel construction.

• A 165° F fusible link closes the fire cover in the event of a fire.

• Recirculating solvent flex hoses are equipped with flow regulating valves.

• A stainless steel drain assembly allows controlled drain-back of solvent.

• 3-filter system for continuously clean solvent.

• A deluxe work lamp provides a well-lit work area.

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Cat Model Numbers 482-9824, 482-9825, 428-9826, 482-9827, 482-9828, and 482- 9829

Base-mounted recirculating parts washers with an optional external filter ensure a supply of clean, fresh solvent. Included in the three-stage filter kit are a clay filter bag, externally mounted canister filter, and an in sink solids filter to collect sludge, which extends the life of the solvent. The standard filter canister is 2 micron, an optional 15 micron filter is also available.

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Specifications

Assembly

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1. 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.

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

3. Read the Tool Operating Manual to become familiar with the components and assembly procedures.

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

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4. Open the smaller cardboard container and remove the base tank 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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5. Place the base tank on the floor, with room to work around it in the location where it will be used.

6. Open the large cardboard container and open the hinged fire cover on the tub. Remove the small cartons from inside the tub and close the hinged fire cover.

   Note: If the parts washer is equipped with the optional filter kit, there will be three small cartons. One carton will contain the parts tray with the optional filter mounted to it. The other Two contain the in sink solids filter to collect sludge, clay filter bag, hardware, and deluxe work lamp.

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

   Note: The tub is heavy. To prevent damage, make sure that the lifting device and slings will support the weight of the tub and accessories.

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8. Open the small cardboard cartons and inspect the contents. Verify that the carton contains all the required parts.
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   Cat No. 465-3516 Work Lamp Assembly

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9. Install lamp pole into the threaded hole at the rear of the hinged fire cover. Tighten the lamp pole so that the welded "U" faces the front of the parts washer. Also be sure it is lined up with the keyhole on the hinged fire cover.
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10. Open the hinged fire cover, and securely engage the fusible link in the keyhole in the center of the hinged fire cover.

    Note: The hinged fire cover weighs enough to cause personal injury if it accidentally falls shut. Always make sure that the fusible link is fully engaged in the keyhole.

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11. Install the filter bag/drain assembly by carefully setting it in the drain hole in the tub. (This allows easier removal for cleaning the filter bag.)
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12. Slide the open end of the filter bag (to collect sludge) over the drain pipe. Position the clamp so that it is over the exposed threads. Tighten securely.
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    Pump mounted with hose and clamp

13. Inspect the clay filter and position inside the Parts Washer tub. Connect hose to flex spout.

Solvent Pump/Filter Installation

1. Mount the solvent pump under the tub. Slide the hook at the end of the pump into the “U” bracket welded under the tub. Open “U” hook at end of pump.

2. Feed the hose coming from the pump, and pump electrical cable, toward the back slit in the tub (see above picture for slot location).
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3. Route the power cable to the right side of the tub, and plug into the outlet.
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4. Route the hose coming from the solvent pump to the left of the tub. It will be fed to the 15 micron external filter. However, first, the tray with mounted filter must be installed.
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5. To install the parts tray, simply secure it over the left side of the tub. Ensure it lines up with the securing pre-drilled hole, and the slots in the lid.

6. The parts tray is secured by a metal fold, which goes over the lip of the tub.

7. To ensure that the tub stays in the same position, use the included screw and two washers. Insert the screw through the parts tray into the pre-tapped hole in the tub.

   Note: The hardware parts kit includes two washers, one silicone and one metal. Ensure the metal washer rests on top of the silicone. This way there is no foreign matter from the tray leaking through.

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8. Now that the parts tray is secured to the tub, we can take the hose routed in step 4 to the intake of the external filter, securing it on the barb. The intake will be marked on the filter, in order to avoid confusion.
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9. using the included solvent hose, clamp one end to the output of the filter in the same way as step 7. Route the other end to the back of the tub, through the slot, and back under the tub.
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10. Take the end of the hose to the external filter output, and secure it with a clamp to the hose barb beneath the tub.
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11. Place the clay bag filter assembly into the Parts Washer Tub. Connect hose to metal flex spout.

