Procedures for Using the 232-4686 Cylinder Washer Tank Group European Union Compliant{0374, 0599, 0680, 0738} #i04447814 Caterpillar


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Usage:

769C 01X   D6D 01Y   768C 02X   40 03G   3306 03N   D6D 03X   943 03Y   3208 03Z   3208 03Z   D6D 04X   943 04Z   D6D 05X   953 05Z   D3 06N   D5 06R   44 06W   D6D 06X   963 06Z   D4D 07R   931 08N   955L 08Y   3306 08Z   3304 09Z   TK711 101   TK721 102   TK722 103   TK732 104   3304 10E   3304 10E   630B 10G   D6C 10K   931 10N   120 10R   772 10S   227 10W   3204 10X   3306 10Z   973 11B   631B 11G   631C 11G   977K 11K   3406 11N   3406B 11N   3406C 11N   140 11R   772 11S   120G 11W   963 11Z   120H 124   12H 125  


Caterpillar Products: All

Introduction

Important Safety Information




Illustration 1g02139237

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 Section

Safety Icon Nomenclature

Personal Protection/Important Information




Illustration 2g02166423

Personal Protection/Important Information

Prohibited Action


No smoking

Hazard Avoidance


Crushing hazard (foot)


Crushing hazard (hand)


Pinch point


Fire hazard


Electrical Shock - Hazard


Fire hazard

Safety Warnings

------ WARNING! ------

At operating temperature, the hydraulic tank is hot and under pressure.

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

----------------------

------ WARNING! ------

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.

----------------------


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.



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 Section

Introduction

This Tool Operating Manual discusses how to use the 232-4686 cylinder/">Cylinder Washer Tank Group to clean the bores of honed or contaminated cylinder tubes.

When reconditioning hydraulic cylinders the honing process introduces abrasive particles throughout the cylinder tube. It is important to thoroughly clean all cylinder components before assembly or installation. Industry tests have shown that particles as small as 30 microns (1 micro = 1 millionth of a meter) in hydraulic oil act as a fine grinding media that can result in loss of efficiency and performance.

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 is designed to catch particles 10 microns and larger. The washer can be used on any cylinder that has been disassembled or overhauled.

The washer brush is designed to be used in a horizontal position.

Position the washer tank in the shop to allow enough space at the end of the cylinder hones' barrel cradle stand, so the brush tooling can be stroked the full length of the longest expected cylinder tube.




Illustration 3g02637560

cylinder/">Cylinder Washer Tank Group.

Additional Contact Information

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

USA: 800-542-8665, Option 1

International: 1-309-578-7372

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

Tooling for Complete Cleaning System

The 232-4686 cylinder/">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 the chart.




Illustration 4g02637576



Illustration 5g02637596

Table 1
Tooling for a Complete cylinder/">Cylinder Tube Cleaning System    
Item     Part No.         Description    
(1)     232-4686     cylinder/">Cylinder Washer Tank Group    
(2)     120-9144     Rotating Valve Group    
(2a)     3B-6490         Pipe Coupling (part of 120-9144)    
(2b)     120-9156         Union (part of 120-9144)    
(2c)     7E-8352         Nipple (3/4 in NPT) 152 mm (6.0 inch) long    
(2d)     112-4036         Valve (part of 120-9144)    
(2e)     9U-7455         Quick-Disconnect Coupling (used with 120-9151)    
(2f)     120-9151         Quick-Disconnect Nipple (part of 120-9144)    
(3)     120-9146     Brush Assembly    
(3a)     120-9149         Brush Head (1 used on 120-9146)    
(3b)     120-9155         Nozzle (6 used on 120-9146)    
(3c)     1M-7914         Retaining Ring (2 used on 120-9146)    
(4)     120-91481     Brush,
76 mm (3.0 inch) Height [for bore diameters of
100 to 190 mm (4.0 to 7.5 inch)]    
20-91471 Brush,
152 mm (6.0 inches) Height [for bore diameters of
190 to 343 mm (7.5 to 13.5 inch)]    
(5)     120-91542     Arbor Tube,
183 cm (72.0 inch) long    
120-91532 Arbor Tube,
305 cm (120.0 inch) long    
120-91522 Arbor Tube,
363 cm (144.0 inch) long    
(6)     171-5688     Pneumatic Drill    
Serviceable Parts    
-     184-2319     Filter Bag (25 micron)    
-     198-3150     Filter Element (2 micron)    
-     9U-6983     Filter Element (5 micron)    
-     9U-5870     Filter Element (15 micron)    
1 Brushes used in quantities of six. Size required depends on cylinder bore diameter.
2 Size required depends on cylinder length.    

