Dealer_guide_ccc_standards.pdf

Cat® Dealer Contamination Control Compliance Guide Caterpillar Contamination Control MAY 2015

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SECTION 1

TRAINING

Training

Inexpensive Action

1.1) Contamination control training program in place.

Good = 10 Good • Initial and on-going formal training program for all parts and service shop personnel, (labor and management to include purchasing authority). • Training program is documented. • Training is on a consistent time line, minimum – yearly. • Documentation consists of who conducted, who participated, when and description of the training content.

Acceptable = 5

NOTE: If the facility employs contract people for housekeeping etcetera then those people are to be included in Contamination Control training.

Acceptable • Informal training program for all parts and service shop personnel, (labor and management to include purchasing authority). • Daily, weekly or monthly team meetings that includes contamination control as a topic. • Documentation consists of who conducted, who participated, when and description of the training content. 4

Training

Inexpensive Action

1.1) Contamination control training program in place.

Not recommended = 0

NO CONTAMINATION CONTROL TRAINING PROGRAM, NOT ALL IDENTIFIED PEOPLE TRAINED, AND OR DOCUMENTATION

Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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SECTION 2

EQUIPMENT WASH FACILITY

Equipment Wash Facility

Inexpensive Action

2.1) Procedures in place to wash all machines and components before they enter shop.

Good = 10 Good • Procedures in place and clearly communicated to all Dealer and Customer personnel. • All machines / components have all removable contaminants (dirt, debris, oil, grease, coolant and other contaminants) removed before entering the shop / work area.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Equipment Wash Facility

Expensive Action

2.2) Medium to high volume wash equipment.

Good = 10 Good • Water volume is significant in order to clean machines / components effectively and efficiently. • Dispensed water is visibly clean. NOTE: When local laws / regulations prohibit the Dealer reaching large enough volumes and pressures, the Dealer complies with the maximum allowed by law.

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Equipment Wash Facility

Expensive Action

2.2) Medium to high volume wash equipment.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

10

Equipment Wash Facility

Intermediate Action

2.3) Hot water and soap / degreaser used with pressure wash equipment.

Good = 10 Good • Machines and components are washed using high pressure, hot water. • Soap / Degreaser injected automatically.

• Machines and components are rinsed with clean water.

Acceptable = 5 Acceptable • Machines and components are washed using high pressure and hot water. • Soap / Degreaser solution applied manually with pressure sprayer. • Machines and components are rinsed with clean water. 11

Equipment Wash Facility

Intermediate Action

2.3) Hot water and soap / degreaser used with pressure wash equipment.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Equipment Wash Facility

Expensive Action

2.4) Oil and mud separation system (from wash water).

Good = 6 Good • Filtered recycling system for mud / solids and petroleum products. • Dispensed water is visibly clean.

Acceptable = 3

NOTE: If the facility does not reuse the wash water then this standard is Not Applicable (NA).

Acceptable • Purpose designed settling pit or similar design that separates mud and silt from the wash water in order to be returned / reused. • Petroleum products are removed from wash water. • Dispensed water is visibly clean. 13

Equipment Wash Facility

Expensive Action

2.4) Oil and mud separation system (from wash water).

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Equipment Wash Facility

Expensive Action

2.5) Keep washed equipment clean as it moves from wash pad to the shop.

Good = 8 Good • Concrete, crushed stone / gravel or other material, (bricks, blocks, asphalt, etcetera), between wash pad and shop. • The pathway is kept free of dirt and debris. • Machine / component arrives in the shop in a clean state.

Acceptable = 4 Acceptable • Concrete, crushed stone / gravel or other material, (bricks, blocks, asphalt, etcetera), between wash pad and shop.

• The pathway is NOT completely free of dirt and debris. • Machine / component arrives in the shop in a clean state.

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Equipment Wash Facility

Expensive Action

2.5) Keep washed equipment clean as it moves from wash pad to the shop.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Equipment Wash Facility

Inexpensive Action

2.6) Wash or clean machines / components before they are returned to the customer.

Good = 6 Good • Procedures in place and clearly communicated to all Dealer personnel. • All machines / components are washed as needed after the repair, prior to returning to customer. • All removable dirt, spills, debris, etcetera is removed.

Acceptable = 3 Acceptable • No procedure in place but all machines / components are washed as needed after the repair, prior to returning to customer. • All removable dirt, spills, debris, etcetera is removed.

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Equipment Wash Facility

Inexpensive Action

2.6) Wash or clean machines / components before they are returned to the customer.

Not Recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Equipment Wash Facility

Inexpensive Action

2.7) Housekeeping… Wash facility is kept clean and orderly.

Good = 6 Good • Facility cleaning procedures are communicated to personnel that perform wash activities. • Inside and outside kept free of debris / clutter / trash. • Wash equipment room / area and supplies kept clean and organized. • Dirt / debris on wash pad does NOT accumulate between uses.

Acceptable = 3 Acceptable • Inside and outside kept free of debris / clutter / trash. • Wash pad has minimal accumulations of mud / dirt and is cleaned at end of each shift. • Wash equipment room / area and supplies kept clean and organized. 19

Equipment Wash Facility

Inexpensive Action

2.7) Housekeeping….Wash facility is kept clean and orderly.

Not Recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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SECTION 3

SHOP ATTRIBUTES

Shop Attributes

Expensive Action

3.1) Concrete apron at shop entrance.

Good = 6 Good • Sized to accommodate the most frequently worked-on machines, (length & width) to be serviced / repaired. • Preventative Maintenance process in place to maintain apron clean with conformance records. • Machine / component arrives in the shop in a clean state. • The apron is free of dirt / debris / clutter.

Acceptable = 3 Acceptable • Sized to accommodate the most frequently worked-on machines, (length & width) to be serviced / repaired.

• Machine / component arrives in the shop in a clean state. • The apron is NOT completely free of dirt / debris / clutter. 23

Shop Attributes

Expensive Action

3.1) Concrete apron at shop entrance.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Attributes

Expensive Action

3.2) Workshop doors installed and functional.

Good = 6 Good • Doors in place to reduce dust levels. • Doors are operational. • Process in place to close doors during inclement weather. NOTE: High speed type doors also earn a ‘Good’ rating if they meet the criteria.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Shop Attributes

Expensive Action

3.3) Floor condition.

Good = 6 Good • Floors are sealed. • Floors have a minimal amount of degradation. • There is NO accumulation of contaminants in degraded areas. NOTE: Floor is not contributing to contaminants in degraded areas.

Acceptable = 3 Acceptable • Floors are non-sealed or incompletely sealed. • Floors have a minimal amount of degradation. • There is minimal accumulation of contaminants in degraded areas. NOTE: Floor is not contributing to contaminants in degraded areas. 26

Shop Attributes

Expensive Action

3.3) Floors condition.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Attributes

Inexpensive Action

3.4) Walkways / safety / storage areas marked and kept free of obstacles (inside and outside).

Good = 6 Good • Walkways / safety and storage areas are properly marked as required. • All demarcation materials in good condition.

• Walkways are free of obstacles. • Stored items are kept organized within the demarcated areas.

Acceptable = 3

NOTE: Facility is not mandated to include demarcated walkways / safety and storage areas.

Acceptable • Walkways / safety and storage areas are properly marked as required. • Demarcation materials have minimal amount of wear, peeling and or chipping. • Walkways / safety and storage areas NOT totally free of obstacles. 28

Shop Attributes

Inexpensive Action

3.4) Walkways / safety / storage areas marked and kept free of obstacles (inside and outside).

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Attributes

Intermediate Action

3.5) Stands used to support components during rebuild / repair.

Good = 6 Good • Stands: –

Used to support major components. o

Not recommended = 0

Frequently worked on.

–

Dedicated and purpose built.

–

Made of metal or a durable material.

–

Clean and maintained clean.

NOTE: If stands are stored outside then a cleaning process is in place to ensure stands are clean before entering the workshop.

Not recommended Criteria for ‘Good’ not met.

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Shop Attributes

Inexpensive Action

3.6) Clean plastic / wooden materials are used to support components or parts.

Good = 6 Good • Materials are in good condition and clean when used. • Robust enough to support the component / part placed on it. • Parts and or components are stored off the floor.

Not recommended = 0

NOTE: Large components on the floor is allowed if placing them on support structures creates a safety concern.

Not recommended Criteria for ‘Good’ not met.

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Shop Attributes

Inexpensive Action

3.7) Designated assembly / disassembly benches are maintained clean.

Good = 6 Good • Benches cleaned daily and as needed, including work surfaces, protective covers, shelves and around vises attached to the workbench. • Durable material: – Covers work surface to protect sensitive parts. – Does not absorb fluids and contaminants. – May be permanent or temporary.

Acceptable = 3 Acceptable • Benches cleaned daily and as needed, including work surfaces, shelves and around vises attached to the workbench. • Smooth metal work surface and not painted.

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Shop Attributes

Inexpensive Action

3.7) Designated assembly / disassembly benches are maintained clean.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Attributes

Intermediate Action

3.8) Air supply lines provide clean and dry air.

Good = 6 Good • A filter and water separator located at each dispensing point, including hose cleaning stations. – 1 to 10 micron filter. • Preventative Maintenance program in place with conformance records. • Airlines for air powered tools only, are labeled. • Airlines NOT utilized are blocked off.

OR Good • A central air drier on the compressor outlet, upstream of the shop’s air supply line. • A 1 to 10 micron filter at each dispensing point. • Preventative Maintenance program in place with documented records. • Hose cleaning station is required to have a water separator and filter at dispensing point. • Airlines for air powered tools only, are labeled. • Airlines NOT utilized are blocked off. 34 NOTE: Labeling. If the facility has more air supply points that not equipped with filters and water separators then ‘Good’ can be achieved with labels only on the supply points that have filters and water separators. Labeling must be consistent.

