M0071122 (en-us) 15 September 2016
Tool Operating Manual Important Safety Information
i06667026
NEHS1259: 469-7632 Swing Gearbox Lifting Tool for 60156090 Hydraulic Mining Shovel SMCS Code: 0629; 7000
Caterpillar Products All Machines
Table of Contents Introduction ...........................................................1 Literature Information .............................................2 Safety Section....................................................2 General Information Section................................2 Operation Section...............................................2 Maintenance Section ..........................................2 Safety Section .......................................................2 General Hazard..................................................2 Information ........................................................2 Crushing Prevention and Cutting Prevention........................................................3 Safety Icon Nomenclature ...................................3 Personal Protection/Important Information ...................................................3 Hazard Avoidance...........................................3 Contact Information ............................................3 General Information Section ...................................4 Introduction........................................................4 References ........................................................4 Specifications.....................................................5 Nomenclature ....................................................5 Operation Section...............................................7 Operation .......................................................7 Inspection and Maintenance................................8 Inspection.......................................................8 Cleaning.........................................................8 Storage ..........................................................8 Disposal .........................................................8 ............................................................................8
Illustration 1
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Think Safety
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, perform 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.
Introduction
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.
European Union Compliant, CE Marked
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Operation Section
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. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The Operation Section is a reference for the new operator and a refresher for the experienced operator. Photographs and illustrations guide the operator through correct procedures for using the tool group. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torque, 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.
Maintenance Section The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.
Safety Section
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.
General Hazard
Literature Information This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group. Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Illustration 2
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
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Information Wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment. Make sure that all protective guards and all covers are secured in place on the equipment.
Safety Section The Safety Section lists basic safety precautions. Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.
Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only.
General Information Section
Obey all local regulations for the disposal of liquids.
The General Information Section describes tooling functions and features. This section provides useful information on individual parts, extra tooling, and resources.
Do not allow unauthorized personnel on the equipment. Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position. Refer to the Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position.
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Crushing Prevention and Cutting Prevention
Personal Protection/Important Information
Support the equipment 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. Stay clear of all rotating and moving parts.
Safety Icon Nomenclature
Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility. Illustration 3
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Personal Protection/Important Information
Hazard Avoidance
Personal injury or death can result from improper lifting or blocking.
Crushing Hazard (foot)
When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.
Crushing Hazard (hand)
Pinch Point
Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.
Contact Information For product support questions concerning this tool, contact the Dealer Service Tools hotline at:
To avoid injury do not stand on or between implement and machine while operating lift control.
USA: 800-542-8665, Option 1 International: 1-309-578-7372 Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.
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General Information Section Introduction
Illustration 4
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The 469-7632 Swing Gearbox Lifting Tool for 6015 6090 Hydraulic Mining Shovels is a lifting tool that is able to correctly position and fasten the gearbox for optimal lifting. With two different mounting locations, the tool is able to lift the gearbox with or without the brake housing being installed. Note: Refer to the appropriate Disassembly and Assembly Service Manual for mounting and lifting hardware and contact location of the lifting point.
References Table 1 References i06298556
Swing Gearbox Removal
I06299335
Swing Gearbox Installation
Note: The list of references may change. Always locate and refer to the appropriate disassembly and assembly service manual for the most current information.
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Specifications
Illustration 5
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Table 2 469-7632 Swing Gearbox Lifting Tool Item
Description
Specifications
A
Height
161 mm (6.3 inch)
B
Length
375 mm (14.8 inch)
C
Width
375 mm 14.82 inch)
–
Weight
13 kg (28.6 lbs)
–
Working Load Limit (WLL)
1362 kg (3000 lbs)
Nomenclature
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Illustration 6
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Table 3 469-7632 Swing Gearbox Lifting Tool Item
Part No.
Description
Quantity
1
–
M10 Clearance Holes
4
1A
8T-4195 (reference only)
M10 - 1.5 x 30 mm Hex Head Bolt
4
1B
8T-4121 (reference only)
M10 Washer
4
2
–
M20 Clearance Holes
4
2A
8T-5460 (reference only)
M20 - 1.45 x 40 mm Hex Head Bolt
4
2B
8T-4123 (reference only)
M20 Washer
4
3
–
Lifting Eye
2
4
(Reference only)
M20 Bolt Pattern
5
(Reference only)
M10 Bolt Pattern
6
(Reference only)
Gearbox
7
(Reference only)
Brake Housing
6
Operation Section Operation
Illustration 7
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1. With the brake (7) assembled, use M20 Bolts (2A) and M20 washers (2B) to fasten the lifting tool to the M20 bolt pattern (4) on the top of the brake housing.
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Illustration 8
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2. With the brake housing (7) removed, use M10 bolts (1A) and M10 washers (1B) to fasten the lifting tool to the M10 bolt hole pattern (5) on the top of the Swing Gearbox.
Cleaning Clean the tooling after each use, using a non-solvent based cleaner.
3. Use an appropriate overhead lifting device to lift the gearbox.
Storage 1. Store the tool in a clean, dry location to prevent rust or corrosion. Tooling can be damaged by moisture or high humidity.
Inspection and Maintenance Inspection
2. The tool should be stored in the most stable position.
1. Inspect all components prior to each use for nicks, burrs, dents, cracks, bends, or worn parts. If damage is found, discontinue use until inspected and released for use by an approved inspector at the dealership.
Disposal At the end of the operational life of the tool, destroy the tool and dispose of as scrap.
2. Inspect all welds and check for damaged, cracked, or bent components.
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3. Inspect all hardware for damaged threads and cracked or bent components. 4. Do not use unless all load identification markings are legible. 5. Do not use if shackle holes or bolt holes are elongated. 6. Have tooling inspected annually by an approved dealership inspector. Maintain a written record of all inspections
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M0071122 ©2016 Caterpillar All Rights Reserved
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CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
15 September 2016
