SEBF8357-11 (en-us)

06 May 2016

Reuse and Salvage Guidelines

i06693452 This Reuse and Salvage Guideline contains the

necessary information to allow a dealer to establish a
General Cleaning Methods parts reusability program. Reuse and salvage
information enables Caterpillar dealers and
SMCS Code: 1000; 7000 customers to benefit from cost reductions. Every
effort has been made to provide the most current
Caterpillar Products information that is known to Caterpillar. Continuing
All improvement and advancement of product design
might have caused changes to your product which
Table of Contents are not included in this publication. This Reuse and
Salvage Guideline must be used with the latest
Introduction ...........................................................1 technical information that is available from Caterpillar.
Canceled Part Numbers and Replaced Part For questions or additional information concerning
Numbers .............................................................1
this guideline, submit a form for feedback in the
Important Safety Information...................................2
Service Information System. To address an urgent
Improving Cleaning Efficiency.................................2 issue, use the following resources to communicate
Design ..................................................................3
your request to Caterpillar Repair Process
Wash Baskets and Storage Racks ..........................3
Engineering:
Basket and Rack Unloading....................................3
Cleaning Solutions.................................................4 • Caterpillar Dealer Technical Communicator
Manual Cleaning Solution Alternatives (Solvent
Cleaning).............................................................4 • Dealer Solution Network
Before Paint Cleaning ............................................5
Miscellaneous Cleaning Methods............................5 • Caterpillar Technical Representative
Asphalt Removal ................................................5
Decal Removal...................................................5 • Knowledge Network
Concrete Removal..............................................5
Canceled Part Numbers and
Replaced Part Numbers
Introduction
This document may not include canceled part
Table 1 numbers and replaced part numbers. Use NPR on
Summary of Changes in SIS for information about canceled part numbers and
Revision
SEBF8357 replaced part numbers. NPR will provide the current
part numbers for replaced parts.
Added new serial number
05 - 11
prefixes.

© 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.

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Important Safety Information

Illustration 2 g00008666

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
Illustration 1 g02139237
identified by “NOTICE” labels on the product and in
this publication.
Work safely. Most accidents that involve product
operation, maintenance, and repair are caused by Caterpillar cannot anticipate every possible
failure to observe basic safety rules or precautions. circumstance that might involve a potential
An accident can often be avoided by recognizing hazard. The safety information in this document
potentially hazardous situations before an accident and the safety information on the machine are not
occurs. A person must be alert to potential hazards. all inclusive. Determine that the tools,
This person should also have the necessary training, procedures, work methods, and operating
skills, and tools to perform these functions properly. techniques are safe. Determine that the operation,
Safety precautions and warnings are provided in this lubrication, maintenance, and repair procedures
instruction and on the product. If these hazard will not damage the machine. Also, determine that
warnings are not heeded, bodily injury or death could the operation, lubrication, maintenance, and
occur to you or to other persons. Caterpillar cannot repair procedures will not make the machine
anticipate every possible circumstance that might unsafe.
involve a potential hazard. Therefore, the warnings in
this publication and the warnings that are on the The information, the specifications, and the
product are not all inclusive. If a tool, a procedure, a illustrations that exist in this guideline are based on
work method, or operating technique that is not information which was available at the time of
recommended by Caterpillar is used, ensure that it is publication. The specifications, torques, pressures,
safe for you d for other people to use. Ensure that the measurements, adjustments, illustrations, and other
product will not be damaged or the product will not be items can change at any time. These changes can
made unsafe by the operation, lubrication, affect the service that is given to the product. Obtain
maintenance, or the repair procedures that are used. the complete, most current information before you
start any job. Caterpillar dealers can supply the most
current information.

Improper operation, lubrication, maintenance or

repair of this product can be dangerous and could Improving Cleaning Efficiency
result in injury or death.
There are many ways of increasing cleaning
Do not operate or perform any lubrication, mainte- efficiency in a parts cleaning operation. Time can be
nance or repair on this product, until you have minimized by designing racks and baskets to use all
read and understood the operation, lubrication, the space available in a parts washing system.
maintenance and repair information. Saving space can include designing and building
multiple-level parts baskets. Wash baskets can be
used for parts storage reducing handling time.
Safety precautions and warnings are provided in this
manual and on the product. If these hazard warnings When cleaning chemicals are worn out or not used at
are not heeded, bodily injury or death could occur to the proper concentration, cleaning time can be greatly
you or to other persons. increased because you may need to wash the parts
multiple cycles.
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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Design Note: The actual rate of savings will vary depending
upon the basket design and the size of the
The size and design of baskets and racks are components being rebuilt. Cleaning efficiency
significant factors when evaluating cleaning improvements can also be achieved for power train
efficiency. Using multiple level baskets will increase components, however the basket design will be
efficiency by eliminating unused space inside the different.
parts washer.