Shop Attributes

Intermediate Action

3.8) Air supply lines provide clean and dry air.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Shop Attributes

Intermediate Action

3.9) Part washing stands filtered to meet cleanliness targets.

Good = 10 Good Solvent (petroleum) stand: • 4 micron final filter. • 15 or 25 micron bag filter on drain.

• Diatomaceous earth media filter. • Documentation of conformance and maintenance of ISO -/16/13.

AND OR Good Aqueous (water based) stand: • Appropriate filtration used to maintain solvent at cleanliness target. • Documentation of conformance and maintenance of ISO -/16/13 using comparative based patch test. Caterpillar Portable Contamination Instructional Kit, part number 202-2301 or equivalent is used. • No evidence of corrosion after wash. NOTE: It is possible for a facility to achieve a ‘Good’ rating if unfiltered solvent stands are used for rough cleaning only and labeled in that manner however, there is a solvent stand(s) readily available for final cleaning that meet the criteria for ‘Good’ rating. NOTE: Any solvent used in a portable sprayer meets ISO -/16/13 and container that is clean has a documented refill procedure.

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Shop Attributes

Intermediate Action

3.9) Part washing stands filtered to meet cleanliness targets.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

NOTE: It is possible for a facility to achieve a ‘Good’ rating if unfiltered solvent stands are used for rough cleaning only and labeled in that manner however, there is a solvent stand(s) readily available for final cleaning that meet the criteria for ‘Good’ rating. NOTE: Any solvent used in a portable sprayer meets ISO -/16/13 and container that is clean has a documented refill procedure.

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Shop Attributes

Intermediate Action

3.10) Dispensed oil supply filtered to meet cleanliness targets.

Good = 10 Good • Dispensing nozzles clean and protected. • Dispensing point filtration. • Dispensed oil meets ISO -/16/13. • Documentation of conformance and maintenance of ISO -/16/13.

Not recommended = 0

NOTE: Includes both permanent and portable storage tanks. Portable containers include but not limited to 330 gallon / 1000 liter totes or 55 gallon / 208 liter barrels are used as the facilities oil supply and storage.

Not recommended Criteria for ‘Good’ not met.

NOTE: If the dispensed oil does not meet ISO -/16/13 the systems filtration may not be adequate. In this situation, installation of additional filtration and or filtration with lower micron filtration and or higher beta ratio. Kidney loop filtration may need to be deployed on storage tanks. Also, it is imperative that the filter installation has the capability inherent to the pressure in the system.

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Shop Attributes

Intermediate Action

3.11) Diesel Exhaust Fluid (DEF) cleanliness managed.

Good = 10 Good

Not recommended = 0

• Bulk containers: – Compatible for use with DEF. – Dispensing point filtration. o Compatible with DEF. – 4 micron breather. o Compatible with DEF. NOTE: Do not use desiccant to remove water. – Documented Preventative Maintenance procedures with conformance records. • Transfer equipment and intermediate containers are maintained clean and are compatible. • Dispensing nozzles are correct size, clean and protected. • Procedure in place to clean fill opening of engine or machine DEF tank. • Concentration is within the range of 29-35%. • Storage temperature is between -9° C (15.8° F) and 25° C (77° F).

Not recommended Criteria for ‘Good’ not met. NOTE: Reference IRM AVAILABILITY OF DIESEL EXHAUST FLUID (DEF) FOR SCR-EQUIPPED ENGINES, PELJ1160-01. DEF concentration can be measured using a refractometer (part number 360-0774, 431-7087 or equivalent). NOTE: Reference current version of Caterpillar Machine Fluids Recommendation, SEBU6250 and Caterpillar Filters Recommendations, SEBU9208.

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Shop Attributes

Expensive Action

3.12) Control of debris generating activities.

Good = 6 Good

Acceptable = 3

• Continuous debris generating activities are performed in a separate shop / area. NOTE: Continuous defined as a constant recurrence or production. • Assembly and clean areas are protected from contaminants during intermittent debris generating activities. • Equipment such as shields, extraction devices, etcetera are available and used. NOTE: There are no contaminants found in assembly and clean areas during or after intermittent debris generating activities.

Acceptable • Assembly and clean areas are protected from contaminants during debris generating activities. – Equipment such as shields, extraction devices, etcetera are available and used. NOTE: There are no contaminants found in assembly and clean areas during or after debris generating activities. 40

Shop Attributes

Expensive Action

3.12) Control of debris generating activities.

Not recommended = 0 Not recommended Criteria for ‘Good’ and ‘Acceptable’ not met.

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Shop Attributes

Inexpensive Action

3.13) Tool and equipment cleanliness management.

Good = 8 Good All tools and equipment that contact liquid or gaseous fluid parts. Example: fuel, hydraulic, oil and air. • Stored organized, clean and protected. • Identified in a tracking system to facilitate cleaning and storage protection. – Tracking system is either computer software or manually using paper.

Acceptable = 4 Acceptable All tools and equipment that contact liquid or gaseous fluid parts. Example: fuel, hydraulic, oil and air. • Stored organized, clean and protected.

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Shop Attributes

Inexpensive Action

3.13) Tool and equipment cleanliness management.

Not Recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Attributes

Inexpensive Action

3.14) Housekeeping... Tool and equipment storage room / areas are clean and orderly.

Good = 6 Good • Tools and equipment, shelves, racks, drawers, bins, and containers are clean and organized. • No buildup of dirt and debris in corners and around column posts, storage devices and benches. • Tools, equipment, supplies that are NOT adaptable to shelves or drawers are stored off the floor. • 5S principles are being applied.

Not Recommended = 0 Not recommended Criteria for ‘Good’ not met.

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SECTION 4

SHOP PRACTICES

Shop Practices

Inexpensive Action

4.1) Supply of clean caps, plugs, protective covers and plastic wrap available.

Good = 8 Good Caps, plugs, protective covers and plastic wrap: • Stored and protected from the environment. • Interior of storage device does NOT contain contaminants.

• Identified for storage. • Readily available for shop and parts personnel. • Reused caps and plugs cleaned prior to storage.

Not Recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Shop Practices

Inexpensive Action

4.2) Use of proper hose / tube end protection.

Good = 10 Good • Clean caps and plugs (plastic or metal) and protective covers are used. NOTE: Protective covers (includes Conduit CoversSM or equivalent) used only on hoses and tubes NOT removed from machine / component. • Proper caps and plugs are used. ‒ Screw type caps and plugs used with threaded

hose / tube fittings. ‒ Push on caps and plugs used with unthreaded

hose / tube fittings. ‒ Cover plates used with split flange hose fittings. ‒ Correct size used.

• Tape NOT used directly on openings.

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Shop Practices

Inexpensive Action

4.2) Use of proper hose / tube end protection.

Acceptable = 5 Acceptable • Hose / tube ends and related ports are protected with plastic that is secured to prevent contaminant entry. • Clean plastic being used. • Tape NOT used directly on openings.

Not Recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Practices

Inexpensive Action

4.3) Critical stored / staged contamination sensitive parts and components are protected.

Good = 10 Good • Individually protected from contaminants and damage. • Stored / staged protection as dictated by work flow timeline and environmental conditions. • The proper type and amount of rust proofing applied, (no evidence of corrosion).

Acceptable = 5

NOTE: Critical contamination sensitive parts include but not limited to crankshafts, camshafts, valves, gears, axles, etcetera.

Acceptable • Protected as a group from contaminants and damage. • Covered with loose plastic covers. • Stored / staged protection as dictated by work flow timeline and environmental conditions. • The proper type and amount of rust proofing applied, (no evidence of corrosion). 50

Shop Practices

Inexpensive Action

4.3) Critical stored / staged contamination sensitive parts and components are protected.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Practices

Inexpensive Action

4.4) Work in process (WIP) parts, components and cavities are protected.

Good = 10 Good • Parts, components and cavities protected with: ‒ Clean drop cloth, clean plastic, or equivalent. ‒ Clean magnetic cover. ‒ Clean closed container.

• Protected during WIP inactivity: ‒ During break periods. ‒ Overnight. ‒ Between shifts.

Not recommended = 0

NOTE: Cavities are completely sealed against the environment.

Not recommended Criteria for ‘Good’ not met.

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Shop Practices

Inexpensive Action

4.5) New parts / components are kept in original packaging until ready for assembly.

Good = 10 Good • Parts / components: – Delivered and stored in original packaging that is not damaged or opened. – Protected clean and dry. NOTE: Parts that have been inspected for part identification or damage concerns have been repackaged as soon as practical to prevent contaminant ingression.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Shop Practices

Intermediate Action

4.6) Approved methods of storing and filtering oil that is to be reused.

Good = 10 Good Storage tank with filtration equipment: • Tank is closed and sealed. • Multi-pass filtration capability. • Filtered prior to being dispensed. –

Fill oil specification of ISO -/16/13. o Documentation of conformance and

maintenance of ISO -/16/13.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Shop Practices

Intermediate Action

4.7) Approved methods of transporting, storing and disposing of waste fluids.

Good = 6 Good • Waste fluids removed from shop with vacuum pump system or vacuum vessel. – Connected directly to the machine / component reservoir. – Used to remove fluid directly from a drain pan / drain cart. • Fluids transferred to waste reservoir without spills.

Acceptable = 3 Acceptable • Waste fluid removed from the shop with wheeled drain carts. – Carts equipped with or without covers. • Fluids transferred to waste reservoir without spills. 55

Shop Practices

Intermediate Action

4.7) Approved methods of transporting, storing and disposing of waste fluids.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Practices

Inexpensive Action

4.8) Assembly aids container (lubricant or grease) cleanliness managed.

Good = 8 Good

Acceptable = 4

Assembly aids and lubricant application containers: • Lube containers cleaned at time of refill with documented refill procedure that is being followed. • Oil used for refill meets ISO -/16/13 with conformance records. • Maintained clean. • Stored in a clean, closed environment. • Covered with a secured cap or lid. • Purposed containers with appropriate label.

