CAT 6015 – 6090 CGM-HMS Front Shovel Buckets Operation and Maintenance Manual – PDF DOWNLOAD

EM030190-0-0 (en-us)

Operation and Maintenance Manual 6015 – 6090 CGM-HMS Front Shovel Buckets R1H1 – Up (Backwall) GA21 – Up (Backwall) FSD1 – Up (Backwall) CY61 – Up (Backwall) CY81 – Up (Backwall) BB31 – Up (Clam) D221 – Up (Clam) Z261 – Up (Clam) CY31 – Up (Clam) CY41 – Up (Clam)

Language: Original Instructions

EM030190-0

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Published by:

Caterpillar Global Mining HMS GmbH Dept. Technical Operator Training D-44149 Dortmund, Caterpillarstrasse 1 Tel. 49 (0) 231 922-3 Fax 49 (0) 231 922-4055 https://mining.cat.com

© Copyright Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2019. The reproduction, distribution and utilization of this manual / file as well as the communication of its content to others without express authorization is prohibited. Offenders will be held liable for the payment of damages.

All rights reserved in the event of the grant of a patent, utility model or design.

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CONTENTS CONTENTS .............................................................................................................................................................. 1 ALL PRODUCTS FOREWORD .................................................................................................................................... 3

Literature Information ............................................................................................................................................... 3 Safety ......................................................................................................................................................................... 3 Operation ................................................................................................................................................................... 3 Product Information .................................................................................................................................................. 3 Maintenance ............................................................................................................................................................. 3 Maintenance Intervals .............................................................................................................................................. 3 Product Capacity....................................................................................................................................................... 3

SAFETY SECTION..................................................................................................................................................... 4 California Proposition 65 Warning ......................................................................................................................... 4 Safety Messages ...................................................................................................................................................... 4 General Hazard Information ................................................................................................................................... 4 Personnel ..................................................................................................................................................................................4 State of the Machine ...............................................................................................................................................................5 State of Work Tools and GET ................................................................................................................................................5 State of Tools and Lifting Devices .........................................................................................................................................5 Trapped Pressure ....................................................................................................................................................................5 Fluid Penetration ......................................................................................................................................................................5 Containing Fluid Spillage ........................................................................................................................................................6 Crushing Prevention and Cutting Prevention ......................................................................................................................6 Welding / Flame Cutting on the Bucket and it´s Wear Protection .....................................................................................6 Burn Prevention .......................................................................................................................................................................6 Pressurized Air and Water .....................................................................................................................................................6 Oils .............................................................................................................................................................................................7 Fire Prevention and Explosion Prevention ...........................................................................................................................7 Dispose of Waste Properly .....................................................................................................................................................7 Lines, Tubes, and Hoses ........................................................................................................................................................8 Modifications of the Work Tool ..............................................................................................................................................8 Transport...................................................................................................................................................................................8

OPERATION SECTION .............................................................................................................................................. 9 Before Starting Operation ....................................................................................................................................... 9 Operation ................................................................................................................................................................... 9 Reference Information Section ............................................................................................................................................10 Park the Machine ...................................................................................................................................................................10

PRODUCT INFORMATION SECTION..........................................................................................................................11 Face Shovel Bucket Mechanical Parts ............................................................................................................... 11 Face Shovel Bucket Mechanical Parts – Continued ......................................................................................... 12 Face Shovel Bucket Hydraulics ........................................................................................................................... 13 Back wall hydraulics ..............................................................................................................................................................13

Face Shovel Bucket Central Greasing System ................................................................................................. 14 Grease distributors and greasing points.............................................................................................................................14

Face Shovel Operator Assist System (If equipped) .......................................................................................... 15 Parts of Operator Assist System (If equipped) ..................................................................................................................15

Specification Information ....................................................................................................................................... 16 Intended Use .......................................................................................................................................................... 16 Misuse...................................................................................................................................................................... 16 Identification Information ....................................................................................................................................... 16 Serial Number Plate ..............................................................................................................................................................16

European Union ..................................................................................................................................................... 17 CE Mark ..................................................................................................................................................................................17

Declaration of Conformity ..................................................................................................................................... 17 OPERATION SECTION .............................................................................................................................................18 FS-Bucket – Operation .......................................................................................................................................... 18 FS-Bucket Backwall and Clam – Disassemble and Assemble ....................................................................... 18

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EM030190-0 December 2019 FS-Bucket Assembly .............................................................................................................................................................19 Clam Disassembly .................................................................................................................................................................23 Clam Assembly ......................................................................................................................................................................24

FS-Bucket – Remove and Install ......................................................................................................................... 25 Storage Information ............................................................................................................................................... 25 Transportation Information.................................................................................................................................... 25 Lifting and Tying Down .........................................................................................................................................................26 Transport.................................................................................................................................................................................29 Decommissioning and Disposal ..........................................................................................................................................29

M AINTENANCE SECTION .........................................................................................................................................30 Before Starting Maintenance Work .....................................................................................................................................30

Maintenance Schedule .......................................................................................................................................... 31 Clam and Backwall - Walk Around Inspection ................................................................................................... 32 Bucket – Clean ....................................................................................................................................................... 32 Clam Cylinder Chambers – Check/Clean ........................................................................................................... 32 Hinge / Pivot Area – Check/Clean ....................................................................................................................... 33 Pins, Bores and Bushings Wear – Check .......................................................................................................... 33 Clam and Backwall Steel Structure - Inspect ..................................................................................................... 34 Mechanical Stops on Backwall and Stick – Check ........................................................................................... 34 G.E.T. Retention Components NDT - Perform .................................................................................................. 35 G.E.T. Mating Surfaces Wear - Check................................................................................................................ 35 Screwed G.E.T. Retention Components (if equipped) – Check Fit and Torque ........................................... 35 REPLACING WEAR PARTS SECTION ........................................................................................................................36 Wear Limits - Check .............................................................................................................................................. 36 Identify the Degree of Wear .................................................................................................................................................36

Replace Wear Parts with Welding ....................................................................................................................... 36 Replace Wear Parts without Welding ................................................................................................................. 36 G.E.T. with CapSure™ Locking System – Bucket Tips Replace ....................................................................................36 Bucket Lip Shroud with CapSure™ Locking System – Replace .....................................................................................38 Bucket Wing Shroud – Replace ...........................................................................................................................................38 G.E.T. with Screwed Locking System – Bucket Tips Replace ........................................................................................39 G.E.T. with Screwed Locking System – Coupler Replace ...............................................................................................41 G.E.T. with Screwed Locking System – Lip Shroud Replace..........................................................................................46 G.E.T. with Screwed Locking System – Wing Shroud Replace ......................................................................................48

TESTING & ADJUSTING SECTION .............................................................................................................................50

Hinge Test and Cylinder Residual Stroke ..........................................................................................................................50 Hinge Test ..............................................................................................................................................................................50 Clam Cylinder Residual Stroke – Measure ........................................................................................................................51 Bolted Stoppers (If equipped) – Re-torque ........................................................................................................................51 Backwall Hydraulic System – Check / Inspect...................................................................................................................52 Central Lubricating System – Check / Inspect...................................................................................................................52

REFERENCE INFORMATION .....................................................................................................................................53 Acronyms ................................................................................................................................................................ 53 NOTES ...................................................................................................................................................................54

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ALL PRODUCTS FOREWORD Literature Information This manual should be read carefully before using this product for the first time and before performing maintenance. This manual should be stored in the product literature holder or in the product literature storage area. Immediately replace this manual if lost, damaged, or unreadable. This manual may contain safety information, operation instructions, transportation information, lubrication information, and maintenance information. Some photographs or illustrations in this publication show details or attachments that can be different from your product.

Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your product, which are not included in this publication.

Whenever a question arises regarding your product, or this publication, consult your dealer for the latest available information.

Safety The safety section, if present, lists basic safety precautions. In addition, this section identifies the text and locations of safety messages used on the product. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance, and repair on this product.

Operation The operation section, if present, is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, controls, attachment controls, transportation, and towing information (if applicable).

Photographs and illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the product. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the product and its capabilities.

Maintenance The maintenance section, if present, is a guide to equipment care. Proper maintenance and repair are essential to keep the equipment and systems operating correctly. As the owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual. The Maintenance Interval Schedule lists the items to be maintained at a specific service interval. Items without specific intervals are listed under the "When Required" service interval.

The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or "one safe source" for all maintenance procedures.

Maintenance Intervals Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely severe, dusty, or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily.

Product Capacity Additional attachments or modifications may exceed product design capacity, which can adversely affect product performance characteristics, safety, reliability, and applicable certifications. Contact your dealer for further information.

Product Information The product information section, if present, may provide specification data, product intended use, product identification plate locations, and certification information.

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SAFETY SECTION

General Hazard Information

California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

WARNING: This product can expose you to chemicals including ethylene glycol, which is known to the state of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

Do not ingest this chemical. Wash hands after handling to avoid incidental ingestion.

WARNING: This product can expose you to chemicals including lead or lead compounds, which is known to the state of California to cause cancer, birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

Wash hands after handling components that may contain lead.

Safety Messages Make sure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if you cannot read the words.

Replace the illustrations if the illustrations are not legible. When you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages.

Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message.

Loose adhesive will allow the safety message to fall.

Replace any safety message that is damaged, or missing. If a safety message is attached to a part that is replaced, install a new safety message on the replacement part. Any Cat dealer can provide new safety messages.

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Fig. 1

Attach a “Do Not Operate” warning tag (Fig. 1) or a similar warning tag to the start switch or to the controls of the machine. Attach the warning tag before you service the equipment or before you repair the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Cat dealer.

Personnel Any work with the machine and it’s work tools must be executed only by reliable, skilled, well trained and authorized personnel in good healthy condition.

Statutory minimum age limits must be observed.

Only experienced persons who are fully knowledgeable of the Accident Prevention Regulations may be responsible for the rigging of loads and the instruction of the crane driver during disassembly and assembly.

Never operate the machine or the work tools while impaired with drugs or alcohol.

Read the safety sections in this Manual carefully and observe the instructions given in this sections.

Observe all job site, all mine site and all workshop safety requirements before attempting to do any work on this work tool.