Fill the Base Tank

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Base Tank with Plastic Liner

1. Set up the base tank in an open working area. Put plastic liner into the base tank so it conforms to the inside of the tank. Fold the excess plastic liner over the top edge of the base tank.

   Note: Position the base tank in the location where the parts washer will be used. Once the base tank is filled, it is heavy and can be difficult to move. When positioning the base tank, allow room for the tub and access to the rear of the parts washer, once assembled.

2. Fill the base tank with the required amount of solvent, ensuring that the solvent will be completely submerging the pump once the tub is installed.

   Note: Always follow the chemical manufacturer instructions for proper handling of solvent. If petroleum-based solvent is used, it must have a flashpoint of 140°F or greater, and be compatible with unit components. Solvent exposed to open sparks/flames, or spilled onto any hot surfaces or components, can cause personal injury or death.

Install the Tub

1. Using a suitable lifting device, and slings with adequate capacity, carefully lift the tub assembly off the support stands and position over the base tank.

   Note: The tub weighs enough to cause crushing injury if dropped. Always wear protective shoes and use care when handling the tub during assembly.

   Note: Ensure that the slot on the back of the tub matches up with the base tank slot. Otherwise, there will not be sufficient room for the pump tubes or electrical cords to be properly routed.

2. Lower the tub assembly onto the base tank. Be sure that both solvent pump tubes and the solvent pump power cord are not pinched, and are correctly placed in the slot at the back of the machine.

Install Work Lamp Assembly

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Hoses and cord through base slot

1. Install Work Lamp Assembly onto the mounting stud. Pull up on the black collar on the work lamp base while inserting it over the mounted stud. Release the collar to lock the lamp into place.
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   Note: Make sure that the collar fully releases to the original position to lock the lamp onto the mounting stud.

2. Route the Work Lamp Assembly power cord to the electrical box and plug it into the outlet.
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3. Use plastic ties (not included) to neatly and securely bundle all hoses and electrical cords, to prevent chaffing or damage during use.
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   Fusible Link attached to lamp pole

4. Plug the electrical assembly power cord into a grounded power supply with the correct voltage rating. The cord is located on the switch box mounted on the side of the tub.

5. Ensure that any remaining bubble wrap or packaging is removed from the machine.

Operation Section

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1. Open the hinged fire cover and engage the fusible link attached to the lamp pole into the keyhole in the fire cover.

   Note: To prevent fires, always keep the hinged fire cover closed when not in use. The fusible link must always be engaged when the hinged fire cover is open.

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2. With the flex hoses directed into the tub, open the flow valves. Turn the power switch to the "on" position. The solvent will now flow through the valves and flex spouts making the unit ready to use.

Maintenance

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

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NOTICE
Running the solvent pump without fluid will cause damage to the pump. Ensure that the base tank is filled with enough fluid to completely submerge the pump during operation.

1. Check the solvent level in the base tank frequently, ensuring the solvent pump is submersed completely.

2. It is recommended that the in-sink filter (to collect sludge) be replaced once every six months or more often if reduced solvent flows through the filter.

3. It is recommended that the external filter element be replaced a minimum of once every three months.

4. Replace solvent at regular intervals, or when the solvent is contaminated and no longer is effective.

   Note: Always follow the chemical manufacturer instructions for proper handling of solvent. If petroleum-based solvent is used, it must have a flashpoint of 140°F or greater, and be compatible with unit components. Solvent exposed to open flame/sparks, or spilled onto any hot surfaces or components, can cause personal injury or death.

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Parts Section for Base Mounted Recirculating Parts Washers

Warranty Form

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EC Declaration of Conformity

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