Acceptable Assembly aids and lubricant application containers: • Lube containers cleaned at time of refill. • Oil used for refill meets ISO -/16/13 with conformance records. • Maintained clean. • Stored in a clean, closed environment. • Covered with a secured cap or lid. • Purposed containers with appropriate label. 57 NOTE: If all lubrication oil containers used for assembly are single use and never refilled then a documented refill process is not required and a ‘Good’ rating can be awarded if the remaining criteria is in compliance.

Shop Practices

Inexpensive Action

4.8) Assembly aids container (lubricant or grease) cleanliness managed.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Practices

Intermediate Action

4.9) Removed hoses and tubes cleaned and protected prior to reinstallation.

Good = 10 Good • Approved hose / tube cleaning procedure, SEBF8485 is posted or available with the tool and is being followed. • All hoses and tubes are capped / plugged after cleaning with appropriate clean cap / plug until installation.

Not recommended = 0 0

NOTE: Reference current version of guideline SEBF8485 for proper hose cleaning procedures. Local translation of the current version of SEBF8485 is considered ‘Good’.

Not recommended Criteria for ‘Good’ not met.

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Shop Practices

Inexpensive Action

4.10) Final delivery of components to technician / customer.

Good = 10 Good Components / engines include: • All ports properly capped / plugged. • All openings protected.

• Shrink wrapped or fitted covers. • Securely fastened to original shipping stand.

Acceptable = 5 Acceptable Components / engines include: • Wrapped completely in plastic (individual openings NOT protected). • Securely fastened to non-original shipping stand.

NOTE: The original shipping stand / container is defined as one that has been manufactured specifically for that component, by the Original Equipment Manufacturer, the Dealer or supplier purchased in order to provide transport in a secure and safe manner.

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Shop Practices

Inexpensive Action

4.10) Final delivery of components to technician / customer.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

NOTE: The original shipping stand / container is defined as one that has been manufactured specifically for that component, by the Original Equipment Manufacturer, the Dealer or supplier purchased in order to provide transport in a secure and safe manner.

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Shop Practices

Inexpensive Action

4.11) Timeliness of cleaning up lubricant, fuel and coolant spills.

Good = 8 Good • Lubricant, fuel and coolant spills are cleaned up immediately.

Acceptable = 4 Acceptable • Lubricant, fuel and coolant spills are cleaned up within one (1) hour after they occur.

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Shop Practices

Inexpensive Action

4.11) Timeliness of cleaning up lubricant, fuel and coolant spills.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Practices

Inexpensive Action

4.12) Floor cleaning methods and frequency.

Good = 6 Good Floors are: • Cleaned with a powered floor scrubber that is equipped with scrubbing action, water, soap and vacuum. ‒ There is no residue left after cleaning process. • Cleaned daily at a minimum, more if needed. • NOT cleaned using granular materials.

AND OR Good Floors are: • Cleaned using manual labor to sweep and mop floors or equivalent. ‒ Clean mop water containing a degreaser is available and used. o Mop buckets / mops are emptied and cleaned after use. • There is no residue left after cleaning process. • Cleaned daily at a minimum, more if needed. • NOT cleaned using granular materials. 64

Shop Practices

Inexpensive Action

4.12) Floor cleaning methods and frequency.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Shop Practices

Inexpensive Action

4.13) Purposed waste containers clean and organized.

Good = 4 Good • Labeled or designated signage is posted. • NOT damaged. • Waste NOT above the rim or overflowing. • Designated for a specific type of waste are applicably labeled or have designated signage and only contain that type. • If painted then paint is in good condition.

Acceptable = 2 Acceptable • NOT damaged. • Waste NOT above the rim or overflowing.

• Designated for a specific type of waste are applicably labeled or have designated signage and only contain that type. • If painted then paint is in good condition. 66

Shop Practices

Inexpensive Action

4.13) Purposed waste containers clean and organized.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Shop Practices

Inexpensive Action

4.14) Grease distribution / protection.

Good = 6 Good • Grease delivered / stored using purpose-built clean containers (bulk system, totes, barrels). • Fill and dispensing nozzles are clean & protected.

• Containers are equipped with 4 micron breather with the ability to remove moisture if the grease contacts air as the container empties during use.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Shop Practices

Inexpensive Action

4.15) Housekeeping… Shop is clean and orderly.

Good = 6 Good • The shop is organized. • Floors walls, ceilings, equipment and tooling are clean and maintained clean on a regular basis. • Storage cabinets, storage racks, storage shelves and storage bins are clean and maintained clean on a regular basis. • No buildup of contaminants in corners, around column posts, benches and permanent equipment. • 5S principles are being applied.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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This is a requirement for a 3 star or greater rating.

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SECTION 5

DISASSEMBLY AREA IN SPECIALIZATION SHOP / CRC

Disassembly Area In Specialization Shop / CRC

Inexpensive Action

5.1) Procedures in place to wash all components before disassembly.

Good = 10 Good • All components / engines have all removable contaminants (dirt, debris, fuel, oil, grease, coolant and other contaminants) removed before entering the disassembly area / shop.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Disassembly Area In Specialization Shop / CRC

Expensive Action

5.2) Washing system with rinse and rust inhibitor application.

Good = 8 Good • Hot automatic washing system with automatic or manual rinse cycle. • Rinse cycle must flush all soap and particulate contaminants. • The proper type and amount of corrosion inhibitor applied (no evidence of corrosion). NOTE: Corrosion inhibitor may be incorporated as part of the wash solution. • A clean and protected part is the outcome.

AND OR Good • Immersion / agitation cleaning system with manual pressure wash rinse. • Rinse cycle must flush all chemical solution and particulate contaminants. • The proper type and amount of corrosion inhibitor applied (no evidence of corrosion). • A clean and protected part is the outcome. NOTE: If local governing body ordinances restrict the use of a hot automatic washing system then this equipment is not required for a ‘Good’, as long as the end result is clean and protected parts.

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Disassembly Area In Specialization Shop / CRC

Expensive Action

5.2) Washing system with rinse and rust inhibitor application.

Acceptable = 4 Acceptable • Components washed using high pressure and hot water with soap / degreaser injected automatically or manually applied. • Low flow / low pressure rinse must flush all soap and particulate contaminants. • The proper type and amount of corrosion inhibitor applied (no evidence of corrosion). • A clean and protected part is the outcome.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Disassembly Area In Specialization Shop / CRC

Inexpensive Action

5.3) Gaskets removed in disassembly area.

Good = 10 Good • All work is done in disassembly area. • Gaskets are removed while wet. • Contaminants from removal process are NOT found in assembly area. • Parts are rinsed completely of all contaminants following the use of a metal conditioning disk.

Acceptable = 5 Acceptable • All work is done in disassembly area. • Gaskets are removed dry. • Contaminants from removal process are NOT found in assembly area. • Parts are rinsed completely of all contaminants following the use of a metal conditioning disk. 75

Disassembly Area In Specialization Shop / CRC

Inexpensive Action

5.3) Gaskets removed in disassembly area.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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SECTION 6

FUEL INJECTION COMPONENT TEST ROOM / AREA

Fuel Injection Component Test Room / Area

Expensive Action

6.1) Fuel injection test equipment located in climate controlled, clean, closed room.

Good = 10 Good • Test equipment located in a closed clean room. • Purpose built heating, ventilation and air conditioning system provides: – Filtered clean and dry air. o Filtration is maintained with conformance records. – All air handling vents are clean. – Pressurized / positive pressure.

Acceptable = 5 Acceptable • Test equipment located in a closed clean room. • Room is climate controlled with filtration. – Filtration is maintained with conformance records. – All air handling vents are clean. NOTE: Climate controlled is in reference to heating and air conditioning only. 79

Fuel Injection Component Test Room / Area

Expensive Action

6.1) Fuel injection test equipment located in climate controlled, clean, closed room.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

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Fuel Injection Component Test Room / Area

Inexpensive Action

6.2) Preventative Maintenance program on all testing equipment.

Good = 8 Good • Documented Preventative Maintenance procedures with conformance records. – All equipment that is used to test fuel injection system components. o Includes fuel injection test bench, pop tester,

unit injector tester, etcetera.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

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Fuel Injection Component Test Room / Area

Inexpensive Action

6.3) Use appropriate calibration fluid and clean lubrication oil.

Good = 10 Good • Calibration fluid and lubrication oil cleanliness are routinely checked with conformance records. – Calibration fluid meets ISO -/15/13 target or cleaner. – Lubrication oil meets ISO -/16/13 target or cleaner. NOTE: Using anything other than calibration fluid such as diesel fuel is not recommended.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

82

Fuel Injection Component Test Room / Area

Inexpensive Action

6.4) No debris generating tooling or activities.

Good = 8 Good • Debris generating tools or activities includes but not limited to files / filing, spray paint / spray painting, sandpaper / sanding, Scotch-Brite™, buffing, drill bits / drilling, etcetera.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

83

Fuel Injection Component Test Room / Area

Inexpensive Action

6.5) Fuel injection test equipment lines and ports are protected.

Good = 8 Good • Lines and ports are capped with proper fuel line caps / plugs when NOT in use.

NOTE: Typically the proper cap is of the threaded type for the fuel injection test bench.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

84

Fuel Injection Component Test Room / Area

Expensive Action

6.6) Floors are in good condition.

Good = 4 Good • Floor is sealed or tiled (smooth surface). • Floor is free of degradation. • Floor mats are NOT perforated or porous type.

Acceptable = 2

NOTE: If safety regulations require perforated or porous matting, the floor must still be free of contamination.

Acceptable • Concrete floor is not sealed or incompletely sealed. • Minimal degradation is acceptable as long as floor remains clean and no accumulation of contaminants in degraded areas. • Floor mats are NOT perforated or porous type. 85

Fuel Injection Component Test Room / Area

Expensive Action

6.6) Floors are in good condition.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

86

Fuel Injection Component Test Room / Area

Inexpensive Action

6.7) Low lint towels are used and available.