Wear a hard hat, protective glasses, protective shes, ear protection and other protective equipment, as required (Fig. 2).

Wear closely fitting working clothing when working on the machine. Loose, wide garments can catch on machine parts and result in injury.

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Trapped Pressure Pressure can be trapped in a hydraulic system. Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings.

High-pressure oil that is released can cause a hose to whip. High-pressure oil that is released can cause oil to spray. Fluid penetration can cause serious injury and possible death.

Fluid Penetration

Fig. 2

When you perform maintenance above ground level, use appropriate devices such as ladders or man lift machines. If equipped, use the machine anchorage points and use approved fall arrest harnesses and lanyards.

If you need assistance to carry out the work, e.g. marshallers, clearly define the responsibilities of each assistant beforehand. The individual responsibilities are to be carefully observed to ensure safety.

Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure.

State of the Machine Operate the machine only if all protective and safety oriented devices, such as removable safety devices, emergency shut-off equipment, soundproofing elements and exhausters, are in place and fully functional.

Only specially trained and qualified personnel with the appropriate technical knowledge can operate, service or repair the hydraulic mining shovel.

Incorrect operation of the machine or the equipment can result in life-threatening situations.

State of Work Tools and GET Secure the work tool against inadvertent movements before start working. Always keep in mind the weight of the work tool. Select chocks and other fixings accordingly.

State of Tools and Lifting Devices Tools, hoists, slings, trestles and other devices must be in a reliable, safe state.

Fig. 3

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Do not use a kinked wire cable or a frayed wire cable. Wear gloves when you handle wire cable.

Use hoists or other appropriate support devices when you install, remove or displace any equipment or component. Thus you prevent them from inadvertent movements, slip or fall.

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Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids.

Welding / Flame Cutting on the Bucket and it´s Wear Protection

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for the following items:

These components containing stored energy are loaded and in most cases kept in position via the surround geometry e.g. welding seams etc. If the geometry were to change due to heat, grinding welding etc. this change may allow the mentioned component to unload, in this case to release its spring tension by snapping into a position with less stress.

This unexpected release of spring tension is especially prevalent with large bent plates which have not been stress relieved.

Keep in mind that an unexpected release of spring tension in steel plates can cause severe injury or death.

To minimize the risk of a component unexpectedly unloading, use only original Cat spare parts when repairing the bucket´s armoring / wear protection.

Assure that a safe distance is observed between the individual executing work and any component assumed to be under load.

• •

Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids Tools that are suitable for containing fluids and equipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Crushing Prevention and Cutting Prevention Support the work tool properly before you perform any work or maintenance beneath that equipment.

Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks.

Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.

Whenever there are equipment control linkages the clearance in the linkage area will change with the movement of the equipment or the machine. Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement.

Stay clear of all rotating and moving parts.

When you strike a retainer pin with force, the retainer pin can fly out. The loose retainer pin can injure personnel. Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear protective glasses when you strike a retainer pin.

Chips or other debris can fly off an object when you strike the object. Make sure that no one can be injured by flying debris before striking any object.

Be careful when handling heavy parts. Heavy parts can cause serious injury when falling down on your feet or other parts of your body. Use applicable lifting gear to move heavy parts safely.

Heavy parts in motion can cause serious injury to your fingers or hands when touching other metal parts. Do not touch heavy parts where they could contact other metal parts. Use an appropriate pry bar to correct the position of heavy parts.

6

Components welded on the bucket, such as wear plates or parts of the armoring / wear protection, may contain stored energy.

Burn Prevention Do not touch any part of an operating work tool. Allow the work tool to cool before any maintenance is performed on the work tool. Relieve all pressure in the air system, in the oil system, or in the lubrication system before any lines, fittings, or related items are disconnected.

Be careful with open flames and unprotected light.

Not only fuel but also other consumables often have a low flash point and catch fire easily.

Do not touch any part of a work tool which is prepared for welding works. The work tool may be heated up to temperatures which can seriously burn your skin.

Pressurized Air and Water Pressurized air and/or water can cause debris and/or hot water to be blown out. The debris and/or hot water could result in personal injury.

When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.

The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the nozzle is deadheaded and the nozzle is used with an effective chip deflector and personal protective equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

EM030190-0 December 2019 Avoid direct spraying of water on electrical connectors, connections, and components. When using air for cleaning, allow the machine to cool to reduce the possibility of fine debris igniting when re-deposited on hot surfaces.

Oils Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin.

Fire Prevention and Explosion Prevention

welding or flame cutting. Ensure that the components are properly grounded in order to avoid unwanted arcs.

Dust that is generated from repairing nonmetallic hoods or fenders may be flammable and/or explosive. Repair such components in a well ventilated area away from open flames or sparks. Use suitable Personal Protection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration.

Replace damaged lines and hoses. The lines and the hoses should have adequate support and secure clamps. Tighten all connections to the recommended torque. Damage to the protective cover or insulation may provide fuel for fires.

Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rags and flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials.

Dispose of Waste Properly Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.

Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

Fig. 4

Do not place the work tool on flammable ground.

During welding works or flame cutting hot sparks or melted metal could cause a fire.

All fuels, most lubricants, and some coolant mixtures are flammable.

To minimize the risk of fire or explosion, Caterpillar recommends the following actions.

Always perform a Walk-Around Inspection, which may help you identify a fire hazard. Do not operate a machine or work on a work tool when a fire hazard exists. Contact your Cat dealer for service.

Do not operate a machine with a fluid leak. Repair leaks and clean up fluids before resuming machine operation. Fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. A fire may cause personal injury or death.

Do not operate the machine near any flame.

Remove flammable material such as leaves, twigs, papers, trash, and so on.

Remove all containers which contain flammable fluids from the immediate vicinity of the work tool.

Clean all accumulations of flammable materials such as fuel, oil, and debris from the work tool.

Do not weld or flame cut on tanks or lines that contain flammable fluids or flammable material. Empty and purge the lines and tanks. Then clean the lines and tanks with a nonflammable solvent prior to

Fig. 5

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Lines, Tubes, and Hoses

Modifications of the Work Tool

Do not bend high-pressure lines. Do not strike highpressure lines. Do not install any lines that are bent or damaged. Use the appropriate backup wrenches in order to tighten all connections to the recommended torque.

Unauthorized conversions or modifications of the work tool is forbidden for reasons of safety.

Replace the affected parts if any of the following conditions are present: •

End fittings are damaged or leaking.

•

Outer coverings are chafed or cut.

•

Wires are exposed.

•

Outer coverings are swelling or ballooning.

•

Flexible parts of the hoses are kinked.

•

Outer covers have exposed embedded armoring.

•

End fittings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly. During machine operation, this will help to prevent vibration, rubbing against other parts, excessive heat, and failure of lines, tubes, and hoses.

8

Never modify the original structure of the work tool and never modify the work tool with foreign parts without explicit approval from Caterpillar.

Caterpillar recommends the use of only genuine Cat replacement parts.

Transport Use only appropriate means of transport and lifting gear of adequate capacity.

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OPERATION SECTION Before Starting Operation Whenever you are working around this product, always wear: a hard hat, protective glasses and protective shoes. Always wear the protective equipment that is required by the conditions of the job site.

Refer to the “Maintenance Section” of this manual for more information on inspecting the work tool before use.

Perform a machine walk around inspection. Report any obvious damage and defects – including changes in the machine’s working behaviour- to your supervisor. In the event of malfunctions, stop the machine immediately and lock it.

Prior to initial commissioning and after repairs on the central lubricating system or the hydraulic cylinders, move the unloaded attachment for abt. 5 minutes. This is required to ensure an adequate supply of grease to the cylinder bearings, to bucket and stick bearings and to linkage bearings when the work starts.

Do not operate the machine when - one or several teeth, - parts of the wear plates, - lip shrouds or side shrouds, - or other parts of the bucket are worn or missing (Fig. 6).

Working under these conditions reduces digging performance, results in heavy wear, potential damage and high repair costs.

Operation Only operate the machine and the bucket while you are in a seat. The seat belt must be fastened while you operate the machine. Only operate the controls while the engine is running.

Check for proper operation of all controls and protective devices while you operate the machine slowly in an open area.

Before you move the machine, make sure that no one will be endangered.

Do not allow riders on the machine unless the machine has the following equipment: -

additional seat additional seat belt Rollover Protective Structure (ROPS).

Never use the work tool for a work platform.

Report any needed repairs that were noted during operation.

Carry attachments close to the ground, approximately 40 cm (15 inches) higher than ground level.

Do not go close to the edge of a cliff, an excavation, or an overhang.

If the machine begins to sideslip, perform the following procedure: -

Discard the load.

Turn the machine downhill.

Be careful to avoid any condition which could lead to tipping. Tipping can occur when you work on hills, banks and slopes. Also, tipping can occur when you cross ditches, ridges or other unexpected obstructions.

Note: Face shovel buckets and other large work tools may create visibility restrictions around and possibly in front of the host machine. For host machines that offer visual aids (e.g. cameras or mirrors), ensure that they are clean and in proper working condition and adjust them using procedures located in the host machine Operation and Maintenance Manual.

For areas that are not covered by the visual aids, the job site organization must be utilized to minimize hazards of this restricted visibility.

Fig. 6

Refer to the host machine Operation and Maintenance Manual, “Visibility Information” and “Restricted Visibility” sections for more information about job site organization.

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Reference Information Section

Park the Machine

For additional information on operational practices as well as on restricted operation please refer to: - The Operation and Maintenance Manual of the machine the bucket is attached to.

- Special Instruction EM027975 “Operational Practices: Working and Traveling” (Available from your Cat dealer).

For additional information on removal and installation of the bucket please refer to: - The Disassembly and Assembly Manual of the machine the bucket is attached to.

Please contact your Cat dealer.

Fig. 7

Park the machine in a location that is smooth, stable, level and hard. The location should also be dry and free of debris and flammable material and not endangered by falling rock. Bring the attachment in a position like shown in (Fig. 7): - Half extend the boom cylinders.

- Bring the stick in a vertical position.

- Lower the boom until the bucket is on the ground.

