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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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Check valves in the hydraulic system may allow pressure to exist in the hydraulic lines after the engine has been stopped. Pressure must be relieved prior to servicing the components of the hydraulic system. Failure to relieve pressure prior to servicing may result in personal injury. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
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For specific information on your host machine, refer to the Operation and Maintenance Manual of your host machine. |
Pre-Delivery Inspection Procedure
- Ensure proper cab safety guarding is in place on excavator.
- Set up and verify the excavator settings.
- Ensure that carrier has the most current software in the ECM. If software is not current, have the dealer representative flash the software. Refer to machine operation maintenance manual for information on ECM software.
- Ensure that machine is at operating temperature. Calibrate the Tool Control System. Refer to machine documentation for procedures. For Cat machines, reference Excavator Tool Control System, UENR6229, "Testing and Adjusting Section", "Process for setting Up the Work Tool".
- Flow and pressure test the Tool Control System with a mechanical flow meter and pressure gauges. Do not use the in-cab monitor as it is not accurate enough for this test. Refer to the “Specifications” section for proper flows and pressures.
Note: Consult your Cat dealer to set proper flow, relief pressure, pilot pressures, and multi-function settings to maximize the productivity of the shear.
- Mount the shear and connect hoses. Refer to “Installation of the Shear” section.
- Grease all points on the shear and mounting pins. Refer to “Maintenance” section for information.
- Purge air from the hydraulic system. Refer to “Installation of the Shear” section.
- Use a stop watch the check the cycle time. The shear should close faster than it opens. Refer to “cycle times” chart for appropriate specs. If cycle time is slow, refer to “Shear opens and/or closes slowly” in the Troubleshooting section.
- Use a stop watch to check the shear rotation speed (if applicable). Refer to “specification for shear” chart for appropriate specs. If shear will not rotate or rotates slowly, refer to “Shear will not rotate” in the Troubleshooting section.
- Inspect torque on blades and piercing tip. Ensure that blades and piercing tip are tight against the pocket. Refer to “Inspect / Tighten Blade and Piercing Tip Bolts” for inspection procedure.
- Inspect blade clearance. Refer to “Inspect / Rotate / Replace Blades and Piercing Tip” for inspection procedure.
Installation of the Shear on the Hydraulic Excavator
Note: Ensure that the shear is compatible with the host machine. Ensure that the mounting bracket is compatible with the host machine and the shear. Consult your Cat dealer for information on matching the shear to the host machine.
Note: There are auxiliary lines kits that are available for the hydraulic system. Become familiar with the controls of your machine. Become familiar with the configuration of your machine.
- For rotating shears, ensure that rotation lock is installed before installation to machine.
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Illustration 1 g06115005 Locking device for rotator - Clean all the pins. Grease all the pins.
- Move the host machine into position.
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Illustration 2 g06118868 Boom Mount with Rotate Shear Show/hide table
Illustration 3 g06101197 Boom Mount with Straight Shear Show/hide table
Illustration 4 g06116776 Stick Mount with Rotate Shear Show/hide table
Illustration 5 g06114936 Stick Mount Rotate
(1) Rotate Clockwise
(2) Jaw CloseShow/hide table
Illustration 6 g06114939 Stick Mount Rotate
(3) Rotate Counter Clockwise
(4) Jaw OpenShow/hide table
Illustration 7 g06114292 Boom Mount Straight
(5) Jaw CloseShow/hide table
Illustration 8 g06114294 Boom Mount Straight
(6) Jaw OpenShow/hide table
Illustration 9 g06114931 Boom Mount Rotating
(7) Rotate Clockwise
(8) Jaw Close
(9) Rotate Counter Clockwise
(10) Jaw Open - Install the pins. Lock the pins.
Note: For boom mounted shears, slowly raise the boom to install the stick cylinder pin
- Stop the engine of the host machine. Cycle all the hydraulic controls to relieve the pressure in the hydraulic system.
Note: Do not use quick disconnect fittings on the hydraulic lines. These fittings are not recommended for use with shears due to their high flow demand and hydraulic shock loads associated with shearing. Additionally, failure of these fittings can cause contamination to the hydraulic system.
Note: Consult your Cat dealer for proper connecting lines to be used with your machine and shear arrangement. Check the length of the hoses. The hoses must be long enough to prevent any damage when the machine moves or the shear is moved.
