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Parts Cleanliness Testing for

Caterpillar Dealers ‐
Cleanliness Testing Process
Dec 2018

GLOBAL SERVICE
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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.

 This document provides:


 A formal instructional on how to validate the cleanliness of a part(s).
 Supports in the successful implementation of a part cleanliness testing process which may be utilized on a part at any
time prior to assembly.

 Potential added benefits of implementing a cleanliness testing process are:


 Ensure that parts are clean prior to / at the time of assembly vs. risk of waiting until the component is on the dyno or test
bench to validate build cleanliness – or even installed on the machine.
 Improvements in the effectiveness and efficiency of the cleaning process: Improved understanding if the cleaning
operation is under‐cleaning and / or over‐cleaning.

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Parts Cleanliness Targets: How Clean is Clean
 This document does not define specific cleanliness targets. It has been developed to support in enabling a dealer to assess
their achieved cleanliness levels using similar methods to that which Caterpillar analyzes parts cleanliness performance levels
internally.

 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.

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Pre‐Test Setup

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.

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Pre‐Test Setup
 Review all safety procedures related to:
 Chemicals to be utilized, including:
• Safety Data Sheets
• Managing and Removal / Disposal of Waste.
 Fire Prevention
 Ensure all personal and facility required Protective Equipment is available and used throughout the testing process.
Safety Glasses Nitrile Gloves Long Sleeve Lab Coat

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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Pre‐Test Setup
 Chemicals for Cleaning Testing Equipment
 Isopropyl Alcohol
Filtered
• Effective for removing solvent / mineral spirits / cleaning test
equipment – quick drying. Isopropyl Alcohol

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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Pre‐Test Setup
 Chemicals required for Parts Rinsing (Rinsing Agent) Filtered
 Filtered Solvent / Mineral Spirits: Solvent / Mineral Spirits
• Required to:
₋ Easily dissolve common machining oils
₋ Remove contaminant from the part
• Brand Example: Shell SOL 142 HT or Equivalent.

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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Pre‐Test Setup
 Compressed Air

 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

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Pre‐Test Setup
 If clean, dry compressed air is not available, use lint free cloths

Brand Example

Important
 Objective is to remove / eliminate all contaminant / fluid that may negatively impact result of
cleanliness test. 12

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Pre‐Test Setup
 Ensure all metal instruments used to touch parts are anti‐static and are demagnetized. Gauss Meter
Forceps Tongs

 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

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Example: Filtering Unit
Pre‐Test Setup
 Filtering Unit

 Purpose of the Filtering Unit is to pull solvent Funnel


which has been used to rinse parts (collect
particulate) through the filter patch.
Clamp
Fritted
Support
Base

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

Fritted Support Base:


Brand Example = Millipore
Fritted Support Base
Attached to Erlenmeyer Flask

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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Pre‐Test Setup
 Filtering Unit ‐ Assembly
 Step 2: Remove filter patch from packaging using forceps.

Brand Example: Millipore


Filter patch Filter Protective
Patch Covering Use Forceps to
pick‐up patch

Important
 47 mm Filter Patch
 Recommended Micron Membrane Rating = 8 16

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Pre‐Test Setup
 Filtering Unit ‐ Assembly
 Step 3: Position filter patch on Fritted Support Base.
• Ensure that filter patch is well centered onto Fritted Support Base:
Eliminate risk that some solvent will pass from funnel to flask
without passing through filter patch.

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

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Pre‐Test Setup
 Filtering Unit – Assembly
 Step 4: Place the funnel onto the Fritted Support Base.

Funnel Aligned
to avoid
Leakage

Important
 Ensure that the funnel and Fritted Support Base are aligned to avoid leakage of solvent. 18

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Pre‐Test Setup
 Filtering Unit ‐ Assemble
 Step 5: Install the Clamp to secure the Funnel to the Fritted Support Base.