Note: Other positions of the attachment are not allowed when parking the machine.

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PRODUCT INFORMATION SECTION Face Shovel Bucket Mechanical Parts This is a typical example, your face shovel may differ in detail.

Fig. 8

1

Front clam

2

Backwall

4

Heel shroud (Protect outer corners)

5

Wear plates, inner (Replaceable, available either individually or as a liner package)

6

Beep (Protects bucket base edge. Note: Not on casted lip)

7

Couplers

8

Adapters (Weld on serviceable)

9

Lip shroud (Quickly field-replaceable with hammerless removal)

10

Tips (Quickly field-replaceable with hammerless removal)

11

Wing shroud / Side cutter (Protects the bucket side plate)

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Face Shovel Bucket Mechanical Parts – Continued This is a typical example, your face shovel may differ in detail.

Fig. 9

3

Hinge section

4

Heel shroud (Protect outer corners)

7

Couplers

11

Wing shroud / Side cutter (Protects the bucket side plate)

12

Wear plates, outer (Replaceable, available either individually or as a liner package)

13

Base edge / Base lip

12

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Face Shovel Bucket Hydraulics This is a typical example, your face shovel may differ in detail.

Fig. 10

Back wall hydraulics Refer to Fig. 10 1- Right hand clam cylinder 2- Hydraulic hoses 3- Distributor, clam cylinder secondary relief valve block 4- Left hand clam cylinder

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Face Shovel Bucket Central Greasing System This is a typical example, your face shovel may differ in detail.

Fig. 11

Grease distributors and greasing points Refer to Fig. 11 Distributor

14

Greasing points

37

Bearing stick – back wall (2)

38

Fork of shovel tilt cylinder (4)

39

Bearing back wall - clam (1) Clam cylinder – back wall (1) Bearing shovel tilt cylinder (2)

40

Fork of shovel tilt cylinder (4)

41

Bearing back wall - clam (1) Clam cylinder – back wall (1) Bearing shovel tilt cylinder (2)

42

Bearing back wall - clam (2)

43

Bearing back wall - clam (2)

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Face Shovel Operator Assist System (If equipped) This is a typical example, your face shovel may differ in detail.

Fig. 12

Parts of Operator Assist System (If equipped) Refer to Fig. 12 No.

Part

1

Face shovel

2

Stick

3

Plate

4

Harness

5

Bucket angle sensor

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Specification Information

Caterpillar Approved Machines

The selection of the optimal face shovel for your machine and for your special application and for material density is only possible with detailed advice.

Please be advised by your Cat dealer.

At the time of publication, Cat face shovel buckets have been approved by Caterpillar for use with the following CGM-HMS machine models: 6015 FS, 6018 FS, 6030 FS, 6040 FS, 6050 FS, 6060 FS, 6090 FS. For use on non-Cat machines please contact the nearest Cat dealer.

Intended Use The face shovel bucket is a work tool intended to be mounted to a hydraulic mining shovel.

Face shovel buckets are used solely for loosening and loading of: - sand, - oil sand, - gravel, - blasted rock, - ore, - coal and - other raw materials.

Operating the machine within the limits of the intended use also involves observing the instructions set out in the Operation and Maintenance Manual and complying with the inspection and maintenance directives.

Identification Information Serial Number Plate Caterpillar work tools are identified with serial numbers.

The serial number plate (Fig. 13) is located on the back right side of a typical face shovel bucket.

Misuse Using the face shovel bucket for purposes other than or extending beyond those stated above, e.g.

- for digging or penetrating unblasted, hard material, - for driving in posts, sheet piles, supports, etc., - for breaking down rocks by beating with the shovel, - for lifting or carrying loads that exceed the maximum load, - for engaging material with the clam open, - for grading operations with the clam open, - for loosening or moving rocks using backwall and clam as pliers, - for scraping material with the backwall or the clam, - moving the face shovel bucket to the endstops with high speed, - for lifting the machine by jacking the bucket is contrary to its intended use and considered as "unauthorized use".

Unauthorized use may involve a life-threatening risk for operators or other personnel or may cause injury or extensive damage.

The manufacturer/supplier cannot be held liable for any damage resulting from other than the intended use. The risk involved in such misuse lies with the user.

16

Fig. 13

1- Group number 2- Assembly number 3- Unique factory number 4- Model applicability 5- Weight 6- Capacity 7- Width 8- Pressure 9- G.E.T Size 10- Machine Type 11- Country of manufacture 12- Year of manufacture

EM030190-0 December 2019

European Union

Declaration of Conformity

For work tools that are compliant to the “EU Directive 2006/42/EC”, the following information is stamped onto the serial number CE plate.

For quick reference, record the identification numbers in the spaces that are provided below.

Serial Number____________________________

When a Hydraulic Mining Shovel machine is sold into the EU, it does not receive an additional Declaration of Conformity for the working attachments like front shovel buckets, as the conformity of the machine with the Machinery Directive covers the entire machine sold.

Model Number____________________________

If the front shovel bucket is sold and shipped separately, a declaration of conformity is issued for it.

Year of Construction_______________________ Mass (kg)________________________________

CE Mark The CE mark is located on the serial number plate (Fig. 13).

17

EM030190-0 December 2019

OPERATION SECTION

FS-Bucket Backwall and Clam – Disassemble and Assemble

FS-Bucket – Operation

For detailed information on disassemble and assemble a backwall and a clam please refer to the machine model related Service Manual.

For example: The Service Manual for the 6060 machines is: - Special Instruction UENR6568 “Disassembly and Assembly, 6060 Hydraulic Shovel Machine Systems”.

To identify the Service Manual related to your machine please contact your Cat dealer.

The face shovel bucket is a work tool intended to be mounted to a hydraulic mining shovel. Face shovel buckets are used solely for loosening and loading of raw materials, please refer to section “Intended use” for more detailed information.

For additional information on Operational Practices as well as on restricted operation please refer to: - The Operation and Maintenance Manual of the host machine the bucket is attached to.

- Special Instruction EM027975 “Operational Practices: Working and Traveling” (Available from your Cat dealer).

If you have any questions, please contact your Cat dealer.

Note: Only assemble matching backwalls and clams. If in doubt, contact your Cat dealer.

Note: If you want to assemble new and used components, make sure that all wear parts on the used component such as bushings and bolts, parts of the armoring / wear plates and the end stops, as well as the G.E.T. are functional and within the wear limits.

Never reuse used bearings or bearing bolts without checking the wear. Information on wear dimensions can be obtained from your Cat dealer.

Note: Follow appropriate safety procedures and use Personal Protective Equipment (PPE) as required.

Observe all local safety regulations.

Observe all mine site safety precautions before attempting to work at the front shovel bucket.

The job must be carried out by skilled, well trained personnel only.

Tools needed: Hardwood chocks

Cleaning rags

Hand tools

Solvent for corrosion inhibitor

Welding equipment

Grease

Bolt pulling tool

Assembly spray

Lifting slings for bolts

Lube truck

4-legged lifting chain for the back wall Tooling A, Part Number 384-9665 for 6060 FS

18

EM030190-0 December 2019

FS-Bucket Assembly

The face shovel in complete as well as the clam and backwall as a part are huge and heavy parts.

When lifted up or when in motion they could cause serious injuries or death. Handle them with care.

Heavy parts in motion can cause serious injury to your fingers or hands when touching other parts during motion. Do not touch heavy parts at areas where they could contact other parts.

Do not touch heavy parts in motion in order to guide them.

Do not check the alignment of bores with your hands.

Do not step under the lifted load.

Step away from lifted loads during crane motion.  Ensure that the working area is stable, clean and level.  Ensure that the clam is resting in a horizontally level position. Support it with beams of hard-wood to keep it from rocking (Fig. 14).  Clean the bushings (1 and 2, Fig. 14) on both sides of the clam and the bushings at the backwall (arrows, Fig. 15) carefully. Do not damage their surfaces.  Clean and prepare the corresponding pins.

Remove the corrosion inhibitor.  Spray the bearing pins with assembly spray.  Lubricate all bushings on clam and backwall (Fig. 14 and Fig. 15) by using the grease channels. This ensures grease flow to the bushings. Use only grease recommended for this purpose, refer to Special Instruction SEBU6250, “Caterpillar Machine Fluids Recommendations”.

Fig. 14

Fig. 15

 Attach a suitable 4-legged lifting chain to the lifting lugs (1, Fig. 16) on the backwall and raise it slowly. Refer to section “Lifting and Tying down” in this manual.

Fig. 16

 Position the backwall above the stationary clam (Fig. 17).

Fig. 17

19

EM030190-0 December 2019 To join backwall and clam:

 Remove the pin cover (2, Fig. 19).  Attach an eyebolt to the end of the pin.

The backwall in motion can crush or cut off your fingers and hands.

Never try to direct the backwall by hand while it is moving.

Never try to insert the pins while the backwall is moving.

Keep your hands away while the backwall is moving.

Note: Do not use a chain to pull out the pin. The dead weight of the chain can pull out the pin unexpectedly.  Pull out about one third of the pin (4). To prevent the pin from falling out secure it with additional support slings (3) and a crane.  Pull out the pin so that it is only held by one bearing bushing (1).

 Carefully lower the backwall (2, Fig. 17) onto the clam (1) until the hinge bores (4 and 6) line up.  Insert the pins on both sides.

 Slowly lower the backwall until it rests on the clam.

The bucket assembly may rock when the center of gravity shifts.

Stay clear of the assembled bucket.

 Remove the lifting gear.  Place the bucket in front of the machine using a crane. Ensure that it is as level as the machine.

Note: If the machine is not level, the bucket must have the same slope as the machine. Machine and bucket must be parallel.

Fig. 19

 Clean the bearings and the pin and spray them with assembly spray.  The stick, boom, and travel functions of the machine can now be used to move the stick into position at the backwall.

 Fill the cavity between the bearings at the end of the stick with grease.

 Align the bearing bushings of the bucket and the stick.

 Remove rubber flaps (arrows, Fig. 18).

 Push the pin into the bearing points.

Check pin clearance  Install one of the pin covers but do not tighten the bolts. Air compressed by the pin must be able to escape.  Push the pin carefully against this cover.

