initial cleaning area

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Sho p Review I n i t i a l Clean ing A r ea

Initial Cleaning Area

SMCS - 7000

SEBF8358-01April 2000

SMCS Code: 0000

Shop Review

Initial Cleaning Area

Introduction

This guideline enables dealers and their customers to benefit from cost reductions madepossible through established cleaning procedures. Every effort has been made to provide themost current and relevant information known to Caterpillar Inc. Since the Company makesongoing changes and improvements to its products, this guideline must be used with the latesttechnical information available from Caterpillar to ensure such changes and improvements areincorporated where applicable.

For questions or additional information concerning this guideline, contact Caterpillar ServiceSupport Division, Dealer Support (309) 675-8263.

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Initial CleaningThe initial cleaning area is the area where equipment or vehicles are first cleaned before theyenter the repair shop. It is typically the location where a water recycling system would belocated.

This area is ideally located such that incoming equipment or components naturally flowthrough it on their way to a specialized shop area.

The initial cleaning area is often referred to by one of the following names:

Wash Rack Mud Pit Wash Pad De-mucking Station

It is a good practice to use "gray" water to quickly remove the bulk of the dirt from componentsor equipment with either a water cannon or fire hose. The "gray" water should be reused toreduce water consumption.

A high or medium pressure wand washer with hot water should be used to remove greasesand oils from the component or equipment. If possible, it is a good practice to separate the

wand washer cleaning area from the water cannon or fire hose cleaning area to reduce theamount of greases and oils in the bulk of the dirt removed from the equipment or component.

Local environmental agencies must be contacted to provide information on water cleanlinessrequirements before reuse or disposal of water from this area. A health and safety analysis ofthe water being reused is recommended.

Tech Tips

1. Ensure all Personal Protective Equipment (PPE) and controls recommended by the

manufacturer are implemented.2. Make someone accountable for the cleanliness of the initial cleaning area, the cleaningequipment, and the cleanliness of the components leaving the area.

3. Install a preset chemical injection system on the wand washer to reduce chemicalconsumption. This will eliminate waste caused by the philosophy, "If a little works good,then a lot will work better."

4. Use non-filtered "gray" water in the fire hose or water cannon, typically water from thesecond stage of a three-stage oil separator.

5. Always use hot water when using a cleaning agent, chemical, or soap.6. Spray a strong soap solution on heavily soiled areas and let the soap "soak" to loosen





the greases and oils before cleaning the area with the wand washer.7. Use a waste water recycling system.8. Use filtered recycled water in the wand washers.9. Properly maintain the system's water filters. Dirt in the water, caused by worn out filters,

will cause premature wear in the wand washer's pump, cylinder, piston, and orifice.10. Water that leaves the dealer's property must meet all environmental and safety

regulations. In some cases, depending on your local regulations, a permit is required.





Note: The shaded areas, in the flow chart above indicate the most efficient cleaning method.





Adhere to all chemical and equipment manufacturers recommended PPE and controls.

All waste streams must be handled in accordance with all local, state, federal, and other applicable regulations.

Equipment

Specifications

Fire Hose

Pressure: minimum 80 to 125 psiVolume: minimum 60 to 100 gal./minWater temperature: (ambient temperature)Chemicals: none

Wand Washer (High Pressure)

Pressure: minimum 2000 psiVolume: minimum 210 gal/hourWater temperature: 60C (140F)Chemicals: refer to Chemicals section.

Wand Washer (Medium Pressure)

Pressure: minimum 800 psiVolume: minimum 15 gal/hourWater temperature: (ambient temperature)Chemicals: none

Water Cannon

Pressure: minimum 500 psiVolume: minimum 20 to 30 gal/minWater temperature: (ambient temperature)Chemicals: none

Supplier Recommendations

1. High Pressure Wand Washer: Available through the Cat Tools and Shop Products Guide(NENG2500). Also, International Resource Management offers complete systems.Phone (815) 872-7400 or 1-800-550-5019.

2. Medium Pressure Wand Washer: Available through the Cat Tools and Shop ProductsGuide (NENG2500) and International Resource Management.

3. Water Cannon: International Resource Management. Phone (815) 872-7400 or 1-800-550-5019.

4. Fire hose: International Resource Management. Phone (815) 872-7400 or 1-800-550-5019.





filtration, evaporation, and chemical encapsulation systems.2. Landa systems - Landa offers over six models of waste water recycling and treatments

systems ranging from simple oil water separators to complete closed-loop recyclingsystems. They also offer pressure washers and part washers.

3. Polybac Enzyme systems - The closed-loop CTX-BIOX Water Cleaning System is apatented system which will efficiently remove oil and grease or other organics from asteam/high pressure washing station in a closed-loop operation. The packaged systems

are pre-engineered and designed to accomplish the following:

a. Collect the steam cleaning waste water which typically contains oil, grease, metals,emulsifiers (surfactants), and other suspended matter.

b. Settle out large particulate matter.c. Biodegrade oil, grease, surfactants, and other soluble organic materials.d. Collect and store the clean water for re-use.

1. International Resource Management.

All of these suppliers have systems currently being used by Caterpillar dealers. The

relative effectiveness of the systems vary depending on the chemicals and maintenanceprogram the dealer uses. All of the systems have satisfied dealers. Choose a system thatmeets the needs of the dealership and also complements other cleaning systems.

All of these suppliers will provide complete turn-key systems that will include the criticaldesign and layout of the wash rack pad.

Note: Contact your local Environmental Agency for a requirement list and any requiredpermits prior to selecting a cleaning system.

Waste Dirt Disposal OptionsUsed wash water and cleaning by-products from machine cleaning can be treated ordisposed of in several ways, depending on applicable laws and regulations. Somepossible treatment and disposal methods include:

1. Pay to have the dirt removed by a waste handling company.2. Clean the soil by aeration (spreading the soil out and working it). This takes a large

section of land and is time consuming.3. Compact waste paper and dirt into a dumpster. This can be accomplished by dumping

mud from the initial cleaning area on top of the waste paper in a dumpster. A compactorwheel can be run over the top of this waste to further compact the material. This methodreduces the volume of waste disposed of by a waste handling company.

4. Heavily oil-saturated soil can be incinerated.5. Heavily oil-saturated soil can be Bio treated. The soil is treated with enzymes that will

biodegrade the grease and oils.6. Give the waste dirt to asphalt processing plants.7. Require the customer to clean extremely dirty machines or machines potentially

contaminated with hazardous materials before shipping them to the dealership.8. Charge the customers an environmental rate based on machine condition and time

required to clean the machine.





Note: Contact your local Environmental Agency prior to implementing any of theabove waste dirt disposal option to verify that the option you select is in fullcompliance with applicable laws

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