Clamp

Important
 Ensure that the Funnel and Fritted Support Base are aligned to avoid leakage of solvent.
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Pre‐Test Setup Brand Example: Fisher
 Filtering Unit ‐ Assemble Scientific Vacuum Tube
 Step 6: Connect the Vacuum Air System
 Assemble a “rubber pressure and vacuum tube” (vacuum tube) to the
Side Arm of the Filtering Unit.

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

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Pre‐Test Setup
 Filtering Unit – Assembly
 If a Vacuum Air System is not available, a Caterpillar SOS
Fluid Sampling Pump with SOS Sample hose is a suitable
replacement.

Caterpillar SOS Fluid


Sampling Pump
Important
 A method for syphoning the solvent through the media is required.
 Caterpillar SOS Fluid Sampling Pump = 1U‐5718
 Recommend using CAT Sample Bottle = 321‐0659
 SOS Sample Hose: 1U‐8757 (100 ft / 30.5 m) of hose
 SOS Oil Sample Hose should fit snuggly into vacuum hose. SOS sample hose
will not fit directly onto the Side Arm of an Erlenmeyer Flask or Fritted Support
Base.
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Pre‐Test Setup Example: Filtering Unit

 Filtering Unit ‐ Options


 Various options are available when selecting the
Filtering Unit. Tester needs to ensure compatibility
between various equipment selected: Stainless
 Funnel, Fritted Support Base and Erlenmeyer Steel Funnel
flask need to be compatible in size – matching
the patch dimensions Stainless Steel
Fritted Support
 Glass can be challenging to work with ‐
Base
especially around metal parts ‐ alternatives to
glass funnels, glass support bases and glass Clamp
Vacuum
flasks are available (Stainless Steel Funnel and
Hose
Fritted Support Base for example).
 Either the Fritted Support Base or the
Erlenmeyer flask requires a Side Arm – not Erlenmeyer Flask Support
both. Stand

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

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Pre‐Test Setup
 Additional Equipment used to support parts cleanliness testing.

Stainless Steel Hand Pump Plastic caps / plugs


Collection Tray Wash Bottle Spray Bottle (to block ports) Nylon Brush

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

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PARTS SELECTION
&
PRE‐TESTING

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Parts Selection & Pre‐Testing
 Selection of Parts for Testing
 While each dealer requirement for testing will be unique, considerations for parts selection include:
• Selecting those parts which are most critical to be cleaned to a specific cleanliness level
− Support in meeting C175 Block Cleanliness Specification
− Oil Wetted Parts
• Selecting the same part(s) in various areas within the work flow to support the analysis of parts cleanliness:
− Immediately after part is removed from the parts washer
− After a part completes the entire cleaning process (before Rust Inhibitor is applied)
− While the part is in WIP Storage
− After part is removed from WIP Storage
− While part is in Assembly
* These are only examples – The objective is to record cleanliness levels in various areas to allow for the
monitoring / managing of a part(s) cleanliness level throughout the rebuild process.

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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Parts Selection & Pre‐Testing
 Select a Part for Testing: Directly from a washer
 When testing the cleaning effectiveness of a washer (cabinet washer, immersion tank, solvent stand, etcetera)
• Part must be tested immediately after it is removed from the washer.
− If transporting the part to a designated testing area, refer to slide 34 for keeping parts clean in transport.
− For large parts (not in a basket), testing must be completed as it is removed from the washer
• Do not let the part sit in the open area outside the washer for any extended period to avoid potential
contamination after the wash / cleaning process.
• If there is “carry‐over” fluids / particulate remaining on the part as it is being removed from the washer, collect it
as it may contain particulate that needs to be analyzed.
• Do not manually rinse or air‐dry the part before completing testing. Testing washer specific performance – the
objective is to assess the cleanliness of the part after it completes it’s automatic wash and rinse cycle.