- Clean all the hydraulic fittings before installing the hydraulic fittings. Inspect all the hydraulic fittings. Repair any damaged fittings. Replace any worn fittings. Connect all the hydraulic hoses. Remove the rotation lock.
- Start the engine of the host machine. Slowly cycle the hydraulic controls. Do not fully open the jaw, fully close the jaw, or attempt to process material before purging air from the shear cylinder. Check for any hydraulic leaks. Repair any hydraulic leaks.
- Raise the shear away from the ground. Slowly move the shear through the full range of motion to check for interference with the hoses, brackets, or machine.
Note: The work tool must move freely from the host machine. The auxiliary hoses should not get pinched or jammed when the machine moves or the shear is moved.
Show/hide tableNOTICE Purge the hydraulic system for the shear after work has been completed. If there is air in the hydraulic system under pressure, the oil can spontaneously ignite. Failure to purge the hydraulic system will result in damage to the work tool.
- Position the shear vertically with the jaw facing the ground.
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Illustration 10 g06101193 - Slowly extend the cylinder (close the jaw) to the full extend position. Do not apply full operating pressure. Slowly retract the cylinder (open the jaw) to the full retract position. Do not apply full operating pressure. Repeat this procedure 5 more times.
- Slowly extend the cylinder to the full extend position reaching full operating pressure. Slowly retract the cylinder to the full retract position reaching full operating pressure. Repeat this procedure 2 more times.
- After the cylinder has been purged of air, fully retract the cylinder (open the jaw). Turn Off the machine, check for leaks, repair any leaks, and check the excavator hydraulic fluid and ensure it is filled to the proper level.
Removal of the Rotating Shear from the Hydraulic Excavator
- Close the jaw of the shear.
- Rotate the shear until the shear is parallel to the ground (laying flat). Curl the shear under the boom as shown.
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Illustration 11 g06109179 Show/hide table
Illustration 12 g06118852 - Lower the shear until the shear is on the ground.
- Stop the engine of the host machine. Cycle all the controls to remove the pressure from the hydraulic system.
Note: Refer to General hazard section "trapped pressure" for safety precautions.
- Close the ball valves on the auxiliary lines, if present.
- Oil will be lost from the system when the machine hydraulic system is opened. Place a suitable container under the hydraulic fittings. Disconnect the shear connecting lines from the shear and cap the shear and machine hydraulics.
Note: Dispose of the oil in a proper manner.
- Remove pins. For boom mounted shears, remove the stick cylinder pin first. For stick mounted shears, remove the linkage pin first.
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Illustration 13 g06118853 (1) Stick Cylinder Pin
(2) Boom PinShow/hide table
Illustration 14 g06118855 (3) Stick Pin
(4) Linkage Pin - Start the engine on the host machine. Move the machine away from the shear.
Note: If the shear is stored for an extended time, place grease in the bores of the mounting bracket on the shear, and place grease on the rod of the cylinder.
Removal of the Straight Shear from the Hydraulic Excavator
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Place the work tool or bucket in a safe position before engaging the quick coupler. Ensure that the work tool or bucket is not carrying a load. Serious injury or death may result from engaging the work tool or bucket when it is in an unstable position or carrying a load. |
- Fully close the jaw of the shear.
- Curl shear under the boom as shown.
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Illustration 15 g06101194 - Stop the engine of the host machine. Cycle all the controls to remove the pressure from the hydraulic system.
Note: Refer to General hazard section "trapped pressure" for safety precautions.
- Close the ball valves on the auxiliary lines, if present.
- Oil will be lost from the system when the machine hydraulic system is opened. Place a suitable container under the hydraulic fittings. Disconnect the shear connecting lines from the shear and cap the shear and machine hydraulics.
Note: Dispose of the oil in a proper manner.
- Remove the stick cylinder pin.
- Slowly lower the boom until the shear rests on the ground as shown.
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Illustration 16 g06101197 - Ensure that the shear is stable on firm, level ground. Wood blocks may be needed to ensure stability. Remove the boom pin.
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Personal injury or death can result from sudden work tool movement.
Sudden movement of the work tool can cause injury to persons near the work tool.
To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool.
- Start the engine on the host machine. Move the machine away from the shear.
- Carefully lower shear on its side for storage or shipment.
Note: If the shear is stored for an extended time, place grease in the bores of the mounting bracket on the shear, and place grease on the rod of the cylinder.