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

Illustration 3 g02446658 eight multiple level baskets to clean all the
Typical rack and basket design. All the baskets have wire mesh
components.
sides, bottoms, and tops to allow water to flow through the baskets
and onto the piece parts. 2. It takes 10 minutes to unload all the components
from one basket onto a storage rack.
(1) Single basket
(2) Multiple layer basket
3. Unloading all the baskets in Steps 1 and 2 takes 80
minutes (1.3 hours).
The following is an example of how to improve time
efficiency: 4. If wash baskets that are also storage racks are
used, the 1.3 hours of parts handling time per
1. A typical large cabinet washer can have a 1.5 m engine can be eliminated. Only the parts that will
(5 ft) diameter table with a height limitation of require removal from the baskets are the parts that
1.8 mm (72 in). need to have gasket material removed while still
hot.
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). Basket and Rack Unloading
3. Loading and cycle time must also be considered. Utilizing baskets and racks during cleaning
For this example, a 20 minute wash cycle will be operations can be a good investment, if the baskets
used. Another factor to consider is it takes an extra are efficiently designed for the desired operation.
5 minutes to load and unload each basket from the However, the baskets will not return full value if not
parts washer. utilized correctly. How baskets are best used can vary
with your choice of cleaning process and equipment.
4. Loading and unloading the baskets and clean all
the parts described in Steps 2 and 3 requires 5 The following suggestions will help get the maximum
hours. return from the investment:

5. Changing the design of the baskets to have 1. Locate the baskets and racks so that the
disassembler can sort parts as the parts are
multiple levels will reduce the number of baskets to
removed from the component. This will help reduce
eight and still clean all the same 3500 parts.
multiple handling of the same piece parts.
6. Loading and unloading the baskets and cleaning all
2. Parts that are worn out, broken, or unrepairable
the parts that are described in Step 5 requires 3.3 parts should immediately be put into a scrap tub
hours.
unless the parts are needed to support a claim or
7. This results in a 1.7 hour cleaning time reduction be shown to a customer. If scrap parts need to be
per engine rebuild. It does not take long to pay for saved, then the parts should be placed in a "hold"
the cost of designing and building new wash basket and properly tagged. This will ensure that
baskets at this rate of savings. scrap parts are not being washed which will reduce
chemical consumption.

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

metallic parts.

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4. Load baskets and racks loosely so that the • When the cabinet washer is opened after cycling,
cleaning solution can contact all surfaces. Surfaces the parts are not clean.
touching each other in a basket or rack will not be
cleaned properly or will not be cleaned at all. • The operator cycles the cabinet washer again
because the parts were not clean after one cycle.
5. If parts are cleaned in a cabinet washer, locate the
parts so that the dirtiest side of the part is facing • Two wash cycles per basket to clean the
toward the outside of the basket. Parts on the components.
outside of the rack or basket will be closest to the
spray orifices and will be flooded with the most • Loading and unloading the baskets and cleaning
cleaning solution. all the parts described above takes 360 minutes
(6.0 hours).
6. Do not wash all loads for the same length of time.
When possible, sort the components into different • Cleaning takes longer with the multiple level
wash racks or baskets by relative dirtiness ( baskets than it did with the single baskets. This
internal aluminum parts, internal ferrous parts,
heavily soiled aluminum parts, and heavily soiled example was used to demonstrate the need to
ferrous parts). manage the cleaning equipment even after new
cleaning baskets are purchased or fabricated.
7. Wash small parts together with related large
components, especially fasteners. Small baskets Scenario #2
with lids can be placed inside larger racks and
baskets. Avoid large containers of fasteners unless • The multiple level baskets are not used and 12
the container is segregated and labeled for baskets are needed to clean all the 3500 Engine
fastener location or use. Time can be wasted components.
searching through large fastener baskets for the
correct fasteners if the basket is not segregated • The cleaning times and chemical condition
and labeled. remains the same from Scenario #1.