Good = 6 Good • Low lint, tear resistant towels are used. • Towels are available in significant quantity. • Towels are stored in a clean environment.

• Towels other than low lint are NOT used. NOTE: Examples of low lint towels are the shop towels 162-5791 or 265-2256.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

87

Fuel Injection Component Test Room / Area

Inexpensive Action

6.8) Fuel injection components are capped or plugged.

Good = 10 Good • Fuel injection components are capped with proper clean caps and plugs. • Cap / plug use includes work in process and ready to ship. NOTE: Applies to all Reman, rebuilt, repaired as well as used components that are tested.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

88

Fuel Injection Component Test Room / Area

Inexpensive Action

6.9) Used in-coming fuel system components flushed before testing.

Good = 10 Good • Drained completely. • Oil and fuel flushed thoroughly.

NOTE: Applies to all rebuilt or repaired (outside of the dealer) as well as used components that are tested.

Not recommended = 0

NOTE: If the facility process does not test used in-coming fuel system components then this standard is Not Applicable (NA).

Not recommended Criteria for ‘Good’ not met.

89

Fuel Injection Component Test Room / Area

Inexpensive Action

6.10) Housekeeping… Fuel injection room / area is clean and orderly.

Good = 6 Good • The fuel injection room / area is organized. • Floors walls, ceilings, equipment and tooling are clean and maintained clean on a regular basis. • Storage cabinets, storage racks, storage shelves and storage bins are clean and maintained clean on a regular basis. • No buildup of contaminants in corners, around column posts, benches and permanent equipment. • 5S principles are being applied.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

90

This is a requirement for a 3 Star or greater rating.

91

SECTION 7

HYDRAULIC CYLINDER REBUILD SHOP / AREA

Hydraulic Cylinder Rebuild Shop / Area

Intermediate Action

7.1) Cylinders washed with brush after honing.

Good = 10 Good • Cylinders are washed with cleaning brush and cleaning solution. • Process in place to check cleanliness of cylinder barrels after washing. ‒ A clean white towel is used to check for contaminants. (Low-lint towels are preferred but not required).

Acceptable = 5

NOTE: Regardless if the dealer or a supplier performs the honing process the cylinder barrel must be cleaned using the proper cleaning equipment and process.

Acceptable • Cylinders are washed with cleaning brush and cleaning solution.

93

Hydraulic Cylinder Rebuild Shop / Area

Intermediate Action

7.1) Cylinders washed with brush after honing.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

94

Hydraulic Cylinder Rebuild Shop / Area

Intermediate Action

7.2) Cylinder barrel storage.

Good = 6 Good • After the cleaning process: – Cylinder ends are covered with clean plastic or clean magnetic covers. – Ports are protected with the appropriate clean cap / plug. • Cylinder barrels stored in dedicated racks and off the floor.

Not recommended = 0

NOTE: Cylinder barrels stored in a manner that will NOT be a safety concern

Not recommended Criteria for ‘Good’ not met.

95

Hydraulic Cylinder Rebuild Shop / Area

Intermediate Action

7.3) Cylinder rod storage.

Good = 6 Good • After the cleaning process, rods and rod ends are wrapped with plastic, or otherwise protected. • Rods stored in dedicated racks off the floor. • To prevent damage: – There is space between rods. – Protective material covers racks at rod / rod eye contact points. NOTE: Rods are to be protected from damage during transit to and from any rework process.

Not recommended = 0

NOTE: Cylinder rods stored in a manner that will NOT be a safety concern

Not recommended Criteria for ‘Good’ not met.

96

Hydraulic Cylinder Rebuild Shop / Area

Inexpensive Action

7.4) Ports in assembled cylinders protected with appropriate caps / plugs.

Good = 10 Good • Ports are protected with the proper clean cap / plug / metal cover. ‒ If port is threaded

then cap or plug must be

threaded. ‒ If ports are split flange then metal covers and

O-rings are used. • Tape NOT used directly on openings.

Acceptable = 5 Acceptable • Ports are plugged with clean plastic non-threaded plug / cap that covers opening and mounting holes. • Rod must be secured in the retracted position and cylinder drained. • Tape NOT used directly on openings. 97

Hydraulic Cylinder Rebuild Shop / Area

Inexpensive Action

7.4) Ports in assembled cylinders protected with appropriate caps / plugs.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

98

Hydraulic Cylinder Rebuild Shop / Area

Inexpensive Action

7.5) Preventative Maintenance program on cylinder test equipment.

Good = 6 Good • Documented Preventative Maintenance procedures with conformance records. • Oil in testing equipment meets ISO -/16/13 with conformance records.

Not recommended = 0 Not recommended

NO PM PROCEDURES, NO CONFORMANCE RECOREDS AND OR OIL DOES NOT MEET ISO -/16/13

Criteria for ‘Good’ not met.

99

Hydraulic Cylinder Rebuild Shop / Area

Intermediate Action

7.6) Side mounted cylinder tubes cleaned before reassembly.

Good = 10 Good • Approved hose / tube cleaning procedure, SEBF8485 is posted or available with the tool and is being followed.

• All hoses and tubes are capped / plugged after cleaning with appropriate clean cap / plug until installation.

Not recommended = 0

NOTE: Reference current version of guideline SEBF8485 for proper hose cleaning procedures. Local translation of the current version of SEBF8485 is considered ‘Good’.

Not recommended Criteria for ‘Good’ not met.

100

Hydraulic Cylinder Rebuild Shop / Area

Inexpensive Action

7.7) Housekeeping…. Hydraulic component rebuild shop / area is clean and orderly.

Good = 6 Good • The hydraulic component shop /area is organized. • Floors walls, ceilings, equipment and tooling are clean and maintained clean on a regular basis. • Storage cabinets, storage racks, storage shelves and storage bins are clean and maintained clean on a regular basis. • No buildup of contaminants in corners, around column posts, benches and permanent equipment. • 5S principles are being applied.

Not Recommended = 0 Not recommended Criteria for ‘Good’ not met.

101

This is a requirement for a 3 Star or greater rating.

102

SECTION 8

POWERTRAIN / HYDRAULIC TEST ROOM / AREA

Powertrain / Hydraulic Test Room / Area

Inexpensive Action

8.1) Preventative Maintenance program on the testing equipment.

Good = 8 Good • Documented Preventative Maintenance procedures with conformance records.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

104

Powertrain / Hydraulic Test Room / Area

Intermediate Action

8.2) Filtration system installed on the testing equipment to meet cleanliness targets.

Good = 10 Good • Appropriate filtration system installed on the testing equipment in order to achieve Roll-off cleanliness target. • Fluid consistently meets applicable Roll-off cleanliness target. • Documentation of conformance and maintenance of applicable Roll-off cleanliness target.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

105

Powertrain / Hydraulic Test Room / Area

Inexpensive Action

8.3) Hoses, fittings and covers capped, covered or properly protected.

Good = 6 Good • Hoses, fittings and adaptors are organized. • All hose assemblies stored with fittings capped / plugged with proper caps or plugs. • Hose couplings / fittings / adaptors that are clean are stored in a clean cabinet, drawer and or both ends properly protected outside of cabinet, drawer. • All covers used for testing are stored clean in a clean cabinet, drawer and or properly protected.

Acceptable = 3

Acceptable • Hoses, fittings and adaptors are organized. • Hose assemblies stored with clean ends that are open in an enclosed clean cabinet or ends covered / wrapped in clean plastic outside of cabinet. • Hose couplings / fittings / adaptors that are clean are stored in a clean cabinet, drawer and or both ends properly protected outside of cabinet, drawer. • All covers used for testing are stored clean in a clean cabinet, drawer and or properly protected. 106

Powertrain / Hydraulic Test Room / Area

Inexpensive Action

8.3) Hoses, fittings and covers capped, covered or properly protected.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

107

Powertrain / Hydraulic Test Room / Area

Inexpensive Action

8.4) Housekeeping… Powertrain test bench room / area is clean and orderly.

Good = 6 Good • The powertrain room / area is organized. • Floors walls, ceilings, equipment and tooling are clean and maintained clean on a regular basis. • Storage cabinets, storage racks, storage shelves and storage bins are clean and maintained clean on a regular basis. • No buildup of contaminants in corners, around column posts, benches and permanent equipment. • 5S principles are being applied.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met

108

This is a requirement for a 3 Star or greater rating.

109

SECTION 9

ENGINE DYNAMOMETER ROOM

Engine Dynamometer Room

Intermediate Action

9.1) Fuel supply filtered to meet cleanliness targets.

Good = 10 Good • Final fuel filtration: – For particulates. – For water removal. – Located between supply and engine connection. • Engine connection fitting is clean and protected. • Documented Preventative Maintenance procedures with conformance records. – Fuel meets ISO 18/16/13 cleanliness target.

Acceptable = 5

NOTE: Fuel sample for cleanliness conformance taken at connection point to engine fuel system .

Acceptable • Final fuel filtration – For particulates. – For water removal. – Located between supply and engine connection. • Engine connection fitting is clean and protected. • Fuel meets ISO 18/16/13 cleanliness with conformance records.

111

Engine Dynamometer Room

Intermediate Action

9.1) Fuel supply filtered to meet cleanliness targets.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

112

Engine Dynamometer Room

Intermediate Action

9.2) Dispensed oil supply filtered to meet cleanliness targets.

Good = 10 Good • Dispensing nozzles clean and protected. • Filter at dispensing point. • Dispensed oil meets ISO -/16/13. • Documentation of conformance and maintenance of ISO -/16/13.

Not recommended = 0

NOTE: Includes both permanent and portable storage tanks. Portable containers include but not limited to 330 gallon / 1000 liter totes or 55 gallon / 210 liter barrels are used as the facilities oil supply and storage.

Not recommended Criteria for ‘Good’ not met.

