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Cleanliness Testing Process
Dec 2018
GLOBAL SERVICE
Caterpillar: Confidential Green GLOBAL SERVICE
Caterpillar: Confidential Green GLOBAL SERVICE
Caterpillar: Confidential Green GLOBAL SERVICE
Objectives of this Document
There are many contamination risks throughout the component rebuild process. While implementing proactive processes
within the wash, rinse, dry and protect processes will support to minimize the risks of contamination – a method to
objectively analyze the results of these processes needs to be in place.
That noted, Caterpillar has published cleanliness specifications for the C175 Block (Cylinder Block Cleaning and Audit
Procedure: M0080689) and is in the process of publishing additional parts cleanliness specifications for other engines and
parts / components. This document and the Parts Cleanliness Testing for Caterpillar Dealers – Visually Identifying
Particulate: SEHS0772 both support dealers in validating overall parts cleanliness performance – not replacing, but
complimenting specific cleanliness test instructions like that for the C175 Block.
Important
All of the equipment required to support parts cleanliness testing is identified within this process. In many cases, a few
different solutions for the same process are displayed, or a specific brand example for the equipment is provided.
It is not mandatory to purchase / utilize the exact equipment, but where equipment specifications have been identified –take
note to ensure that whichever equipment brands are chosen, the equipment meets the specifications.
Important
Ensure that all local / company policies and requirements are being followed as they pertain to the
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process steps outlined in this presentation.
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Pre‐Test Setup
Test Equipment and Cleanliness
The validity and accuracy of parts cleanliness testing requires that no “external influences” negatively impact
the results of a parts cleanliness test.
The testing area and all of the equipment needs to be clean both prior to testing and after testing: Tables,
funnels bottles, forceps, beakers, flasks, collection trays, etcetera need to be cleaned both prior to use and
after use.
Important
If starting with new equipment for the first time, ensure to
thoroughly clean it as well. Contaminants from production,
packaging, etcetera could also impact the first cleanliness
tests.
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Important
Personnel are trained on / facilities are set‐up to manage the identified chemicals prior to use.
Bottles are well marked: Designating safety concerns (Health, Flammability, Reactivity, etcetera).
Bottles are labeled to easily differentiate between rinsing agent / other chemicals used within
the operation. It may also be an option to use different colored bottles for different chemicals.
o See‐through bottles are easier to fill / refill than non‐see through.
All wash bottles / sprayers used to hold rinsing agent are cleaned with isopropyl alcohol /
confirmed contaminant free prior to being filled / refilled.
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Important
Personnel are trained on / facilities are set‐up to manage the identified chemicals prior to use.
Bottles are well marked: Designating safety concerns (Health, Flammability, Reactivity, etcetera).
Bottles are labeled to easily differentiate between rinsing agent / other chemicals used within the
operation. It may also be an option to use different colored bottles for different chemicals.
o See‐through bottles are easier to fill / refill than non‐see through.
All wash bottles / sprayers used to hold rinsing agent are cleaned with isopropyl alcohol /
confirmed contaminant free prior to being filled / refilled.
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Use dry, filtered air to dry off all test equipment (Funnels, beakers, flasks,
etcetera) and parts after testing is completed.
Important
Dry, filtered air is the optimal means for drying off all test equipment after it has been cleaned with Isopropyl
Alcohol.
o Ensure there are no in‐line lubricators (oils) attached to the air lines.
Filtration should be at a micron rating lesser than the smallest particulate you are testing for. 11
Brand Example
Important
Objective is to remove / eliminate all contaminant / fluid that may negatively impact result of
cleanliness test. 12
Anti‐Static forceps, tongs, etcetera are available from companies like Fisher Scientific
Use a Gauss Meter to confirm that the instruments are not magnetized.
If magnetized, demagnetize prior to use. Various brands of demagnetizing equipment are
available for consideration – depending on the size of tooling and / or parts requiring
demagnetization.
Important
If instruments are magnetized, there is a risk that ferrous metal contaminant will stick to them.
To avoid risk of cross‐contamination, ensure that tongs and forceps have been cleaned with isopropyl alcohol prior
to use. 13
Important
Ensure ALL testing equipment / materials are free from Vacuum Hose
contaminant prior to use. Erlenmeyer connected to
Flush filtering funnels / beakers / flasks with Isopropyl Flask Side Arm
Alcohol to remove contaminants.
