EM030753-00

16. March 2021

General Service Information

Elimination of Live Work
Task: Check Residual Stroke on Clam Cylinders

Model
Prefix Serial Number
Type
6018 FS DHD all
6030 FS DHG all
DHX
6040 FS CC9 all
ELZ
6050 FS DH2 all
DH3
6060 FS 6C6 all
6D6
DHS
6090 FS all
DM6

Introduction
This “Elimination of Live Work (ELW) Procedure” replaces the corresponding description
in the HMS machine documentation.
The intention of the procedure is to eliminate live work by removing the technician from
the area of the machine to reduce possible hazard of injury while inspecting or
maintaining the machine.

Task: This document describes, how to measure the residual stroke at the Clam Cylinders
on Face Shovel machines

The Residual stroke is defined by the remaining possible stroke of cylinder (Fig.3 & 4),
when the corresponding function is fully engaged – in this case the bucket is completely
closed. That means that the position of the piston rod is fully extended until their steel
structure limits; the bucket front has contact to the bucket back wall.

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All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.
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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 damages of
both cylinders.

Important Safety Information

Operators and maintenance personnel should be protected in the best possible way while
working on the machine. Therefore, all work should only be carried out (if not described
differently):
 not with and on running engines / motor
 not while the machine is moving
 not with moving work equipment
 not under raised work equipment
 not on systems under pressure
 not on components that are too hot to be touched by hand with gloves.

Attention:
It is essential that all applicable safety measures and procedures are
carried out. For more information refer to the operation and
maintenance manual, service manual as well as those measures
outlined by the executing parties, mine regulations and associated
agencies.
Personal protective equipment must be used as required. When
applicable, observe all local safety regulations.
Only skilled, trained personnel is allowed to work on the Hydraulic
Mining Shovel.

Sudden movement or accidental starting of the machine can cause personal injury
or death to persons on or near the machine.
To prevent personal injury or death, perform the following general preparations:
Carry out maintenance work only if the machine has been secured against inadvertent
movements.
 Park the machine on a hard, horizontal and level surface.
Note: The surface must be solid enough to support the weight of the machine and any
tooling that is used to support the machine. Select places free of danger by flooding
and other water damage.
 Place the machine in the servicing position, stand the attachment on the ground (refer
to Fig. 1 and Fig. 2).
 Engage the track parking brake and the swing brake.

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 Engage the lockout controls depending on the maintenance work to be done

Fig. 1: Servicing position for FS machines Fig. 2: Servicing position for BH machines

If one or more conditions can not be guaranteed, to perform a necessary job on the
machine, detailed instructions must be requested by submitting a DSN ticket to the
Product Support Team.

Required Tools

Description Part-No. Illustration

Measuring Tape local purchase

Table 1: Tools

Procedure
Before measuring the residual stroke, the bucket clam must be fully closed. Stand the
attachment safe to the ground, stop the engines.
Usable stroke “L” can be measured with measuring tape; distance between face of guide
and bottom of fork eye (Fig. 5 & 6) must be measured. If the maximal value “L” (table 2) is
not exceeded, sufficient residual stroke is ensured, thus avoiding cylinder damage. If the
value “L” is exceeded, bucket wear plates (Fig. 7) must be renewed.

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Part-No. Clam Shell Cylinder Maximum of

Machine Type measured
CAT HMS SAP Legacy HMS length "L"
Cat 6015 471-2145 4023720 3672043 330 mm

Cat 6018 471-2148 4026122 3710270 460 mm

Cat 6030 455-9942 4105785 3713770 450 mm

Cat 6040 471-2146 4025366 3694497 664 mm

Cat 6040 467-1599 1453541 4525841 712 mm

Cat 6050 467-1599 1453541 4525841 712 mm

Cat 6050 471-2150 4235643 3734821 707 mm

Cat 6060 - 1453538 3684640 712 mm

Cat 6060 - 1467010 3713737 712 mm
Cat 6060 471-2150 4235643 3734821 707 mm
Cat 6060 - 4518093 3734822 707 mm
Cat 6060 459-2050 4191687 3734813 715 mm

Cat 6090 471-2147 1524416 3705007 820 mm

Cat 6090 510-5011 - - 820 mm
Table 2: Length of residual stroke

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Fig. 3: Small arrows indicate possible contact of Fig. 4: Length “L”; which must be measured,
the piston and guide when cylinder is when the cylinder is installed in the bucket
extended. This must be avoided. backwall, and the bucket is fully closed.

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Fig. 5: Clam cylinders installed; bucket fully closed = cylinders extended / usable stroke “L” measured

Fig. 6: Clam cylinders installed; bucket fully closed = cylinders extended / usable stroke “L” measured

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Fig. 7: If the minimum residual stroke can not be reached (measured length “L” is higher than listed
values), the wear plates must be renewed.

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