Tighten the cover bolts.  Measure distance from other end of pin to the outer side of the bearing. There must be a significant distance. If not, place a suitable spacer ring under the cover before tightening it. Alternatively, you can turn a suitable recess in the cover.

Fig. 18

20

 Install the other pin cover and tighten the bolts in accordance with the specified tightening method (see chapter 2.9 of the Service Manual).

EM030190-0 December 2019 Installation of the bucket cylinders on the bucket  Remove one pin cover from each bottom fork of the bucket cylinders.  Pull the pins out so that they are held by only one bearing bushing and clean them carefully.  Spray the bearing points and pins with assembly spray.  Start one engine and let it run in low idle.  Extend the bucket cylinders (1, Fig. 20) and move the stick (2) to align the forks at the bearing points (3) of the bucket rear panel.

If necessary, use the travel forward function and the stick float function simultaneously to move the stick in and to have the bucket cylinders suspended right above the bucket bearing points (3, Fig. 20).

Fig. 21

 Attach a sling (1, Fig. 22) to one clam cylinder (2) and raise it slowly with a crane.

Remove the hardwood beam previously used to support the cylinder.

Fig. 22 Fig. 20

 Insert the pins and screw on the pin covers in accordance with the specified tightening method /see chapter 2.9 of the Service Manual).  Shut down the engine.  Connect hydraulic hoses and install missing lubrication tubes between stick and bucket.  Connect LH and RH clam cylinders.

 Start one engine and let it run in low idle.  Activate clam cylinder extension slowly until the fork (3, Fig. 22) and clam bearing points line up. One of the clam cylinders will extend before the other. Start with this cylinder.

In case the second clam cylinder begins to extend, ensure that it cannot damage ports or components: Secure the fork of the second clam cylinder to the cylinder with a steel cable.  Insert the pin (5, Fig. 22) and install the pin retainer plate (4).

Connection of the clam cylinders on the clam  Connect the clam supply hoses (1, Fig. 21) between stick bottom chord and attachment control manifold (see hydraulic schematics).

 Attach lifting gear (1, Fig. 22) to the second cylinder (2) and raise it with the crane.

Remove the hardwood beam previously supporting the cylinder.  Remove the steel cable from the second cylinder. Repeat the procedure described to align clam cylinder fork (3, Fig. 22) and clam bearing point.

21

EM030190-0 December 2019  Insert the pin (5, Fig. 22) and install the pin retainer plate (4).  Shut down the engine.  Connect lubrication lines to the clam cylinder forks (6, Fig. 22).  Connect main lubrication lines (6) from the stick bottom chord to the bucket back wall.  Install the cover plates (1 and 2, Fig. 23) on both sides of the backwall.

Remove the welded support beams (1 & 2, Fig. 24) from the clam using a cutting torch and grind smooth.

Note: If hard metal wear plates were removed in the factory to accommodate the support beams, these strips need to be welded into place to complete the buckets wear plates.

If you need more information on welding the wear plates, contact your Cat dealer.

 Install both the rubber flaps (3, Fig. 23).

Fig. 24 Fig. 23

22

 Check contact surfaces of the clam and backwall. Ensure that the bucket parts close completely, otherwise you will damage the clam cylinders.

Refer to section “Hinge Test and Cylinder Residual Stroke” in this manual.

EM030190-0 December 2019

Clam Disassembly

 Remove the cover plates (1 and 2, Fig. 26) on both sides of the backwall.  Remove both the rubber flaps (3, Fig. 26).

The face shovel in complete as well as the clam and backwall as a part are huge and heavy parts.

When lifted up or when in motion they could cause serious injuries or death.

Handle them with care.

Heavy parts in motion can cause serious injury to your fingers or hands when touching other parts during motion. Do not touch heavy parts at positions where they could contact other parts.

Do not touch heavy parts in motion in order to guide them.

Do not step under the lifted load.

Step away from lifted loads during crane motion.  Ensure that the working area is clean and level.

Fig. 26

 Attach a sling (1, Fig. 27) to one clam cylinder (2) and secure it with a crane.

 Stand the implement to the ground so that the stick is perpendicular.  Ensure that the clam is resting in a horizontally level position. Support it with beams of hard-wood to keep it from rocking.  Weld steel beams (1 and 2, Fig. 25) into the clam, this reinforces the clam and prevents the clam from warping when it is removed.  Preheat the involve area to 175 °C (347 °F) prior to the tack-welding operation

Fig. 27

 Disconnect lubrication lines from the clam cylinder fork (6).  Disconnect lubrication lines from the bearing pin of the clam, accessible under cover (2, Fig. 26).  Remove the pin retainer plate (4).

Fig. 25

23

EM030190-0 December 2019  Install tooling (A, Fig. 29) to pin (5).  Attach a suitable lifting device to pin (5).

Note: The weight of the pin varies from about 50kg to 100kg (110lb to 220lb) depending on the size of the bucket.

Make sure that the lifting device holds the pin approx. in the middle of the length. This keeps the pin horizontal and prevents the pin from tipping to one side.  Pull out the clam cylinder pin (5).  Activate clam cylinder retraction slowly until the fork (3, Fig. 27) come clear from the clam.  Repeat the procedure with the other clam cylinder.

Fig. 29

 Repeat the procedure with the other clam bearing pin.  Carefully lift the backwall until the clam is free (Fig. 30), use the hydraulic functions "Lift boom" and "Tilt shovel".

Fig. 28

 Install tooling (A, Fig. 29) to pin (8).  Attach a suitable lifting device to pin (8).

Note: The weight of the pin varies from about 50kg to 100kg (110lb to 220lb) depending on the size of the bucket.

Make sure that the lifting device holds the pin approx. in the middle of the length. This keeps the pin horizontal and prevents the pin from tipping to one side.  Pull out the clam bearing pin (8).

24

Fig. 30

Clam Assembly The assembly of the clam is described in the section "FS-Bucket Assembly" of this manual.

EM030190-0 December 2019

FS-Bucket – Remove and Install

Storage Information

Note: Ensure that the FS-bucket is compatible with the host machine. Consult your Caterpillar dealer for information on matching the FS-bucket to the host machine.

For detailed information on Removal and Installation procedures of a complete assembled new or refurbished face shovel bucket from the machine please refer to the machine model related Service Manual. For example: The Service Manual for the 6060 machines is: - Special Instruction UENR6568 “Disassembly and Assembly, 6060 Hydraulic Shovel Machine Systems”.

To identify the Service Manual related to your machine please contact your Cat dealer.

The face shovel as well as the clam should be placed on flat, firm and level ground. Both must be supported with chocks to prevent unintentional movement.

The back wall should be stored lying down.

Note: If the work tool is stored for an extended period of time, place grease in the bores and bushings of the work tool. Protect the work tool from environmental influences.

Tie the hydraulic hoses to the work tool in order to keep the hoses off the ground. Install high-quality, matching protective caps over the fittings of the hydraulic hoses and the greasing hoses in order to protect the hoses from being contaminated.

For additional information on conservation for short time or longtime storage please refer to CGM-HMS Service Manual Volume 2, chapter 18 or Special Instruction SEHS9031 “Storage Procedure for Caterpillar Products”.

Transportation Information

The face shovel in complete as well as the clam and backwall as a part are huge and heavy parts.

When lifted up or when in motion they could cause serious injuries or death.

Handle them with care.

Heavy parts in motion can cause serious injury to your fingers or hands when touching other parts. Do not touch heavy parts at positions where they could contact other parts.

Do not step under the lifted load.

To avoid personal injury or death: Use only properly rated cranes and lifting devices which can bear the load. Cranes as well as lifting devices must be in good condition without any failures. Cranes as well as lifting devices must be checked for cracks and wear on a regular basis.

Only well-trained and skilled personnel with transportation experience may load or transport complete face shovel buckets as well as clams or backwalls.

Personnel must wear appropriate Personal Protection Equipment (PPE).

Before transporting on public roads, check the national regulations and laws and follow them.

Only use vehicles with sufficient capacity for transport. Do not overload the vehicles. Information about the mass of the bucket, clam or backwall can be found on the serial number plate.

25

EM030190-0 December 2019

Lifting and Tying Down

If a work tool shifts it could cause personal injury or death.

A work tool may shift if improper procedures or equipment are used for lifting and tying down for transport. Ensure that proper equipment and procedures are used for lifting and tying work tools down for transport.

NOTICE Do not use the lifting eyes on the work tool in order to lift the host machine. Damage to the work tool and host machine may result.

Do not use the bore of the bearing bushes to fasten lifting devices or tying devices. Damage of the bearing bushes may result.

Lifting eyes are labeled with films like shown in Fig. 31.

Lifting precautions Use properly rated cranes and lifting devices in order to lift the work tool.

Position the lifting device for level lifting of the work tool.

Use only the marked lifting eyes for attaching lifting hoists.

Position the hydraulic lines in order to prevent any damage to the hydraulic lines.

If equipped, position the wiring harness in order to prevent any damage to the wiring harness.

If equipped, position the greasing lines and hoses in order to prevent any damage to the greasing lines and hoses.

Lifting the face shovel bucket, the clam and the back wall Fig. 33 shows a typical example of lifting eyes on a face shovel bucket. Shape and position of lifting eyes on your face shovel bucket may differ in detail.

In order to lift the face shovel bucket, attach the lifting device to the lifting eyes (1 to 4, Fig. 33).

Fig. 31

Tying down eyes are labeled with films like shown in Fig. 32.

Fig. 32

26

Fig. 33

EM030190-0 December 2019 Lifting the clam

Lifting the backwall

Fig. 34 shows a typical example of lifting a clam. A lifting harness with four strands (1, Fig. 34) is used and attached to the four lifting eyes on the base of the clam.

If there are no lifting eyes on a used clam, new lifting eyes must be welded.

Note: In order to keep the side walls of the clam in a perpendicular position to the base of the clam, struts must be welded in as reinforcements before lifting and transporting the clam (refer to Fig. 34).

Fig. 35 shows a typical example of lifting a backwall.

A lifting harness with four strands (1, Fig. 35) is used and attached to the four lifting eyes on the backwall.