It is necessary to have two (2) Erlenmeyer Flasks. One
for clean filtered rinsing agent and one for capturing
used rinsing agent. Size recommendation = 1 to 2
liters.
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Pre‐Test Setup
Filtering Unit – Assembly
Step 1: Before placing the Fritted Support Base onto the Erlenmeyer Flask, if both are made of glass, ensure to apply
glass lubricant (vacuum grease) to the connection surfaces of the Erlenmeyer Flask and the Fritted Support Base
Glass Lubricant:
Brand Example = Dow Corning
Important
There is the risk of damaging the flask or the Fritted Support Base if lubricant is not used.
Ensure that the Fritted Support Base is designed to support 47 mm filter patch.
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Important
47 mm Filter Patch
Recommended Micron Membrane Rating = 8 16
Important
Do not touch filter patch with bare hands: Use new nitrile gloves and clean
forceps: Ensure that forceps have been cleaned with Isopropyl Alcohol prior
to use.
Use caution when handling filter patch with forceps – to avoid tearing. 17
Funnel Aligned
to avoid
Leakage
Important
Ensure that the funnel and Fritted Support Base are aligned to avoid leakage of solvent. 18
Clamp
Important
Ensure that the Funnel and Fritted Support Base are aligned to avoid leakage of solvent.
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Vacuum Tube
connected to Side
Arm of Erlenmeyer
Flask
Vacuum Tube
Connected to
Vacuum Fitting
Important
A method for syphoning the solvent through the media is required – especially
for parts where higher volumes of debris is found. 20
Important
Ensure to follow manufactures recommendations on use of stainless steel and
grounding wires when using a Stainless Steel Funnel / Fritted Support Base.
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Pre‐Test Setup
Brand Example: Nalgene Filtering Unit
Filtering Unit – Portable / Disposable Option Fisher Scientific Catalog
Number: 0974021BLC
Nalgene (available via Fisher Scientific) offers a “disposable” Filtering
Unit. These Filtering Units work exceptionally well for remote /
portable testing.
• This Filtering Unit only offers a .45 micron filter. Due to the
thickness of the filter which is provided with the Filtering Unit,
the recommendation is to place the 8 Micron Millipore filter
patch over the .45 micron Nalgene filter patch.
− The .45 micron filter patch is thick, and particulate has a
tendency to embed itself within the patch. The Millipore
filter patch is significantly thinner and enables for easier
viewing of particulate found.
Important
The Nalgene Filtering Units are designed for medical particulate analysis,
but serve exceptionally well for portable parts cleanliness testing.
Do not re‐use the disposable test Filtering Units – It presents too high a
risk of cross contamination from earlier tests.
Remember to remove the protective cover from the filter prior to placing
the Millipore patch onto the Nalgene patch.
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Pre‐Test Setup
Filtering Unit – Portable / Disposable Option
A vacuum pump is also required when using the Nalgene Filtration
Unit.
The Caterpillar SOS Fluid Sampling Pump with SOS Sample Hose is the
best solution.
Nalgene
Filtering
Unit
SOS Sample
Pump
Important Over‐flow
It is common, even with the Caterpillar SOS Fluid Sampling Pump, to Bottle
crack the Nalgene filter Unit base when applying too much suction.
The bottle attached to the sample pump is used only to collect rinse
agent over‐flow. One option is CAT Part 321‐0659. This bottle can be
rinsed and reused. 24
Important
Ensure that Hand Pump Sprayer or Wash Bottle materials are compatible with rinsing agent used.
Standardization in the spraying of each parts is desired to ensure consistency (where possible).
Select easy to pour from / rinse stainless steel collection trays. 25
26
Important
Need to ensure that only that those parts that are part of the control are flushed and collected.
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Parts Selection & Pre‐Testing
Select a Part for Testing
Selecting a part will be dependent on:
• Which area(s) within the rebuild center requires validation for parts cleanliness
• Whether a specific part or a random part needs to be targeted for testing
When first starting a testing program, it may be optimal to random sample various parts from various areas / stages in
the rebuild process.
As time progresses, with good record management supporting the monitoring of cleanliness trends will allow for a
more focused selection of parts and even specific areas within a part may be targeted for testing
• As an example, the fluid wetted portion of a part will typically have a more stringent cleanliness level than a
portion of a part which is not wetted.
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Important
To avoid introducing contamination, do not touch the testing areas of a part without clean nitrile gloves
Ensure that all carts, containers and lids for transporting a part are cleaned prior to placing the part on / inside.