NOTE: If the dispensed oil does not meet ISO -/16/13 the systems filtration may not be adequate. In this situation, installation of additional filtration and or filtration with lower micron filtration and or higher beta ratio. Kidney loop filtration may need to be deployed on storage tanks. Also, it is imperative that the filter installation has the capability inherent to the pressure in the system.

113

Engine Dynamometer Room

Inexpensive Action

9.3) Proper breather on lubricant and fuel storage tanks.

Good = 8 Good • 4 micron filtered breather filter with ability to remove moisture. • Documented Preventative Maintenance procedures with conformance records.

Acceptable = 4

NOTE: Includes both permanent and portable storage tanks. Portable containers include but not limited to 330 gallon / 1000 liter totes or 55 gallon / 210 liter barrels are used as the facilities oil supply and storage.

Acceptable • 4 micron filtered breather.

• Documented Preventative Maintenance procedures with conformance records.

114

Engine Dynamometer Room

Inexpensive Action

9.3) Proper breather on lubricant and fuel storage tanks.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

NOTE: Reference the companies below for suitable breathers Des-Case Corp www.descase.com Schroeder Industrial www.schroederindustries.com Air Sentry www.airsentry.com 115

Engine Dynamometer Room

Inexpensive Action

9.4) Housekeeping… Engine dynamometer room is clean and orderly.

Good = 6 Good

Good = 6

• The dynamometer room is organized. • Floors walls, ceilings, equipment and tooling are clean and maintained clean on a regular basis. • Storage cabinets, storage racks, storage shelves and storage bins are clean and maintained clean on a regular basis. • No buildup of contaminants in corners, around column posts, benches and permanent equipment. • 5S principles are being applied.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

116

This is a requirement for a 3 Star or greater rating.

117

SECTION 10

UNDERCARRIAGE REBUILD SHOP / AREA

Undercarriage Rebuild Shop / Area

Inexpensive Action

10.1) Procedure in place to wash all undercarriage components before entering the shop / area.

Good = 8 Good • Procedures in place and clearly communicated to all Dealer and Customer personnel. • All track assemblies and undercarriage components have all removable contaminants (dirt, debris oil and grease and other contaminants) removed before entering the shop / work area.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

119

Undercarriage Rebuild Shop / Area

Expensive Action

10.2) Process and equipment in place to wash undercarriage parts / components.

Good = 8 Good • Hot automatic washing system with automatic or manual rinse cycle. • Rinse cycle must flush all soap and particulate contaminants. • The proper type and amount of rust proofing applied, (no evidence of corrosion). NOTE: Rust inhibitor may be incorporated as part of the wash solution. • A clean and protected part is the outcome.

Acceptable = 4 Acceptable • Components washed using high pressure and hot water with soap / degreaser injected automatically or manually applied. • Low flow / low pressure rinse must flush all soap and particulate contaminants. • The proper type and amount of rust proofing applied (no evidence of corrosion). • A clean and protected part is the outcome. 120

Undercarriage Rebuild Shop / Area

Expensive Action

10.2) Process and equipment in place to wash undercarriage parts / components.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

121

Undercarriage Rebuild Shop / Area

Intermediate Action

10.3) Part washing stands filtered to meet cleanliness targets.

Good = 10 Good Solvent (petroleum) stand: • 4 micron final filter. • 15 or 25 micron bag filter on drain.

• Diatomaceous earth media filter. • Documentation of conformance and maintenance of ISO -/16/13.

AND OR Good Aqueous (water based) stand: • Appropriate filtration used to maintain solvent at cleanliness target. • Documentation of conformance and maintenance of ISO -/16/13 using comparative based patch test. Caterpillar Portable Contamination Instructional Kit, part number 202-2301 or equivalent is used. • No evidence of corrosion after wash. NOTE: It is possible for a facility to achieve a ‘Good’ rating if unfiltered solvent stands are used for rough cleaning only and labeled in that manner however, there is a solvent stand(s) readily available for final cleaning that meet the criteria for ‘Good’ rating. NOTE: Any solvent used in a portable sprayer meets ISO -/16/13 and container that is clean has a documented refill procedure.

122

Undercarriage Rebuild Shop / Area

Intermediate Action

10.3) Part washing stands filtered to meet cleanliness targets.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

NOTE: It is possible for a facility to achieve a ‘Good’ rating if unfiltered solvent stands are used for rough cleaning only and labeled in that manner however, there is a solvent stand(s) readily available for final cleaning that meet the criteria for ‘Good’ rating. NOTE: Any solvent used in a portable sprayer meets ISO -/16/13 and container that is clean has a documented refill procedure.

123

Undercarriage Rebuild Shop / Area

Expensive Action

10.4) Control of debris generating processes.

Good = 6

Weld Curtain

Acceptable = 3

Good • Continuous debris generating activities are performed in a separate shop / area. NOTE: Continuous defined as a constant recurrence or production. • Assembly and clean areas are protected from contaminants during intermittent debris generating activities. • Equipment such as shields, extraction devices, etcetera are available and used. NOTE: There are no contaminants found in assembly and clean areas during or after intermittent debris generating activities.

Acceptable • Assembly and clean areas are protected from contaminants during debris generating activities. – Equipment such as shields, extraction devices, etcetera are available and used. NOTE: There are no contaminants found in assembly and clean areas during or after debris generating activities. 124

Undercarriage Rebuild Shop / Area

Expensive Action

10.4) Control of debris generating processes.

Not recommended = 0 Not recommended Criteria for ‘Good’ and ‘Acceptable’ not met.

125

Undercarriage Rebuild Shop / Area

Intermediate Action

10.5) Dispensed oil supply filtered to meet cleanliness targets.

Good = 10 Good • Dispensing nozzles clean and protected. • Dispensing point filtration. • Dispensed oil meets ISO -/16/13. • Documentation of conformance and maintenance of ISO -/16/13.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

NOTE: If the dispensed oil does not meet ISO -/16/13 the systems filtration may not be adequate. In this situation, installation of additional filtration and or filtration with lower micron filtration and or higher beta ratio. Kidney loop filtration may need to be deployed on storage tanks. Also, it is imperative that the filter installation has the capability inherent to the pressure in the system.

126

Undercarriage Rebuild Shop / Area

Inexpensive Action

10.6) Housekeeping…. Undercarriage shop / area is clean and orderly.

Good = 6 Good • The undercarriage shop / area is organized. • Floors walls, ceilings, equipment and tooling are clean and maintained clean on a regular basis. • Storage cabinets, storage racks, storage shelves and storage bins are clean and maintained clean on a regular basis. • No buildup of contaminants in corners, around column posts, benches and permanent equipment. • 5S principles are being applied.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

127

This is a requirement for a 3 Star or greater rating.

128

SECTION 11

PARTS STORAGE

Parts Storage

Inexpensive Action

11.1) Parts remain in original packaging.

Good = 8 Good • Parts stored in original packaging until used. • Packaging NOT opened or open due to damage. • Part NOT damaged.

Acceptable = 4

NOTE: When a part is opened to inspect for damage concerns or part verification, it must be repackaged in its original packaging in a manner that prevents contaminants ingression.

Acceptable • Parts previously opened are repackaged in material other than their original packaging. • Repackaged in a manner that prevents contaminant ingression. • Part NOT damaged. 130

Parts Storage

Inexpensive Action

11.1) Parts remain in original packaging.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

131

Parts Storage

Inexpensive Action

11.2) Filters remain in original packaging.

Good = 8 Good • Filters stored in original packaging until used. • Original packaging NOT opened or open due to damage.

• Filters NOT damaged.

Acceptable = 4

NOTE: When a part is opened to inspect for damage concerns or part verification, it must be repackaged in its original packaging in a manner that prevents contaminants ingression.

Acceptable • Filters previously opened are repackaged in material other than their original packaging. • Repackaged in a manner that prevents contaminants ingression. • Filters NOT damaged. 132

Parts Storage

Inexpensive Action

11.2) Filters remain in original packaging.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

133

Parts Storage

Inexpensive Action

11.3) O-rings stored protected and clean.

Good = 6 Good • O-rings stored with TWO levels of clean protection.

Acceptable = 3 Acceptable • O-rings stored with ONE level of clean protection.

134

Parts Storage

Inexpensive Action

11.3) O-rings stored protected and clean.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

135

Parts Storage

Intermediate Action

11.4) New fluid-carrying hoses and tubes stored with end protection in place.

Good = 10 Good • All new fluid-carrying hoses and tubes stored with proper end protection in place. • Procedure in place to clean hoses & tubes found without or compromised end protection. ‒ Approved hose / tube cleaning procedure, SEBF8485 is followed and proper clean end protection added.

Not recommended = 0

NOTE: Reference current version of guideline SEBF8485 for proper hose cleaning procedures. Local translation of the current version of SEBF8485 is considered ‘Good’.

Not recommended Criteria for ‘Good’ not met.

136

Parts Storage

Inexpensive Action

11.5) All parts (will-call parts areas) kept clean and delivered to customer in that manner.

Good = 10 Good • Parts are clean and organized. • Parts are NOT damaged. • Parts properly protected and packaging NOT damaged. • Area(s) are organized and clean. NOTE: Includes new, salvaged and used parts.

Not recommended = 0

NOTE: External and internal customer will-call is included. Internal will-call could be but not limited to work shop parts staging and field service parts staging.

Not recommended Criteria for ‘Good’ not met.

137

Parts Storage

Inexpensive Action

11.6) Housekeeping…. Parts storage facility / area is clean and orderly.

Good = 6 Good • Facility and parts are organized. • Floors, walls, ceilings, storage areas, shelves, cabinets, bins and material handlers are clean and maintained clean on a regular basis.

• No buildup of contaminants in corners, around column posts, benches and permanent equipment. • 5S principles are being applied.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

138

This is a requirement for a 3 Star or greater rating.