Fig. 35

Fig. 34

27

EM030190-0 December 2019 Tying down for transport Use properly rated lashing devices in order to secure the work tool when tying down.

Use only the marked lashing eyes for attaching lashing devices.

Fig. 36 shows a typical example of a smaller face shovel loaded on a flatbed trailer and tied down.

Note: Road safety devices like additional lights and warning signs are not yet installed on this photo.

Fig. 37 shows a typical example of a backwall loaded on a flatbed trailer and tied down.

Note: Lashing devices tying down the lower side of the backwall are not visible on this photo. These lashing devices have been attached to eyes shown in Fig. 33.

Note: Road safety devices like additional lights and warning signs are not yet installed on this photo.

Fig. 37 Fig. 36

1 - Lashing devices 2 - Wooden chocks 3 - Anti-slip mats

1 - Lashing devices 2 - Wooden blocks and anti-slip mats 3 – Barrier against moving forward due to braking Fig. 38 shows a typical example of a clam loaded on a flatbed trailer and tied down.

Note: Lashing devices tying down the opposite side of the clam are not visible on this photo. These lashing devices are attached to similar lashing eyes like visible.

Note: Road safety devices like additional lights and warning signs are not yet installed on this photo.

Fig. 38

1 - Lashing devices 2 - Wooden blocks and anti-slip mats

28

EM030190-0 December 2019

Transport

Decommissioning and Disposal

The face shovel bucket as well as the clam or the backwall must be loaded and transported only after all safety regulations have been observed and complied with.

Choose an area for loading that is flat and stable.

Only use vehicles with sufficient capacity for transport. Do not overload the vehicles. Information about the mass of the bucket, clam or backwall can be found on the serial number plate.

Secure the transport vehicle against rolling away.

Remove oil, grease, soil, mud, snow, ice and other materials from the loading platforms of the transport vehicle to minimize slipping.

Use anti-slip mats between the work tool and the loading platform of the transport vehicle to minimize slipping.

Secure the hydraulic lines to the work tool. Install high-quality, matching protective caps.

Secure the greasing lines to the work tool. Install high-quality, matching protective caps.

Secure the electric wiring to the work tool. Install high-quality, matching protective caps.

Use lashing devices to secure the work tool. In order to tie down the work tool, attach the lashing devices to the lashing points that are located on each side of the work tool.

Start the transport only after the work tool is properly tied down to the transport vehicle and secured against any movement. Follow the laws and regulations for secure transport valid in your country / area / mine.

When transporting the work tool over public roads follow all laws and regulations for transporting such loads on public roads valid in your country / area / mine.

When the product is removed from service, local regulations for the product decommissioning will vary. Disposal of the product will vary with local regulations.

Consult the nearest Cat dealer for additional information.

The assemblies of the work tool contain hydraulic fluid and lubricants. These substances may pollute the environment (so-called hazardous substances) and must therefore be disposed of properly.

Observe the national laws and regulations governing the non-polluting disposal of these substances.

Remove all operating fluids from the systems, remove all lubricants and dispose of these substances properly:  Hydraulic fluid: hydraulic cylinders, hosepipes, piping and hydraulic valve.  Grease from the central lubricating system: piping and hosepipes, distributors, grease accumulations in bearings of the work tool.

29

EM030190-0 December 2019

MAINTENANCE SECTION Before Starting Maintenance Work

Personal injury or death can result from bucket falling or moving. Lower the bucket to the ground and block the cutting edge off the ground before disassemble or assemble components of the bucket.

Due to the difference in wear rate by application, maintenance work must be adjusted to match the severity of the application.

Park the machine as described in section “Park the machine” Only block up the cutting edge to a sufficient height for removing components of the bucket.

Shut off the engines.

Wear appropriate personal protection equipment such as gloves, safety goggles, protective shoes and overall to protect against injuries.

To prevent possible injury to the eyes, wear a protective face shield when using a hammer.

Metal shards, when struck, can fly around and cause severe injury to nearby personnel.

Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country, state, region, mine site.

Note: Carefully clean the bucket before maintenance work.

30

EM030190-0 December 2019

Maintenance Schedule Maintenance Intervals related to Operating Hours (OH): T = Every 10 OH or every working shift

C = Every 1000 OH

W = Every 60 OH or every working week

D = Every 5000 OH

A = Every 250 OH

E = Every 10000 OH

B = Every 500 OH

Location

Servicing Work

Clam and backwall, walk around inspection

Interval T

W A

B

C

D

E

Check for damage, leaks, worn components, lost components.

Inspect the welds for cracks.















Hinge / pivot area

Check, remove all accumulated foreign objects.















Clam cylinder chambers

Check, remove all accumulated foreign objects.















Mechanical stops on backwall and stick Mechanical stops on clam and backwall (Welded and/or bolted stoppers, if equipped)

Check for wear.





























Check for tightness / Re-torque















Check pins and bushings for unusual play and wear.

Check adapters, cast lip etc. for damage and wear





















Check for wear.

Perform “Hinge Test and Cylinder Residual Stroke” if significant wear is visible.

Bolted stoppers on backwall and clam (If equipped) Pins, bores, bushings and covers G.E.T. weld-on components G.E.T. retention components (if equipped)

Perform Non Destructive Test (NDT)







G.E.T. mating surfaces

Check for wear







Screwed G.E.T. retention components (if equipped)

Check fit and torque 24 hours after installation of new G.E.T.

Screwed G.E.T. retention components (if equipped) Clam and backwall, steel structure, lip and G.E.T.

Check fit and torque 48 hours after installation of new G.E.T. Visual inspection according to “Structural Inspection Report every 500 OH” 1 If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrant, magnetic powder or ultrasonic test.

















1 „Structural Inspection Reports“ for inspections every 500 OH are available on SIS-Web, Media-ID-

No. BI644777.

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EM030190-0 December 2019

Clam and Backwall - Walk Around Inspection This inspection prevents unexpected down time.

Maintenance personnel should be informed of any items found during this inspection so that it can be taken care of as soon as possible.  Check the work tool mechanical parts for the following conditions: loose bolts, worn teeth, broken parts, worn parts, missing parts and for cracks.  Check the bucket tips and adapters and the edge protectors for wear or damage. Refer to section “Wear limits” for information on replacing bucket tips and the edge protectors.  Check the sidebar protectors for wear or damage. Refer to section “Wear limits” for information on replacing sidebar protectors.  Check the inner and outer wear plates for wear or damage. Refer to section “Wear limits” for information on replacing components of the inner or outer wear plates liner packages.  Check pins and bushings for increased play, for wear and damage.  Check the welds for cracks.  Check all greasing points for used grease squeezed out. If no grease is squeezed out the respective grease line might be clogged or damaged.  Check hydraulic components and hydraulic connections for leakages.  Check hydraulic lines and greasing lines coming from the stick and their connections to the face shovel for correct fixture, for leakages and damages.  Remove any defects identified (or have them removed) before proceeding with the machine.

Bucket – Clean To prevent possible injury to the eyes, wear a protective face shield when using a high pressure water jet cleaner or steam cleaner to clean the bucket.

Damaged components, cracks in the steel structure and cracks at welds are only recognizable when the face shovel has been cleaned.  Remove debris with steam cleaning or high pressure water.  Clean out the dirt inside the hinge/pivot area as needed.  Clean out the dirt inside the clam cylinder chambers as needed.

Clam Cylinder Chambers – Check/Clean In unfavorable circumstances during working operation loose material can reach the clam cylinders chambers in the shovel backwall.

To avoid damage to the clam cylinders and their hydraulic lines and hoses, inspect the clam cylinder chambers before starting each working shift.

Fig. 39

 Lift up the rubber cover plate of the clam cylinder chambers (arrows, Fig. 39).  Remove all accumulated material from the chamber.  Check cylinders and all hydraulic lines, hoses and connections for damage and leaks.

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EM030190-0 December 2019

Hinge / Pivot Area – Check/Clean In unfavorable circumstances during working operation loose material can reach the hinge/pivot area between the stick and the shovel backwall.

To avoid damage to the stick and the shovel backwall, inspect the hinge/pivot area before starting each working shift.

Fig. 40

Pins, Bores and Bushings Wear – Check To check the rotatable connections on backwall and clam for unusual wear two persons are needed.

One person stands in a safe distance to the face shovel so that the face shovel could well be seen like shown in Fig. 40. One person sits on the operator seat. This operator person must be trained to work with the machine.  Start one engine and let it run in low idle.  Swing the superstructure at a very slow speed a short distance to the right and to the left. This makes axial play visible between the stick and the backwall.  Move the boom at a very slow speed a short distance up and down. This makes radial play visible between the stick or the bucket cylinders and the backwall.  Shut down engine.

If any kind of play is visible, inform the responsible maintenance staff as soon as possible. Maintenance work is necessary to avoid further damage and greater costs.

 Check the hinge / pivot area (arrows, Fig. 40) for accumulated material and remove all the material.  Remove all squeezed out used grease and all accumulated foreign objects.

33

EM030190-0 December 2019

Clam and Backwall Steel Structure - Inspect

Mechanical Stops on Backwall and Stick – Check

 Thoroughly clean the face shovel bucket.  Visually inspect the steel structure for cracks and broken components and damages.

If cracks in the steel structure or cracks at welds were detected, a detailed inspection is recommended to avoid further damage and greater costs.  Carry out a visual inspection and further detailed Non Destructive Testing (NDT) work on clam and backwall according to “Special Instruction Structural Inspection Report BI644777” available from your Cat dealer or from the SIS Web.  Remove any defects identified (or have them removed) before proceeding with the machine.

There are mechanical stops on backwall and stick.

Fig. 41 shows a typical example, shape and position of stops on your face shovel may differ in detail.

These mechanical stops avoid mechanical contact between backwall and stick in case that shovel cylinders are fully extended or fully retracted. Forced contact between backwall and stick may lead to damage of backwall and upper and lower chord of the stick.

NOTICE Always avoid to fully extend or fully retract shovel cylinders to their end stops with high speed.

Fig. 41

 Check the play between backwall and stick both with the shovel cylinders fully extended and fully retracted.