Note – If the part is to be removed directly from a washer the part(s) may still be hot.
Allowing for a cool‐down period inside the washer may be required to avoid personal injury 29
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Parts Selection & Pre‐Testing Examples of 3 x 5 Card with
Test Detail Description
Document all details about the part selected
Document key information about part and patch test on a 3 x 5 index card
identifying the part(s) to be tested.
This is the card that the petri dish with the filter patch will be attached to later
in the process.
Details to consider
• Part name and part number
• Location where the part came from within the Rebuild Center
• # of Pieces tested from that same location / date
− If more than 1 part is selected from that location on the same date
• Initials of person who completed test
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Important
To avoid introducing contamination, do not touch the testing areas of a part without clean nitrile gloves
Gauss is the unit of measure used to identify the magnitude of magnification. Specific to parts cleaning, ferrous particles:
o Will adhere to magnetized parts if they reach a gauss level above 200 μT or 2 gauss
o Will strongly adhere to magnetized parts if they reach a gauss level above 1000 μT or 10 gauss 31
Important
To avoid introducing contamination, do not touch the testing areas of a part without clean nitrile gloves
Rust, flash rust is normally visible with the naked eye. That noted, a hand‐held lighted magnification
glass (10 to 40 times optical zoom) is recommended for closer inspection. 32
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Important
There are times when particulate / contaminant will stick / adhere to tools for collection / nitrile gloves. Rinse the
tools / gloves into the contaminant collection tray.
Working with and around cranes and parts in suspension – Requires proper training and caution. 34
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Parts Cleanliness Testing Process
Testing the Part for Cleanliness
Ensure that the collection process does not contaminate the part to be tested.
• Ideally, a part can be tested directly in the location of interest: At the washer, WIP, Assembly.
− This minimizes the risk of cross‐contamination or impacting the integrity of the test by having to transport the
part to another location.
• In some cases, transporting the part to a clean / controlled area for testing is required.
− Objective in transport is to avoid the risk of a part being contaminated as it is moved from the point of origin to
the testing area. In addition, ensure that the part is protected against physical damage – For example, use
caution when transporting metal parts in a metal container.
− Transport in a closed, clean demagnetized container or cover with a new clean plastic bag.
Important
To avoid introducing contamination, do not touch the testing areas of a part without clean nitrile gloves
Ensure that all carts, containers and lids for transporting a part are cleaned prior to placing the part on / inside.
Note – If the part is to be removed directly from a washer the part(s) may still be hot.
Allowing for a cool‐down period inside the washer may be required to avoid personal injury. 35
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Parts Cleanliness Testing Process
Once the part is in the final location for cleanliness testing
Pick‐up the part with clean utensils, clean gloves, or crane and position a demagnetized stainless steel collection tray
underneath it
Position the part to allow it to be sprayed with a wash bottle or sprayer
Spray the part, internal passages, areas where the level of cleanliness is of interest / concern with the rinsing agent.
Important
To avoid introducing contamination, do not touch the testing areas of a part without clean nitrile gloves.
Ensure to rinse all visible particulate into the collection tray. 36
Important
Collect all solvent and particulate into the collection tray.
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Important
Collect all solvent and particulate.
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Important
Ensure to rinse the funnel thoroughly.
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Important
The patch will be fragile. Caution should be used when removing the patch from the Fritted Support
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Base.
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Parts Cleanliness Testing Process Brand Example:
Transferring the patch to the Petri Dish Millipore Petri Dish
Carefully move the patch off the Fritted Support Base and into the base of a 47mm Petri Dish
Cover the petri dish
Label the Petri Dish to ensure that the patch details are recorded when attaching the Petri Dish to
the 3 x 5 card completed at the beginning of the testing process.
Important
The patch will be fragile. Caution should be used when moving the patch.
Try to keep the patch as flat / level as possible while moving the patch. 41
Attach the Petri Dish to the completed 3 x 5 card with all of the details on the
part.
See the Parts Cleanliness Testing for Caterpillar Dealers – Visually Identifying
Particulate: SEHS0772 document for detailed instructions on how to analyze
the patch under a microscope and on how to store / manage information.
Important
Try to keep the patch / Petri Dish as flat / level as possible while moving / transporting. 42
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Establish a structured approach to collecting, analyzing and actioning any issues identified from
cleanliness testing.
Objective is to both manage daily results as well as monitor and manage trends over time.
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