Brush and Rotating Arbor (Tube) Assembly




Illustration 6g02637598

Arbor (Tube) And Brush Nomenclature.

(3a) Brush Head. (3b) Nozzle. (3c) Retaining Ring. (4) Brush. (5) Arbor Tube.

  1. From the Table 1, select brushes (4) that exceeds the cylinder bore size by no more than 50 mm (2.0 inch). If a desired brush size is not available, use shears or a utility knife to trim the bristles on a larger brush to fit the inside diameter of the cylinder tube.

  1. 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.

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

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

    Note: If desired, the length of the arbor can be shortened and rethreaded for a specific cylinder tube application.




    Illustration 7g02637600

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

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

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

  1. 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 (.5 inch) Jacobs® chuck. It runs at 500 rpm using a _bd_ hp high-torque motor. Many other types of air drills will work equally 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 installs in place of the 120-9146 Brush Assembly . Select the appropriately sized brush, based on the cylinder bore size, from the chart below. When using this method, set the pressure regulator between 68 and 103 kPa (10 and15 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).

Table 2
Hand Brushes for cylinder/">Cylinder Cleaning    
Part No.     Maximum Diameter    
4C-6342    
88 mm (3.5 inch)    
4C-6343    
101 mm (4.0 inch)    
1U-7429    
114 mm (4.5 inch)    
1U-9788    
127 mm (5.0 inch)    
4C-6344    
140 mm (5.5 inch)    
4C-6345    
152 mm (6.0 inch)    
4C-6346    
165 mm (6.5 inch)    
4C-6347    
178 mm (7.0 inch)    
4C-6348    
190 mm (7.5 inch)    
4C-6349    
203 mm (8.0 inch)    
4C-6350    
241 mm (9.5 inch)    



Illustration 8g02637602

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

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

  1. Use two 4B-9808 Setscrews (3) [1/4-20 x 12 mm (.5 in) long] to hold the brush in place.

Start-up Preparation

  1. Raise the screen assembly and fill the tank with 40 to 46 cm (16.0 to 18.0 inch) of clean water. Add a water-based cleaning solution to the water to aid in the cleaning performance of the washer.

  1. Slide the 6V-1986 Support Tube through a roll of 120-9150 Filter Paper and put it into brackets on the tank.

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

  1. 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 it end-for-end on the rear of the barrel cradle stand.

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

  1. Use a V-block from the barrel cradle stand or a block of steel or wood to elevate the closed end of the cylinder to make sure the cleaning solution easily drains from the cylinder when cleaning is complete.

  1. 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 (6.0 to 12.0 inch).

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

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

  1. Connect the air pump to a regulated air supply.

  1. Make sure valve (9), Illustration 7) is in the "OFF" position.

  1. Insert the brush head into the cylinder. Turn the pump "ON" to start the flow of cleaning solution.

  1. Open valve (9). Start the air drill and adjust the speed so the brush head runs smoothly. Stroke the brush through the entire length of the cylinder. Removing the brush head from the cylinder while it is rotating can result in injury to the operator or other personnel standing close to the cylinder washer.

  1. If the brushes are the correct size and the solution is the correct concentration, sufficient cleaning will be accomplished with 1 to 2 minutes of cleaning.

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

  1. 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 white towel is not discolored.


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