There must be a clear distance between backwall and stick. No mechanical contact is allowed.

In case there is too much wear on the mechanical stops on backwall or stick, this can be repaired by build-up welding. Please contact your Cat dealer.

34

EM030190-0 December 2019

G.E.T. Retention Components NDT - Perform Perform Non Destructive Testing (NDT) examination of all retention components.

Examine all welded components using dye penetrant or magnetic particle testing to check for cracking as a result of time in service.

Examine the transition from the lip to the wing using dye penetrant or magnetic particle testing to check for cracking as a result of time in service.

The transition should be checked on the internal transition and from the corner nose station into the wing.

For more detailed information, e.g. Special Instructions please contact your Cat dealer.

G.E.T. Mating Surfaces Wear Check Check mating surfaces with for wear.

Visually look for contact wear on the mating surfaces of parts.

Using the appropriate gauge, check any nose, lip shroud, or wing shroud that shows visual indications of wear or showed evidence of fit issues when GET was installed.

If any location does not conform to the gauge requirements then, it must be rebuilt before returning to surface. Proceed to the rebuild section of this maintenance guide for instructions for each location.

For more detailed information, e.g. Special Instructions please contact your Cat dealer.

Screwed G.E.T. Retention Components (if equipped) – Check Fit and Torque During service, the motion of the bucket and the interaction with material may force the GET to shift slightly.

This shifting along with the initial torque of the retention will “break in” the mating surfaces between the GET and bucket.

After 24 hours, the newly installed GET should be checked to make sure that the torque has not relaxed on the new GET. Keeping the torque at the specified values helps to prevent damage to the GET and to mating bucket components.

Refer to the installation instructions for the torque requirements of the specific components.

Also, this break-in could expose an improper fit that was not initially seen. If any of the newly installed GET is not fitting correctly after checking torque, notify maintenance personnel immediately.

For more detailed information, e.g. Special Instructions please contact your Cat dealer.

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EM030190-0 December 2019

REPLACING WEAR PARTS SECTION

Be careful when handling heavy parts. Heavy parts can cause serious injury when falling down on your feet or other parts of your body.

Use applicable lifting gear to move heavy parts safely.

Heavy parts in motion can cause serious injury to your fingers or hands when touching other metal parts. Do not touch heavy parts where they could contact other metal parts. Use an appropriate pry bar to correct the position of heavy parts.

To guard against death or injury, mine site safety precautions should be observed before attempting to install or remove components of the G.E.T. Note: Caterpillar recommends the use of only genuine Cat replacement parts. Please refer to the machines parts manual to find the matching spare part or contact your Cat dealer.

Depending on the machine model, the application and the density of the material to load, several G.E.T. systems are in use.

Replace Wear Parts with Welding Special information brochures are available for this work. Please refer to the "Reference Infomation" section. If you do not have access to the Cat web pages and the Special Instructions available there, please contact your Cat dealer.

Replace Wear Parts without Welding G.E.T. with CapSure™ Locking System – Bucket Tips Replace Bucket tips assist the bucket while penetrating the soil.

Tips were made from highly wear-resistant steel.

Never the less they must be replaced when they reach the wear limits. This prevents the bucket from being damaged and enhances digging performance.

Tips are large, heavy parts. Use appropriate lifting devices to move the tips safely.

Tips are fastened to the adapters at the bucket lip using the CapSure™ locking system (Fig. 42).

Wear Limits - Check Identify the Degree of Wear For components with wear indicators (lip and wing shrouds) these should be checked to see if the indicators are visible since last checked. If they are visible, then they should be replaced as soon as possible.

Components without wear indicators should be examined to determine if they should be replaced. If internal pockets are visible, the components should be replaced. Also, longer lasting components can be checked for remaining life. The percentage of wear material left should be noted.

For checking wear on the lip noses there are inspection gauges available. For more detailed information, e.g. Special Instructions please contact your Cat dealer.

36

Fig. 42

To replace worn or damaged tips:  Carefully clean tip, the locking device and the area around from dirt.  Weld a lug made from strong wire onto the tip to be replaced.  Fasten tip with a lifting device (Fig. 43).

EM030190-0 December 2019

Fig. 43

 Unlock the tip by turning the locking devices with a ¾” ratchet. Turn by 180° (Fig. 43).  Remove worn tip.  Carefully clean the adapter. Remove any dirt and corrosion.

Fig. 45

 Lock the tip by turning the locking devices with a ¾” ratchet. Turn by 180° (Fig. 45).

Fig. 44

 Fasten new tip with a lifting device (Fig. 44).  Move new tip over the adapter (Fig. 44).  Check for correct fit of the tip to the adapter.

If the component does not fit as described in the installation instructions provided with the component, then maintenance personnel should be notified immediately.

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EM030190-0 December 2019

Bucket Lip Shroud with CapSure™ Locking System – Replace Lip shrouds are large, heavy parts. Use appropriate lifting devices to move this parts safely.

Lip shrouds are fastened to the bucket lip using the CapSure™ locking system (Fig. 46).  Carefully clean lip shroud (1, Fig. 46), the locking devices (2) and the area around from dirt.  Weld a lug made from strong wire onto the shroud to be replaced.  Fasten lip shroud with a lifting device.  Unlock locking devices like described in chapter “G.E.T. with CapSure™ locking system – Bucket tips replace”.  Remove worn lip shroud.  Carefully clean the lip and the lip shroud adapter (3). Remove any dirt and corrosion.  Fasten new lip shroud with a lifting device.  Move new lip shroud over the lip shroud adapter.  Lock locking devices like described in chapter “G.E.T. with CapSure™ locking system – Bucket tips replace”.  Start the engines.  Raise the bucket and remove the supporting blocks. Lower the bucket to the ground.

Fig. 46

38

Bucket Wing Shroud – Replace Wing shrouds (2, Fig. 47) protect the bucket side walls from excessive wear.

They were made from highly wear-resistant steel.

Never the less they must be replaced when they reach the wear limits. This prevents the bucket from being damaged.

Wing shrouds are large, heavy parts.

Wing shrouds are fastened to the bucket walls using spring clips (1) and bolts (3).

To replace worn or damaged wing shrouds:  Carefully clean wing shroud (2) and the area around from dirt.  Weld a lug made from strong wire onto the wing shroud to be replaced.  Fasten lip shroud with a lifting device.  Drive out bolts (3).  Detach wing shroud (2).  Remove spring clips (1) from the bores.  Carefully clean the bucket side walls and the bores. Remove any dirt and corrosion.  Insert new spring clips (1) into the bores. Fix with grease if necessary.  Fasten new wing shroud with a lifting device.  Place the new side shroud (2) to the side wall, watch for aligned bores.  Drive in bolts (3).

Fig. 47

EM030190-0 December 2019

G.E.T. with Screwed Locking System – Bucket Tips Replace Shown in this example on a CL-1 G.E.T. system.

Note: Tips are large, heavy parts. Use appropriate lifting devices to move the tips safely. Ensure tips are sufficiently supported and stable at all times during the installation and removal of retainer components.

Tools needed: ¾” Drive – 600mm wrench

Screwdriver

¾” Drive wrench extension

500mm Pry bar

Needle gun To remove worn or damaged tips:  Carefully clean tip, the locking device and the area around from dirt.  Weld a lug made from strong wire onto the tip to be replaced.  Fasten tip with a lifting device

Fig. 48

 Remove all dirt and pry out the dust plug (Fig. 48).

Fig. 50

 Slide retaining pin out (square drive side) (Fig. 50).

The rope pull or the pin must not be reused.

Fig. 51

 Remove the tip (Fig. 51). Clean nose of all dirt before assembling new tip.

To install new tips: Note: Upon installation of any new G.E.T., the fit of the component must be evaluated before installation of the retention components. If the component does not fit as described in the installation instructions provided with the component, then maintenance personnel should be notified immediately.

After installation of the component and retention, each retention component should be checked for proper torque as outlined in the installation instructions provided with the component.

Fig. 49

 Insert square drive into tip retaining pin and turn counter-clockwise for pin to release and eject (Fig. 49).

39

EM030190-0 December 2019

Fig. 52

Components of tip and retaining system (Fig. 52): 1- Coupler 2- Tip assembly 3- Rope pull 4- Tip retaining pin 5- Dust plug

Fig. 54

 Ensure tip pocket and coupler nose are clean of fines and slide the tip onto the coupler nose (Fig. 54).

Fig. 55

Fig. 53

 Before performing the tip installation, ensure the retainer ring is securely seated in the cavity of the tip ear (Fig. 53).

40

 If not previously installed, install dust plug into square drive of the tip retaining pin.

Screw the rope pull into tail end of pin and tighten (Fig. 55).

EM030190-0 December 2019

G.E.T. with Screwed Locking System – Coupler Replace Shown in this example on a CL-1 G.E.T. system.

Note: Couplers are large, heavy parts. Use appropriate lifting devices to move the couplers safely.

Ensure couplers are sufficiently supported and stable at all times during the installation and removal of retainer components.

Tools needed: 1/2” Drive – Torque wrench (200 – 700 Nm) 1/2” Drive 16mm AF socket Extra long (140mm min.) 17mm Hex Bit Socket Magnalube-GTM Teflon (PTFE) Grease Fig. 56

 Insert tip retaining pin into the tip and coupler assembly, rotating pin clockwise until pin shoulders butt up to cast shoulders (Fig. 56).

Needle gun Suitable Pry Bar To remove worn or damaged couplers:  Carefully clean coupler, the locking device and the area around from dirt.  Weld a lug made from strong wire onto the coupler to be replaced.  Fasten coupler with a lifting device

Fig. 57

 Insert a suitable pry bar through loop of rope pull and lever across to lock tip retaining pin into place (Fig. 57).

Fig. 58

 Remove the dust plug with a suitable pry bar and clear fines from around the retainer bolt head (Fig. 58).

41

EM030190-0 December 2019

Fig. 59

 Unscrew the bolt retainer plug so that the bolt head is exposed and withdraw the retainer from the assembly (Fig. 59).

Fig. 60

 Unfasten the captured bolt and continue to remove the bolt end wedge from the retainer body (Fig. 60). A pry bar can be used to lever wedges from cavity using the grooves provided. Remove wedge.

