STARTING AID GP 1023599 - Caterpillar

Parts Cleaning
Once the cylinder has been disassembled and the parts are determined to be reusable, the parts should be cleaned. An automatic method to wash parts is preferable. A cabinet washer works well for cylinder parts and hardware. The washer should be high pressure, hot, with soap.Maintenance of the wash water is critical for the cabinet to clean the parts well. Inefficient parts washing is due in large to poor maintenance practices along with improper basket loading. Manual cleaning in a solvent tank is not the best use of technician time. If an automatic method of parts washing is used, the technician can move on to other tasks. When the parts cleaning cycle has completed, the technician can simply blow dry the parts and start assembly.In-Process Racks/Baskets
In-process racks/baskets should be used only to store disassembled, clean cylinder parts that are not going to be assembled immediately. Typically, an A-frame type rack works well. The racks should be placed very close to the D&A bench. The in-process rack should be able to accommodate tubes and rods as well as small parts.All small parts should be placed in a contamination free bin or container. The container should be marked with the work order number. The container should be in a separate shelving unit next to the rack or below the rack if room allows.The tube and/or rod should also be marked with the work order. The rods should be wrapped in plastic while on the in-process rack. The tubes should be capped and plugged.Dealers who do not effectively use in-process racks commonly have small parts piled on bench tops as well as tubes and rods on the floor. Using in-process racks is more important to high volume dealers operating multiple shifts in the cylinder shop. Inmanycasesthe same person may not assemble the cylinder that disassembled the cylinder.Re-rodding and Re-tubing
Caterpillar has documents to support re-rodding and re-tubing activities. Refer to Special Instruction, SEBF8072, "Inspection and Salvage of Hydraulic Cylinder Components". Once the decision to replace a rod or tube has been made, the guideline will assist in the steps necessary to replace the damaged parts.Hone
Caterpillar has documents to support the hone process. Refer to Special Instruction, REHS2689, "Hydraulic Cylinder Honing" for repair process information.After the cylinder tube has been determined fit to be honed, the tube should be moved to the hone. Movement of the tube should be done with a jib crane or an overhead crane. The same crane should be able to reach the hone and the cylinder D&A bench as well as an in-process rack.There are several areas of consideration when a tube is honed such as set-up, feed, speed, stone grit selection, and hone oil. All of which are covered in the Special Instruction, REHS2689. In terms of process, the overall objective is the correct bore dimension and correct surface roughness in the least amount of time. How the five items listed above are addressed, can have a negative or positive effect on the results.The Caterpillar hones