139

SECTION 12

HYDRAULIC HOSE BUILDING / REBUILDING

Hydraulic Hose Building / Rebuilding

Inexpensive Action

12.1) Bulk hose storage.

Good = 10 Good • Hose storage is organized. • Hoses are capped or plugged with the appropriate sized clean cap or plug in each opening.

Acceptable = 5 Acceptable • Hose storage is organized. • Hose ends are covered with clean plastic that is secured to prevent contaminant entry.

141

Hydraulic Hose Building / Rebuilding

Inexpensive Action

12.1) Bulk hose storage.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

142

Hydraulic Hose Building / Rebuilding

Intermediate Action

12.2) Hose cutoff saw exhausted.

Good = 6 Good • Hose saw exhausted to an operational, filtered dust collector (preferably outside of building). • Minimal evidence of hose cutting debris.

Acceptable = 3 Acceptable • Hose saw exhausted to outside of building without a dust collector. • Minimal evidence of hose cutting debris.

143

Hydraulic Hose Building / Rebuilding

Intermediate Action

12.2) Hose cutoff saw exhausted.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

144

Hydraulic Hose Building / Rebuilding

Intermediate Action

12.3) Hoses cleaned after cutoff.

Good = 10 Good • After hose is cut the approved hose cleaning procedure, SEBF8485 is being followed.

Not recommended = 0

NOTE: Reference current version of guideline SEBF8485 for proper hose cleaning procedures. Local translation of the current version of SEBF8485 is considered ‘Good’.

Not recommended Criteria for ‘Good’ not met.

145

Hydraulic Hose Building / Rebuilding

Inexpensive Action

12.4) Couplings stored clean and protected.

Good = 8 Good • O-ring face of couplings are protected with proper full cover. • Couplings stored in clean, closed cabinet or drawer containing no visible debris. OR

• Both ends of couplings are individually covered.

Acceptable = 4 Acceptable • O-ring face of couplings are protected with proper full cover. • Couplings stored in clean cabinet / bin with a covering.

146

Hydraulic Hose Building / Rebuilding

Inexpensive Action

12.4) Couplings stored clean and protected.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

147

Hydraulic Hose Building / Rebuilding

Intermediate Action

12.5) Assembled hoses cleaned and capped.

Good = 10 Good • After hose is fully assembled the approved hose cleaning procedure, SEBF8485 is being followed. • Assembled hoses are protected after cleaning with the proper clean cap / plug and or Clean Seal Capsule.

Not recommended = 0 PROCEDURE, SEBF8485 NOT BEING FOLLOWED

NOTE: Reference current version of guideline SEBF8485 for proper hose cleaning procedures. Local translation of the current version of SEBF8485 is considered ‘Good’.

Not recommended Criteria for ‘Good’ not met.

AND OR HOSE ASSEMBLIES WITHOUT THE APPROPRIATE END PROTECTION NOTE: The Cat® Certified Clean Hose Decal part number NEEG2828-00

148

Hydraulic Hose Building / Rebuilding

Inexpensive Action

12.6) Hose cleaning equipment and supplies stored clean and protected.

Good = 10 Good • Approved hose cleaning procedure, SEBF8485 is posted in the area or available with the tool. • Hose cleaning tool adaptors clean and stored clean. • Hose cleaning projectiles available and stored clean out of direct contact with light and not degraded. • Caps, plugs and Clean Seal Capsules are available and stored clean and protected.

Not recommended = 0

NOTE: Reference current version of guideline SEBF8485 for proper hose cleaning procedures. Local translation of the current version of SEBF8485 is considered ‘Good’.

Not recommended Criteria for ‘Good’ not met.

NOTE: Reference standard 3.8 for requirements for clean and dry air. Reference standard 4.1 for requirements for the proper storage of caps and plugs.

149

Hydraulic Hose Building / Rebuilding

Inexpensive Action

12.7) Housekeeping…. Hose building / rebuilding area is clean and orderly.

Good = 6 Good • The hose building / rebuilding area is organized. • Floors walls, ceilings, equipment and tooling are clean and maintained clean on a regular basis. • Storage cabinets, storage racks, storage shelves and storage bins are clean and maintained clean on a regular basis. • No buildup of contaminants in corners, around column posts, benches and permanent equipment. • 5S principles are being applied.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

150

This is a requirement for a 3 Star or greater rating.

151

SECTION 13

CRC or REMAN PARTS CORE RETURN AREA

Core Return Packaging Tips For All Remanufactured Products • Heavy soil and grease buildup should be removed from cores being returned for remanufacture. • Drain all fluids, such as, oil and anti-freeze from cores, remove all oil filters to facilitate complete drainage, plug or tape all openings.

• The most acceptable way to return cores is in the original packaging with rust inhibitor applied to the core.

153

Core Return Packaging Tips For All Remanufactured Products • If the original packaging isn't available, package in sturdy / durable cartons, crates, boxes etc. with rust inhibitor applied to the core. • Shrink wrapping is preferred when shipping large components such as transmissions, engines, torque converters, spindles, etcetera and they should be shipped on the original metal stands. If the original stands aren't available, secure using a wood frame for example. • Shrink wrapping is not necessary or desirable for small to mid-size cores. 154

CRC or Reman Parts Return Area

Inexpensive Action

13.1) Core is drained and openings are capped or otherwise properly protected.

Good = 4 Good • All cores are drained of all fluid. • All ports are capped / plugged. • All openings are protected.

Acceptable = 2 Acceptable • All cores are drained of all fluid. • Cores are wrapped in plastic in a manner that covers all ports and openings.

NOTE: For specific information about returning cores, refer to the Reman website at dealer.cat.com

155

CRC or Reman Parts Return Area

Inexpensive Action

13.1) Core is drained and openings are capped or otherwise properly protected.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

156

CRC or Reman Parts Return Area

Inexpensive Action

13.2) Components such as cranks, cylinder heads, hydraulic pumps, etcetera, are returned in appropriate shipping boxes.

Good = 4 Good • Return core packed in original shipping box. • Proper packing materials used. • The proper type and amount of corrosion inhibitor used when applicable.

Acceptable = 2 Acceptable • Return core shipped in other than original shipping box that is substantial enough to endure return transit. • Proper packing materials used. • The proper type and amount of corrosion inhibitor used when applicable. NOTE: For specific information about returning cores, refer to the Reman website at dealer.cat.com

157

CRC or Reman Parts Return Area

Inexpensive Action

13.2) Components such as cranks, cylinder heads, hydraulic pumps, etcetera., are returned in appropriate shipping boxes.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

158

CRC or Reman Parts Return Area

Intermediate Action

13.3) Large components are covered and shipped on a shipping stand.

Good = 6 Good • Completely wrapped with plastic. • Plastic wrapping or shrink wrap not damaged. • Shipped on original shipping stand. • Adequately secured for shipment.

Acceptable = 3 Acceptable • Completely wrapped with plastic. • Plastic wrapping or shrink wrap not damaged.

• Shipped on other than original shipping stand durable and substantial enough to protect component. • Adequately secured for shipment. NOTE: For specific information about returning cores, refer to the Reman website at dealer.cat.com

159

CRC or Reman Parts Return Area

Intermediate Action

13.3) Large components are covered and shipped on a shipping stand.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

160

161

SECTION 14

BULK AND PORTABLE FLUID STORAGE

Bulk And Portable Fluid Storage

Expensive Action

14.1) Bulk fluids filtered entering permanent storage tanks.

Good = 10 Good • Large capacity filtration used for each oil type and fuel. – Bulk tanks supply: o Workshops. o Dynamometer. o Undercarriage. o Lube trucks. o Etcetera.

Not recommended = 0

NOTE: Apply this standard if the facilities oil supply is from permanent bulk tank(s) and if the portable tank(s) is refilled at the facility.

Not recommended Criteria for ‘Good’ not met.

NOTE: A publication, Best Practices in Bulk Lubricant Storage and Handling is available from the Contamination Control Group.

163

Bulk And Portable Fluid Storage

Intermediate Action

14.2) Portable containers use kidney loop capability as needed.

Good = 10 Good • Kidney loop filtration system has the capability to achieve applicable ISO cleanliness targets for each oil type. – Portable containers supply: o Workshops. o Dynamometer. o Undercarriage. o Lube trucks. o Etcetera.

Not recommended = 0

NOTE: Apply this standard if facilities oil supply is from a portable container. Portable containers include but not limited to 330 gallon / 1000 liter totes or 55 gallon / 208 liter barrels are used as the facilities oil supply and storage.

Not recommended Criteria for ‘Good’ not met.

164

Bulk And Portable Fluid Storage

Inexpensive Action

14.3) Proper breather on lubricant and fuel storage tanks.

Good = 8 Good • 4 micron filtered breather filter with ability to remove moisture. • Documented Preventative Maintenance procedures with conformance records.

Acceptable = 4

NOTE: Includes both permanent and portable storage tanks. Portable containers include but not limited to 330 gallon / 1000 liter totes or 55 gallon / 208 liter barrels are used as the facilities oil supply and storage.

Acceptable • 4 micron filtered breather.

• Documented Preventative Maintenance procedures with conformance records.

NOTE: 4 micron breather filter with moisture removal capability are required on all storage and dispensing containers.

165

Bulk And Portable Fluid Storage

Inexpensive Action

14.3) Proper breather on lubricant and fuel storage tanks.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

NOTE: Reference the companies below for suitable breathers Des-Case Corp www.descase.com Schroeder Industrial www.schroederindustries.com Air Sentry www.airsentry.com 166

Bulk And Portable Fluid Storage

Intermediate Action

14.4) Dispensed fuel supply filtered to meet cleanliness targets.

Good = 10 Good • Fuel filtration: – At the dispensing point. o Filtration has the ability to remove water. NOTE: Entry filtration required per standard 14.1. • Dispensed fuel meets ISO 18/16/13. • Documentation of conformance and maintenance of ISO 18/16/13. • Dispensing nozzles clean and protected.