Fig. 61

 Remove remaining wedge using a pry bar inserted to the pry bar groove and lever out (Fig. 61).

Fig. 62

 Remove coupler from nose and remove retainer body from nose (Fig. 62).

To install new couplers: Note: Upon installation of any new G.E.T., the fit of the component must be evaluated before installation of the retention components. If the component does not fit as described in the installation instructions provided with the component, then maintenance personnel should be notified immediately.

After installation of the component and retention, each retention component should be checked for proper torque as outlined in the installation instructions provided with the component.

42

EM030190-0 December 2019 Components of coupler and retainer

Fig. 65 Fig. 63

Refer to Fig. 63: 1 – Coupler 2 – Retainer end (threaded) 3 – Nose (part of the lip) 4 – Retainer body 5 – Retainer end (captured bolt) 6 – Bolt retainer plug 7 – Dust plug

 Fit coupler or box point tooth, ensuring it is firmly engaged with the nose (1, Fig. 65).

Fig. 66

 Insert the two retainer ends into the retainer body (2 and 5, Fig. 66).  Align bolt thread to opposing retainer end and engage threads.  Lubricate end sections with Teflon (PTFE) grease.

Fig. 64

 Insert the retainer body (4, Fig. 64) into the nose cavity (3).  Lubricate O-Rings with Teflon (PTFE) grease (Fig. 64).

Note: If refitting or using a rebuild kit, ensure Orings are intact and undamaged. If O-rings are damaged or missing, replace. Lubricate O-rings with Teflon (PTFE) grease. The retainer body must be clear and free of fines. Ensure O-ring orientation is correct. Inside O-ring is black, outside is white.

43

EM030190-0 December 2019 Note: Extra long hex bit socket is not included (A, Fig. 68 and Fig. 69).

Reference Cat part no. 493-6895. Please contact your Cat dealer.

Fig. 67

Note: It is recommended that the retainer end (captured bolt) be installed on the inside of the bucket to reduce the effects of wear on the removal and reinstall. See Fig. 67 showing the torque wrench on the recommended side of the nose.

Fig. 70

 Insert bolt retainer plug (6, Fig. 70) to engage with the main bolt.  Ensure rubber and washers in bolt retainer are buttet up against hex bar (B, Fig. 71)  Tighten to compress rubber to complete the installation. Use hand held wrench Note: Do not overtighten torque retainer bolt to 40Nm (30 ft lb) as this will damage the rubber making removal difficult.

Note: Dust plug and bolt retainer plug will need to be removed and refitted to facilitate re-tensioning of retainer end captured bolt. Refer to tables for re-tensioning intervals and torque requirements.

Fig. 68

Fig. 71

Fig. 69

 Tighten the captured bolt to specified torque using a handheld wrench (Fig. 68 and Fig. 69).

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EM030190-0 December 2019

 Insert dust plug (7, Fig. 72).

Fig. 72

Captured Bold Torque Table Nose base size

Captured bolt torque

W850 / W900

300 Nm (220 ft lbf)

W950 / W1150

300 Nm (220 ft lbf)

W1050

400 Nm (300 ft lbf)

Re-Tensioning Intervals Table Re-Tensioning intervals Initial / First Fit (Delivery) 24 Hours 48 Hours Next Scheduled Service Operation

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EM030190-0 December 2019

G.E.T. with Screwed Locking System – Lip Shroud Replace

Components of lip shroud and mounting

Shown in this example on a CL-1 G.E.T. system.

Note: Lip shrouds are large, heavy parts. Use appropriate lifting devices to move the lip shrouds safely. Ensure lip shrouds are sufficiently supported and stable at all times during the installation and removal of retainer components.

To guard against death or injury, mine site safety precautions should be observed before attempting to install or remove this assembly.

Note: A new retainer kit should be used for every shroud installation. The retainer kit is to be used for the life of the shroud.

Tools needed: Torque wrench

Appropriate socket

Torque capacity depends on the size of lip shroud and retainer kit.

Size depends on the size of lip shroud and retainer kit.

Please refer to the documentation delivered together with the spare parts.

Retainer kit components

Fig. 74

Refer to Fig. 74 1 – Mounting boss weldment 2 – Cast lip 3 – Retainer kit 4 – Lip shroud To remove worn or damaged lip shrouds  Carefully clean tip shroud, the locking device and the area around from dirt.  Weld a lug made from strong wire onto the lip shroud to be replaced.  Fasten lip shroud with a lifting device.

To install a new shroud

Fig. 73

Refer to Fig. 73: 1 – Retaining bolt 2 – Belleville washer (2) 3 – Washer 4 – Cone nut 5 – Retainer clip (2)

46

Fig. 75

 Insert retaining bolt into shroud recess and secure into position with one retainer clip pushed into the bottom of shroud cavity (3, Fig. 75).  Insert second retainer clip and position on start of bolt shaft.

EM030190-0 December 2019

Fig. 78 Fig. 76

 Ensure all mating faces on the cast lip and the shroud are clean and free of fines.  Align the shroud with the mounting boss weldment (1, Fig. 76).  Fully engage the shroud to the cast lip surfaces, ensuring the retaining bolt aligns with the boss groove (3, Fig. 76).

Note: Orientation of Belleville washers (2, Fig. 78) is important. Ensure concave sides face the shroud mounting boss weldment.

Lip Shroud Retainer Kit Torque Table Lip size

Socket size

Retainer Kit torque

W850 x 4300

1-7/8” AF

800 Nm (590 ft lbf)

W900 x 4300

1-7/8” AF

800 Nm (590 ft lbf)

W950 x 4300

1-7/8” AF

800 Nm (590 ft lbf)

W950 x 5100

1-7/8” AF

800 Nm (590 ft lbf)

W1050 x 5100

2-1/4” AF

1000 Nm (740 ft lbf)

W1050 x 5600

2-1/4” AF

1000 Nm (740 ft lbf)

W1150 x 5100

2-1/4” AF

1000 Nm (740 ft lbf)

Please refer to the documentation delivered together with the spare parts.

Note: All torque settings are for dry application. If lubrication is applied, adjust torque accordingly.

Re-Tensioning Intervals Table Re-Tensioning intervals: Fig. 77

 In order, install to the retaining bolt (Fig. 77):  Belleville washer (2), thick washer (3), Belleville washer (2), then cone nut (4) onto the retaining bolt, as shown in Fig. 77 and Fig. 78.  Tension to specifications shown in table “Lip Shroud Retainer Kit Torque Table”.  Important: Re-Tensioning is necessary. Refer to “Re-Tensioning Intervals Table”.

Initial / First Fit (Delivery) 24 Hours Next Scheduled Service Operation

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EM030190-0 December 2019

G.E.T. with Screwed Locking System – Wing Shroud Replace

Components of wing shroud and mounting

Shown in this example on a CL-1 G.E.T. system.

Note: Wing shrouds are large, heavy parts. Use appropriate lifting devices to move the wing shrouds safely. Ensure wing shrouds are sufficiently supported and stable at all times during the installation and removal of retainer components.

To guard against death or injury, mine site safety precautions should be observed before attempting to install or remove this assembly.

Note: A new retainer kit should be used for every shroud installation. The retainer kit is to be used for the life of the shroud.

Tools needed:

Fig. 80

Torque wrench

Torque capacity depends on the size of wing shroud and retainer kit.

Appropriate socket

Size depends on the size of wing shroud and retainer kit.

Please refer to the documentation delivered together with the spare parts.

Retainer kit components

Refer to Fig. 80 1 – Upper wing shroud 2 – Lower wing shroud 3 – Retainer kits 4 – Wing plate 5 – Mounting boss weldments 6 – Shear blocks 7 – Cast lip To remove worn or damaged wing shrouds  Carefully clean wing shrouds, the locking device and the area around from dirt.  Weld a lug made from strong wire onto the wing shroud to be replaced.  Fasten wing shroud with a lifting device.

To install a new wing shroud

Fig. 79

Refer to Fig. 79: 1 – Retaining bolt 2 – Belleville washer (2) 3 – Washer 4 – Cone nut 5 – Retainer clip (2) Fig. 81

 Insert retaining bolt into shroud recess and secure into position with retaining clips.

Push first clip to bottom of shroud cavity (3, Fig. 81). Insert second clip and push to start of the bolt shaft.

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EM030190-0 December 2019

Fig. 84 Fig. 82

 Ensure all mating faces on the wing plate and the wing shrouds are clean and free of fines.  Align the lower wing shroud (2, Fig. 82) with the mounting boss.  Fully engage the lower wing shroud to the wing plate and the cast lip surfaces, ensuring the retaining bolt aligns with the mounting boss groove.  Repeat for upper wing shroud (1), ensuring full engagement to the wing plate.

Note: Orientation of Belleville washers (2, Fig. 84) is important. Ensure concave sides face the shroud mounting boss weldment.

Wing Shroud Retainer Kit Torque Table Retainer Kit Part #

Socket size

Retainer Kit torque

444-1747

1-7/8” AF

800 Nm (590 ft lbf)

444-1748

1-7/8” AF

1000 Nm (740 ft lbf)

444-1749

1-11/16” AF

550 Nm (300 ft lbf)

444-1752

2-1/4” AF

800 Nm (590 ft lbf)

444-1747

2-1/4” AF

800 Nm (590 ft lbf)

Please refer to the documentation delivered together with the spare parts.

Note: All torque settings are for dry application. If lubrication is applied, adjust torque accordingly.

Re-Tensioning Intervals Table Re-Tensioning intervals: Initial / First Fit (Delivery) 24 Hours Next Scheduled Service Operation Fig. 83

 In order, install to the retaining bolt (Fig. 83):  Belleville washer (2), thick washer (3), Belleville washer (2), then cone nut (4) onto the retaining bolt, as shown in Fig. 83 and Fig. 84.  Tension to specifications shown in table “Wing Shroud Retainer Kit Torque Table”.  Important: Re-Tensioning is necessary. Refer to “Re-Tensioning Intervals Table”.