8. If a component with many right and left side parts is • Loading and unloading the baskets and cleaning
being disassembled, keep the parts from the two all the parts described above would take 540
sides separate. Keeping the parts separate will minutes (9.0 hours).
avoid confusion and wasted time sorting parts later.
The result of insufficient cleaning solution in either
9. Wash all components that need repairs together. scenario is more time spent washing parts, resulting
After cleaning the parts can be shipped to the in decreased dealer profits.
appropriate repair area immediately.
Note: Inspect baskets, lifting devices, storage racks,
and all other related equipment for damage and
Manual Cleaning Solution
repair before use. Alternatives (Solvent Cleaning)
Check with your local governing bodies before using
Cleaning Solutions any of the following parts washing alternatives.

Using the correct chemical concentration is an The following parts washing systems are adequate
important factor in controlling the cleaning efficiency alternatives. The employee health and safety, cost,
of a cabinet washer or any other cleaning process and environmental requirements of each should be
that uses a chemical to clean parts. Refer to the considered before making a selection.
following example:
Solvent cleaning may result in hazardous waste due
A 3500 Engine rebuild requires the use of eight to flash points or contaminants. Refer to all local,
multiple level baskets to clean all the components. state, federal, and other applicable environmental
The cleaning cycle time of the cabinet washer is 20 laws and regulations.
minutes. An extra 5 minutes is needed to load and
Note: Use all Personal Protective Equipment (PPE)
unload each basket from the cabinet washer. The
and controls to ensure employee health and safety.
cabinet washer has the correct amount of cleaning
Refer to all local, state, federal, and other applicable
agent as specified by the chemical and equipment
safety laws and regulations.
manufacturers. To load, unload, and clean all the
baskets , takes 200 minutes (3.3 hours). Solvents may also be recycled using a Finish
Thompson solvent recycler (vacuum distillation).
Now consider the following two inefficient scenarios
Contact the Caterpillar Service Technology Group for
Scenario #1 more information about vacuum distillation and Finish
Thompson solvent recyclers. Regardless of the
• Multiple level parts baskets are used and the method, solvents must be separated from waste
washing procedure has consumed or has an water discharge.
insufficient amount of cleaning agent.

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Table 2
List of Controlled Solvents
Solvent Name Additional Recommendations d. Use dry ice blasting system. Dry ice evaporates
quickly, reducing waste materials and leaving
Abbey Chem Water Based Cleaner behind only paint and rust flakes. Also, bearing
and seals are not contaminated with an abrasive
Brake Cleaner -
grit.
Diesel Fuel -
Note: Used steel grit can be sold or given to asphalt
EPA2000 Similar to Safety-Kleen
companies to be used as filler material, reducing the
Mineral Spirits (Turbo Clean) volume of disposable waste.
Hill Manufacturing
system

Kerosene
Miscellaneous Cleaning Methods
Mineral Spirits

Most Dealers find this service Asphalt Removal

Safety Kleen expensive, but the cleaning sol-
ution and service is acceptable. 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.
Table 3
List of Controlled Solvents 2. Dry blast the area with the Armex Blast Cabinet (for
more information, contact Caterpillar Service
A water-based cleaning system Technology Group.
that uses bioremediation. Biore-
Smart Chem by Chem Free mediation uses microbes to
break hydrocarbons (oils) into Decal Removal
water and carbon dioxide.
Mineral Spirit recycling system 1. Steam or hot air gun.
System One
using vacuum distillation.
2. 3M decal remover disk.
Zep Similar to Safety Kleen
3. Use a spray-type paint and decal remover and
Zymo
Bioremediation cleaner similar hand scrape.
to Smart Clean

Note: For a complete list of suppliers, telephone Concrete Removal

numbers, and addresses refer to Reuse and Salvage 1. Presoak with mild acid cleaner, then clean with a
Guidelines, SEBF8356, “Introduction to the Cleaning high-pressure wand washer.
Guide”.
2. Wet or dry sand blast the component.

Before Paint Cleaning 3. Dry blast the area with the Armex Blast Cabinet (for
more information, contact Caterpillar Service
The following are cleaning alternatives for equipment Technology Group).
and components before painting. Each method
should be evaluated for cost and environmental ■
requirements before selecting a method.

1. Remove only dirt and oils

a. Manual clean. Refer to Shop Review,

SEBF8358, "Initial Cleaning Area"

2. Remove paint and rust.

a. Shot blast with sand grit

b. Shot blast with steel grit

c. Use Armex Blast Cabinet which can be operated

wet or dry. For further information contact
Caterpillar Service Technology Group.

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SEBF8357 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.

6 06 May 2016