Acceptable = 5 Acceptable

NOTE: Fuel water content should not exceed 500 ppm at the dispensing point.

• Fuel filtration: – At the dispensing point. o Filtration has the ability to remove water. – Kidney loop instead of entry filtration. • Dispensed fuel meets ISO 18/16/13. • Documentation of conformance and maintenance of ISO 18/16/13. • Dispensing nozzles clean and protected. 167

Bulk And Portable Fluid Storage

Intermediate Action

14.4) Dispensed fuel supply filtered to meet cleanliness targets.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

168

Bulk And Portable Fluid Storage

Inexpensive Action

14.5) Preventative Maintenance program in place.

Good = 8 Good • Documented Preventative Maintenance procedures with conformance records to include: – Periodic tank cleaning and maintenance. o Permanent & portable (if reused) bulk tanks). – Drainage of water and sediment. o Permanent bulk tanks. – Filtration inspection and replacement. – Dispensed ISO cleanliness targets. – Proper housekeeping of all respective areas.

Not recommended = 0

NOTE: A Preventative Maintenance Program is required for all lubricant and fuel storage tanks both permanent or portable.

Not recommended Criteria for ‘Good’ not met.

169

Bulk And Portable Fluid Storage

Inexpensive Action

14.6) Lubricant barrel storage.

Good = 6 Good • Barrels stored vertically with bungs / openings up. AND OR • Barrels stored horizontally on designated racks with bungs / openings orientated approximately at 3:00 and 9:00 respectively.

AND OR

All Barrels:

– Stored inside clean and dry. o Barrel covers if used fit properly and not

damaged. 

No contaminants under barrel cover.

– Stored outside clean and dry. o

Barrel covers used. 

Fit properly and not damaged.



No contaminants under barrel cover. 170

Bulk And Portable Fluid Storage

Inexpensive Action

14.6) Lubricant barrel storage.

Acceptable = 3 Acceptable • Stored under roof (but NOT inside) protected from the elements. – Stored clean and dry. – Stored with bungs / openings up and or horizontally on designated racks with bungs / openings orientated approximately at 3:00 and 9:00 respectively. – No contaminants under barrel cover if used. o Barrel covers fit properly and not damaged.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

171

172

SECTION 15

LUBE VEHICLE

Lube Vehicle

Intermediate Action

15.1) Dispensed oil supply filtered to meet cleanliness targets.

Good = 10 Good • Filtration at the entry and dispensing point. NOTE: If the oils being supplied to the lube vehicle bulk tanks are from dispensing points that consistently deliver oil at ISO -/16/13 or cleaner, an entry filter is not necessary. • Dispensed oil meets ISO -/16/13. • Documentation of conformance and maintenance of ISO -/16/13.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

174

Lube Vehicle

Inexpensive Action

15.2) Proper breather on lubricant storage tanks.

Good = 8 Good • 4 micron filtered breather filter with ability to remove moisture. • Documented Preventative Maintenance procedures with conformance records.

Acceptable = 4 Acceptable • 4 micron filtered breather.

• Documented Preventative Maintenance procedures with conformance records.

175

Lube Vehicle

Inexpensive Action

15.2) Proper breather on lubricant storage tanks.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

NOTE: Reference the companies below for suitable breathers Des-Case Corp www.descase.com Schroeder Industrial www.schroederindustries.com Air Sentry www.airsentry.com 176

Lube Vehicle

Inexpensive Action

15.3) Compartment or container to transport new filters.

Good = 6 Good • Integral compartment or portable container – Clean and sealed to prevent contaminant entry. • Filters in storage: – Clean. – Original packaging NOT opened or open due to damage. – NOT opened until used. – NOT damaged.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

177

Lube Vehicle

Inexpensive Action

15.4) Clean fluid fill nozzles and grease couplers.

Good = 8 Good • Contained in a clean sealed compartment. OR • Clean caps / plugs or secured covering that is protecting individual nozzles / couplers from contaminants.

Acceptable = 4 Acceptable • Nozzles / couplers are cleaned before each use. • Cleaning supplies are readily available and in sufficient quantity for use.

178

Lube Vehicle

Inexpensive Action

15.4) Clean oil fill nozzles and grease couplers.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

179

Lube Vehicle

Inexpensive Action

15.5) Preventative Maintenance program on vehicle and compartments.

Good = 8 Good • Documented Preventative Maintenance procedures with conformance records to include: – Periodic tank cleaning and maintenance. – Filtration inspection and replacement. – Breather inspection and replacement. – ISO cleanliness targets.

Not recommended = 0

NOTE: Suggested practice is to combine Contamination Control Preventative Maintenance procedures with the vehicles Preventative Maintenance program.

Not recommended

NO PM PROGRAM, NO CONFORMANCE RECORDS AND OR CRITERIA FOR PM NOT MET

Criteria for ‘Good’ not met.

180

Lube Vehicle

Inexpensive Action

15.6) Housekeeping…. The lube vehicle is clean and orderly.

Good = 6 Good • The lube vehicle is organized. • Cab, body, hose reel / fluid dispensing and recovery area, new filter storage compartment, storage areas, equipment and tooling are clean and maintained clean on a regular basis. • Presents a professional image.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

181

This is a requirement for a 3 Star or greater rating.

182

SECTION 16

FIELD SERVICE VEHICLE

Field Service Vehicle

Inexpensive Action

16.1) Caps, plugs, protective covers and plastic wrap available and used.

Good = 10 Good • Caps, plugs, protective covers and plastic wrap: – Stored and protected from the environment. – Interior of storage device does NOT contain

contaminants. – Identified for storage. – Readily available on the service vehicle. – Are used to protect systems / components.

Not Recommended = 0 Not recommended Criteria for ‘Good’ not met.

184

Field Service Vehicle

Intermediate Action

16.2) Cleaning equipment / materials available and used.

Good = 6 Good • Portable parts washer with a filter. – Closed cover or protection when not in use. – Clean and functional for use. – Available: On service vehicle or from tool room. OR • Non-recoverable aerosol fluid or spray which evaporates quickly and does NOT leave a residue. – Available: On service vehicle or from tool room.

Not Recommended = 0

Example: Portable parts washer, part Number 212-1503.

Not recommended Criteria for ‘Good’ not met.

185

Field Service Vehicle

Expensive Action

16.3) Particle count capability available and used.

Good = 10 Good • Particle counter is available on the field service vehicle or from the tool room. OR • Bottle sample is taken and then analyzed at the Dealership or qualified fluid analysis lab. NOTE: Proper sampling techniques used. Particle counter, sample bottles, sample probes, vacuum pump, tubing, fittings, supplies, etcetera clean and protected.

Not Recommended = 0 PARTICLE COUNTER NOT AVAIALBLE

Not recommended Criteria for ‘Good’ not met.

AND OR BOTTLE SAMPLES NOT TAKEN 186

Field Service Vehicle

Intermediate Action

16.4) Air supply lines provide clean and dry air.

Good = 6 Good • A filter and water separator located at the dispensing points. – 1 to 10 micron filter. • Preventative Maintenance program in place with conformance records. • Airlines for air powered tools only, are labeled. • Airlines NOT utilized are blocked off.

Not Recommended = 0 Not recommended Criteria for ‘Good’ not met.

187

Field Service Vehicle

Intermediate Action

16.5) Waste fluids and used filters managed to facilitate transport and disposal.

Good = 6 Good • Closed sealed container (integral or portable) for waste fluids and used filters. – Dedicated and labeled. – No leaks or spills. – Compatible with the fluid being transported. AND OR • Dealer lube vehicle or customer takes responsibility for the transporting and disposal of the waste fluids and used filters.

Not Recommended = 0 Not recommended Criteria for ‘Good’ not met.

188

Field Service Vehicle

Expensive Action

16.6) Kidney loop equipment available and used.

Good = 10 Good • Kidney loop equipment is available on the field service vehicle or from the tool room. • Documented process includes: – Roll-off cleanliness targets are met after a system invasion repair. – Drain cart and filter(s) changed if cart is used for more than one oil type. • All connection fittings and adaptors clean and protected.

Not Recommended = 0 KIDNEY LOOP EQUIPMENT NOT AVAIALBLE, NO DOCUMENTATION TO ENSURE ROLL-OFF, NO DOCUMENTATION TO PREVENT CROSS CONTAMINATION AND OR FITTINGS NOT CLEAN

NOTE: After a system invasion repair if the customer refuses necessary kidney loop filtration to achieve applicable machine Roll-off cleanliness targets then a notation should be made on the work order.

Not recommended Criteria for ‘Good’ not met.

189

Field Service Vehicle

Inexpensive Action

16.7) Housekeeping…. The field service vehicle is clean and orderly.

Good = 6 Good • The field service vehicle is organized. • Cab, body, bed, storage areas, equipment and tooling are clean and maintained clean on a regular basis. • Presents a professional image.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

190

This is a requirement for a 3 Star or greater rating.

191

SECTION 17

HYDRAULIC HOSE VEHICLE

Hydraulic Hose Vehicle

Inexpensive Action

17.1) Bulk hose storage.

Good = 6 Good • Hose storage is organized. • Hoses are capped or plugged with the appropriate sized clean cap or plug in each opening.

Acceptable = 3 Acceptable • Hose storage is organized. • Hose ends are covered with clean plastic that is secured to prevent contaminant entry.

193

Hydraulic Hose Vehicle

Inexpensive Action

17.1) Bulk hose storage.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

194

Hydraulic Hose Vehicle

Inexpensive Action

17.2) Hose cutoff saw debris contained.

Good = 4 Good • Hose saw debris does NOT enter assembly area. Exhaust containment examples: – Exhaust is ducted to a operational filtered dust collector. – Guarding, liquid suppression, etcetera.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

195

Hydraulic Hose Vehicle

Intermediate Action

17.3) Hoses cleaned after cutoff.

Good = 4 Good • After hose is cut the approved hose cleaning procedure, SEBF8485 is being followed.