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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Parts Selection & Pre‐Testing
 Test the part identified for magnetism prior to cleanliness testing. Gauss Meter
 Ensure that parts are not magnetized.
• If the magnetism is strong enough, the ferrous particles may not
wash off during the testing process – providing an inaccurate reading
• In addition, magnetized parts may not allow for the cleaning process
to remove all magnetic particulate ‐ which could later release during
machine operation and potentially cause system damage or failure.
 If the part fails the magnetism test, ensure to document the details on the
part for issue follow‐up and resolution. It is recommended to trace the
path of that part within the rebuild center to identify where the part
become magnetized (Typically could happen in a machining environment).
 Demagnetize and re‐clean the part (Wash, Rinse, Dry & Protect)

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

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Parts Selection & Pre‐Testing
 After the part passes the magnetism check, review the part for rust.
 Visible signs of rust are typically cause for a part to fail a cleanliness check – especially for fluid carrying (wetted) parts.
• Either the part was not successfully cleaned (rust was not removed during the wash process)
• Rust inhibitor was not correctly / adequately applied
 If the part fails because of rust, ensure to document the details on the part for issue follow‐up and resolution: It is
recommended to trace the path of that part within the rebuild center to identify where the rust originated (If the rust
was never removed during wash, or occurred as a result of the wash / cleaning process)
Inspecting a part for rust using a lighted magnifying glass

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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PARTS CLEANLINESS
TESTING PROCESS

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Parts Cleanliness Testing Process
 Testing the part for Cleanliness
 Ensure the collection process does not contaminate the part
• Pick‐up the part with cleaned tongs or other antistatic, demagnetized utensils – As long as there is no risk of
damaging the parts.
• If the part could be damaged or it is too heavy to be collected with a utensil, pick up the part with your hands –
Always wear clean nitrile gloves.
• For large / heavy parts (crankshafts, blocks, differential housing), it may be best to hoist them with a crane and test
them while suspended.

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

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Parts Cleanliness Testing Process
 Testing for cleanliness
 Depending on the degree of cleanliness that needs to be evaluated, using a nylon brush to further remove
contaminant that is adhering to the part may be required for a more thorough cleanliness assessment.
 Consistency in rinsing and brushing technique (exact same amount of solution, pressure, etcetera) is necessary for
repeatable results, but do to the variety / variability of parts – it is not always feasible.

Patch where only Patch where both


solvent was brush and solvent
sprayed on part was used: On the
same part after
the first test was
conducted.

Important
 Collect all solvent and particulate into the collection tray.
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Parts Cleanliness Testing Process
 Rinse all rinsing agent / contaminant into the collection funnel.
 Pour all of the contents into the funnel
 Rinse off the collection tray with the same rinsing agent used for the part – collecting all fluid and particulate into the
funnel

Important
 Collect all solvent and particulate.

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Parts Cleanliness Testing Process
 Syphon all rinsing agent / particulate through the filter patch.
 Use the vacuum pump to pull all of the solvent through the patch.
 Rinse all remaining contaminant out of the funnel and onto / through the patch.

Important
 Ensure to rinse the funnel thoroughly.
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Parts Cleanliness Testing Process
 Remove the funnel from the Filtering Unit
 Remove the vacuum hose to release pressure from the Filtering Unit
 Remove the funnel to access the patch
 Carefully remove the patch with cleaned forceps

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.

Brand Example: Dymo


LetraTag – Paper Label
Tape

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

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Parts Cleanliness Testing Process Examples of 3 x 5 Card with
Test Detail Description
 Complete the Cleanliness Testing Process

 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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Logging Results / Managing History

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Logging Results / Managing History
 Monitoring and Managing Cleanliness Results

 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.

Examples of a Cleanliness Log


Cleanliness
Rebuild Center Work Order Rust Magnetism Patch Test
# Date Location Number Part Name Part Number Pass / Fail Pass / Fail Pass / Fail Action Taken
1 3‐Nov‐18 Assembly 867530 Adapter 378‐0983 P P F Found Glass Beeds, Review Rinse and Protect Process
2
3
4
5
6
7
8
9
10

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Returning
Parts

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Returning Parts
 Prepare Parts for Return to original location
 Clean parts with isopropyl alcohol or return to wash

 Dry part with dry / filtered air

 Protect part from rust and contamination accordingly

 Returning part to its original location

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