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EM030190-0 December 2019

TESTING & ADJUSTING SECTION Hinge Test and Cylinder Residual Stroke

Risk of serious injury or death due to moving heavy parts.

Stay clear of the moving face shovel and clam.

Do not touch any part in motion.

The job must be carried out by skilled, well trained personnel only.

Follow appropriate safety procedures and use Personal Protective Equipment (PPE) as required.

Observe all local safety regulations.

Observe all mine site safety precautions before attempting to work at the front shovel bucket.

Tools needed:

Fig. 85

Refer to Fig. 85: 1 – Clam cylinder 2 – Back wall 3 – Clam L – Possible stroke of clam cylinder

Measuring tape The cylinder residual stroke is defined by the remaining possible stroke of the clam cylinder (L, Fig. 85), when the corresponding function is fully engaged – in this case the face shovel bucket is completely closed.

That means that the position of the piston rod is fully extended until steel structure limits – clam movement contacts bucket back wall.

Residual stroke of the clam cylinders is necessary to avoid the piston from hitting the cylinder guide internally when the piston rod extends. This could lead to major damage of cylinders.

Hinge Test  Start one engine and let it run in low idle.  Lift the attachment until the shovel bucket is about 50 cm / 1.5 ft above ground.  Slowly open the clam completely (Fig. 86).  Slowly close the clam completely. The movement of the clam must be smooth and jerk-free.

The stoppers on clam and backwall (arrows, Fig. 86) must have contact. Watch carefully for gaps between stoppers on clam and backwall. In the grey marked areas on clam and backwall (arrows, Fig. 86) no gap is allowed.

If there are gaps, measure the residual stroke of the clam cylinders (Refer so section: “Clam Cylinder Residual Stroke – Measure”).

50

Fig. 86

EM030190-0 December 2019

Clam Cylinder Residual Stroke – Measure Usable stroke (L, Fig. 87) can be measured with a measuring tape; distance between face of guide and bottom of fork eye must be measured.

If the maximal value “L” (Refer to “Clam cylinder stroke table”) is not exceeded, sufficient residual stroke is ensured, thus avoiding cylinder damage.

If the measured value “L” is exceeded, the wear plates (stoppers) on clam and/or backwall have to be renewed. This can be done by welding replacement of the complete wear plates or by build-up welding. Bolted stoppers can be replaced (Refer to your corresponding parts manual).

If you need more information regarding repair work, please contact your Cat dealer.

Fig. 87

Clam cylinder stroke table Part-No. Clam Cylinder Machine Type

Cat No.

HMS SAP Part No.

Legacy HMS Part No.

Maximum of measured length “L”

Cat 6015

471-2145

4023720

3672043

330 mm

Cat 6018

471-2148

4026122

3710270

460 mm

Cat 6030

471-2149

4105785

3713770

450 mm

Cat 6040

503-9755

1453541

4525841

712 mm

Cat 6050

503-9754

4235643

3734821

707 mm

Cat 6060

459-2050

4191687

3734813

715 mm

Cat 6090

471-2147

1524416

3705007

820 mm

519-5011

800 mm

Bolted Stoppers (If equipped) – Retorque Backwall and clam can be equipped with bolted stoppers (2, Fig. 88).

Check tightness of all bolts (1) regularly. If loose, retighten nuts with torque wrench.

Torque = 1150Nm +/- 150Nm.

Fig. 88

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EM030190-0 December 2019

Backwall Hydraulic System – Check / Inspect  Stand the face shovel bucket to the ground, shut off the engines.  Depressurize the hydraulic system (Refer to Service Manual, chapter 8 “Hydraulic System” for a description of the correct procedures).  Remove cover plate at the rear of the back wall.  Remove the rubber plates covering the clam cylinder chambers.  Check hydraulic hoses, lines and fittings for leaks and wear.  Check hydraulic cylinders for leaks.

There is a distributor installed on the bucket back wall between the clam cylinders (This component is position 186 in the hydraulic schematic, refer to chapter 8 “Hydraulics” of the machines Service Manual).). The distributor contains a secondary pressure relief valve with 330 bar setting which protects the clam cylinders from too high pressure. The distributor connects the hydraulic lines from the rod ends of the clam cylinder to their head ends and protects the hydraulic system from pressure peaks.

This secondary pressure relief valve is already set by the factory. The pressure setting should not be changed to protect hoses, cylinders and other components of the face shovel.

52

Central Lubricating System – Check / Inspect  Check all grease points for squeezed out used grease. If no used grease is squeezed out, the grease line might be clogged. Check grease line and distributor.  Check grease lines, hoses and fittings for leaks, wear and damage. Retighten leaking connections. Replace worn or damaged components.  Check distributors for leaks and inspect correct function.

EM030190-0 December 2019

REFERENCE INFORMATION

Acronyms

For additional information on specifications and front clam / backwall matching please contact your Cat dealer.

Acronym

Meaning

approx..

approximately

AF

Across Flats (spanner or socket)

CGM-HMS

Caterpillar Global Mining-Hydraulic Mining Shovels

FS

Face shovel

G.E.T.

Ground Engaging Tool

kPa

KiloPascal, unit of pressure

NDT

Non Destructive Testing

Nm

Newtonmeter, value of torque

OH

Operating Hours

PPE

Personal Protective Equipment

psi

Pounds per square inch, unit of pressure

For additional information on optimized operating techniques please refer to: - Special Instruction EM027975 “Operational Practices: Working and Traveling”.

For additional information on reuse and salvage procedures on the bucket please refer to: - Special Instruction M0069828 “Hydraulic Mining Shovel Bucket Reuse and Salvage Guideline: Face shovels”.

For additional information on doing welding repair on the bucket please refer to: - Special Instruction SEBD0512 “Reuse and Salvage Guideline: Caterpillar Service Welding Guide”.

- Special Instruction M0075256 “Expanded Mining GET Master Document”.

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EM030190-0 December 2019

NOTES

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EM030190-0 December 2019

Index A Acronyms ............................................................................. 53 All products Foreword ........................................................... 3

B Backwall Hydraulic System – Check / Inspect ...................... 52 Before Starting Maintenance Work ..................................... 30 Before Starting Operation ..................................................... 9 Bolted Stoppers (If equipped) – Re-torque.......................... 51 Bucket – Clean ..................................................................... 32 Bucket Lip Shroud with CapSure™ Locking System – Replace ........................................................................................ 38 Bucket Wing Shroud – Replace ............................................ 38 Burn Prevention..................................................................... 6

C California Proposition 65 Warning......................................... 4 Caterpillar Approved Machines ........................................... 16 Central Lubricating System – Check / Inspect...................... 52 Clam – Assembly .................................................................. 24 Clam – Disassembly ............................................................. 23 Clam and Backwall - Walk Around Inspection ..................... 32 Clam and Backwall Steel Structure - Inspect ....................... 34 Clam Cylinder Chambers – Check/Clean .............................. 32 Containing Fluid Spillage........................................................ 6 Contents ................................................................................ 1 Crushing Prevention and Cutting Prevention ........................ 6

D Declaration of Conformity ................................................... 17 Decommissioning and Disposal ........................................... 29 Dispose of Waste Properly .................................................... 7

E European Union ................................................................... 17

F Face Shovel Bucket – Hydraulics.......................................... 13 Face Shovel Bucket Central Greasing System ...................... 14 Face Shovel Bucket Mechanical Parts.................................. 11 Face Shovel Bucket Mechanical Parts – Continued ............. 12 Face Shovel Operator Assist System (If equipped) .............. 15 Fire Prevention and Explosion Prevention............................. 7 Fluid Penetration ................................................................... 5 FS-Bucket – Assembly .......................................................... 19 FS-Bucket – Operation ......................................................... 18 FS-Bucket – Remove and Install........................................... 25 FS-Bucket Backwall and Clam – Disassemble and Assemble18

G G.E.T. Mating Surfaces Wear - Check .................................. 35 G.E.T. Retention Components NDT - Perform ..................... 35

G.E.T. with CapSure™ Locking System – Bucket Tips Replace .........................................................................................36 G.E.T. with Screwed Locking System – Bucket Tips Replace 39 G.E.T. with Screwed Locking System – Coupler Replace ......41 G.E.T. with Screwed Locking System – Lip Shroud Replace .46 G.E.T. with Screwed Locking System – Wing Shroud Replace .........................................................................................48 General Hazard Information ..................................................4

H Hinge / Pivot Area – Check/Clean ........................................33 Hinge Test and Cylinder Residual Stroke..............................50

I Identification Information ....................................................16 Index ....................................................................................55 Intended Use ........................................................................16

L Lifting and Tying Down.........................................................26 Lines, Tubes, and Hoses .........................................................8

M Maintenance Schedule ........................................................31 Maintenance section ...........................................................30 Mechanical Stops on Backwall and Stick – Check ................34 Misuse ..................................................................................16 Modifications of the Work Tool .............................................8

N Notes ....................................................................................54

O Oils .........................................................................................7 Operation ...............................................................................9 Operation section ..................................................................9 Operation section ................................................................18

P Park the Machine .................................................................10 Personnel ...............................................................................4 Pins, Bores and Bushings Wear – Check ..............................33 Pressurized Air and Water .....................................................6 Product Information Section ................................................11

R Reference information .........................................................53 Reference Information Section ............................................10 Replace Wear Parts with Welding........................................36 Replace Wear Parts without Welding ..................................36 Replacing wear parts section ...............................................36

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EM030190-0 December 2019

S

T

Safety Messages .................................................................... 4 Safety section ........................................................................ 4 Screwed G.E.T. Retention Components (if equipped) – Check Fit and Torque ................................................................. 35 Serial Number Plate ............................................................. 16 Specification Information .................................................... 16 State of the Machine ............................................................. 5 State of Tools and Lifting Devices .......................................... 5 State of Work Tools and GET ................................................. 5 Storage Information ............................................................ 25

testing & adjusting section ..................................................50 Transport .............................................................................29 Transport ...............................................................................8 Transportation Information .................................................25 Trapped Pressure ...................................................................5

56

W Wear Limits - Check .............................................................36 Welding / Flame Cutting on the Bucket and it´s Wear Protection ..........................................................................6

EM030190-0 December 2019

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