Not recommended = 0

NOTE: Reference current version of guideline SEBF8485 for proper hose cleaning procedures. Local translation of the current version of SEBF8485 is considered ‘Good’.

Not recommended Criteria for ‘Good’ not met.

196

Hydraulic Hose Vehicle

Inexpensive Action

17.4) Couplings stored clean and protected.

Good = 4 Good • O-ring face of couplings are protected with proper cover. • Couplings stored in clean, closed cabinet or drawer containing no visible debris. OR

• Both ends of couplings are individually covered.

Acceptable = 2 Acceptable • O-ring face of couplings are protected with proper cover. • Couplings stored in clean cabinet / bin with a covering.

197

Hydraulic Hose Vehicle

Inexpensive Action

17.4) Couplings stored clean and protected.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

198

Hydraulic Hose Vehicle

Intermediate Action

17.5) Assembled hoses cleaned and capped.

Good = 6 Good • After hose is fully assembled the approved hose cleaning procedure, SEBF8485 is being followed. • Assembled hoses are protected after cleaning with the proper clean cap / plug and or Clean Seal Capsule.

Not recommended = 0 PROCEDURE, SEBF8485 NOT BEING FOLLOWED

NOTE: Reference current version of guideline SEBF8485 for proper hose cleaning procedures. Local translation of the current version of SEBF8485 is considered ‘Good’.

Not recommended Criteria for ‘Good’ not met.

AND OR HOSE ASSEMBLIES WITHOUT THE APPROPRIATE END PROTECTION NOTE: The Cat® Certified Clean Hose Decal part number NEEG2828-00

199

Hydraulic Hose Vehicle

Inexpensive Action

17.6) Hose cleaning equipment and supplies stored clean and protected.

Good = 6 Good • Approved hose cleaning procedure, SEBF8485 is posted in the area or available with the tool. • Hose cleaning tool adaptors clean and stored clean. • Hose cleaning projectiles available and stored clean out of direct contact with light and not degraded. • Caps, plugs and Clean Seal Capsules are available and stored clean and protected.

Not recommended = 0

NOTE: Reference current version of guideline SEBF8485 for proper hose cleaning procedures. Local translation of the current version of SEBF8485 is considered ‘Good’.

Not recommended Criteria for ‘Good’ not met.

200

Hydraulic Hose Vehicle

Inexpensive Action

17.7) O-rings stored protected and clean.

Good = 4 Good • O-rings stored with TWO levels of clean protection.

Acceptable = 2 Acceptable • O-rings stored with ONE level of clean protection.

201

Hydraulic Hose Vehicle

Inexpensive Action

17.7) O-rings stored protected and clean.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

202

Hydraulic Hose Vehicle

Inexpensive Action

17.8) Caps, plugs, protective covers and plastic wrap available and used.

Good = 6 Good • Caps, plugs, protective covers and plastic wrap: – Stored and protected from the environment. – Interior of storage device does NOT contain

contaminants. – Identified for storage. – Readily available on the service vehicle. – Are used to protect systems / components.

Not Recommended = 0 Not recommended Criteria for ‘Good’ not met.

203

Hydraulic Hose Vehicle

Intermediate Action

17.9) Cleaning equipment / materials available and used.

Good = 4 Good • Portable parts washer with a filter. – Closed cover or protection when not in use. – Clean and fit for use. OR • Non-recoverable aerosol fluid or spray which evaporates quickly and does NOT leave a residue.

Not Recommended = 0

Example: Portable parts washer, part Number 212-1503.

Not recommended Criteria for ‘Good’ not met.

204

Hydraulic Hose Vehicle

Intermediate Action

17.10) Air supply lines provide clean and dry air.

Good = 4 Good • A filter and water separator located at the dispensing points. – 1 to 10 micron filter. • Preventative Maintenance program in place with conformance records. • Airlines for air powered tools only, are labeled. • Airlines NOT utilized are blocked off.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

NOTE: Labeling. If the vehicle has more air supply points that not equipped with filters and water separators then ‘Good’ can be achieved with labels only on the supply points that have filters and water separators.

205

Hydraulic Hose Vehicle

Inexpensive Action

17.11) Dispensed oil supply filtered to meet cleanliness targets.

Good = 10 Good • Dispensing nozzles clean and protected. • Dispensing point filtration. • Dispensed oil meets ISO -/16/13. • Documentation of conformance and maintenance of ISO -/16/13.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

206

Hydraulic Hose Vehicle

Inexpensive Action

17.12) Housekeeping…. Hydraulic hose vehicle is clean and orderly.

Good = 6 Good • The hydraulic hose vehicle is organized. • Cab, body, work areas, storage areas, equipment and tooling are clean and maintained clean on a regular basis. • Presents a professional image.

Not recommended = 0 Not recommended Criteria for ‘Good’ not met.

207

This is a requirement for a 3 Star or greater rating.

208

SECTION 18

YARD PRACTICES

Yard Practices

Inexpensive Action

18.1) Work tools are stored with lines / fittings protected.

Good = 8 Good • Clean caps and plugs (plastic or metal) and protective covers are used. NOTE: Protective covers includes Conduit CoversSM or equivalent. • Proper caps and plugs are used. ‒ Screw on caps and plugs

used with threaded

hose / tube fittings. ‒ Push on caps and plugs

used with unthreaded

hose / tube fittings. ‒ Cover plates used with split flange hoses. ‒ Correct size used.

• Tape NOT used directly on openings.

210

Yard Practices

Inexpensive Action

18.1) Work tools are stored with lines /fittings protected.

Acceptable = 4 Acceptable • Hose / tube ends and related fittings are protected with plastic that is secured to prevent contaminant entry.

• Clean plastic being used. • Tape NOT used directly on openings.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

211

Yard Practices

Intermediate Action

18.2) Work tools are stored organized.

Good = 10 Good • Work tools are stored on dedicated stands / racks that allow easy retrieval. – Stands / racks are made of metal or a durable material other than wood. o Material limits the creation of contaminants. • Buckets and other non-hydraulic tools stored on wood / plastic pallets or blocks. – Pallets and or blocks are clean and in good condition.

Acceptable = 5 Acceptable • Work tools, buckets, other non-hydraulic tools etcetera are stored on wood / plastic pallets or blocks in order to keep them off the ground. – Wood / plastic pallets or blocks are clean and in good condition.

212

Yard Practices

Intermediate Action

18.2) Work tools are stored organized.

Not recommended = 0 Not recommended Criteria for ‘Good’ or ‘Acceptable’ not met.

213

Yard Practices

Intermediate Action

18.3 Work tool hydraulic system is filtered / cleaned before delivery to user.

Good = 10 Good • Oil is filtered / cleaned using procedures in the current version of the following documents: – Procedure for "Off-board" Filtering 307-385B Excavator

Hydraulic Oil Equipped with Auxiliary Hydraulic Lines. o Media Number – SEBF8757. – Procedure for “Off-Board” Filtering Backhoe Loader and Integrated Toolcarrier Hydraulic Oil Equipped with Auxiliary Lines. o Media Number – SEBF8800.

• Documentation of conformance records.

Not recommended = 0

NOTE: Reference Dealer Service Tool Catalog for part numbers required for use with the Filter Group.

Not recommended

NO FILTERING / CLEANING PROCEDURE USED

Criteria for ‘Good’ not met.

AND OR RESULTS NOT DOCUMENTED 214

Yard Practices

Inexpensive Action

18.4) Housekeeping…. Yard is clean and orderly.

Good = 6 Good • The work tool storage yard is organized. • There is no trash, waste, scrap, etcetera in the yard area. • Tools stored in a way that allows easy retrieval for lift vehicles. • Trucking aisles are maintained and free of obstructions.

Not Recommended = 0 Not recommended Criteria for ‘Good’ not met.

215

This is a requirement for a 3 Star or greater rating.

216

THRESHOLD QUESTIONS

Threshold Questions Machine Cleanliness - New & Repaired

Answer "yes" or "no"

-

All the following requirements must be met to achieve a 3 star or higher rating.

(If n/a answer yes) SM

Is machine cleanliness check performed utilizing particle count technology (S.O.S. or Portable): : Prior to new machine delivery, if machine prep involved invasion of system with a Roll-off cleanliness target? : Prior to delivery of machine repair involving system with a Roll-off cleanliness target - Field? : Prior to delivery of machine repair involving system with a Roll-off cleanliness target - Shop? If necessary based on preceding inspection, is oil filtered back to Roll-off cleanliness target? After rebuilding components, do the fluids in the components tested on a stand meet ISO -/16/13?; and for components that are not tested, are particle counts taken on the machines after these components are installed, to ensure machine Roll-off cleanliness targets are met before the machine is returned to work? Both answers should to be "Yes", to be able to respond with a "Yes". Are housekeeping standards 4.15, 6.10, 7.7, 8.4, 9.4, 10.5, 11.6, 12.7, 15.6, 16.7, 17.12 and 18.4 rated 'Good'?

218

Caterpillar Roll-Off Specifications Machine System

ISO Code (4um/6um/14um) Hydraulic Systems (Implement & Steering) -/18/15 Electric Rope Shovel (ERS) HydraCrowd System 16/14/12 Hydraulic Shovels 6015 and above Hydraulic Systems 19/16/13 Electronic Transmissions -/18/15 Mechanical Transmissions -/21/17 *1 Differentials / Wheels / Axles -/18/15 Engines (Recommended) -/18/15 Other Components ISO Code *2 Components Tested with Oil -/16/13 Fill Oils -/16/13 Fuel Injection Test Equipment Calibration Fluid -/15/13 Fuel 18/16/13 Note 1: This standard applies only to the 700 family of rigid frame trucks; 777 size & larger. Note 2: This to include components such as hydraulic pumps, valves, transmissions, governors, etcetera. These systems should be tested by particle counting the fluid coming out of the component, not necessarily out of the test stand.

219

220

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