Caterpillar Global Mining HMS GmbH

Karl-Funke-Str. 36
44149 Dortmund
Germany
Phone: +49 (0) 231 / 922 -3

Structural Inspection Report

for Hydraulic Mining Shovels

CAT 6015 (FS) CAT 6090 (FS)

Regular Inspection (every 500 hours)
1st VI Visual Inspection
2nd PT, MT, (UT) (Page 3) to verify any visual identified or assumed crack
development but also to verify quality of any local repair

Machine-Type:

Serial-No.:

Operating Hours:

Date of Inspection:

Customer:

Site Location:

Country:

Name of Inspector:

Cracks found: Yes No

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General
This inspection report has to be used for regular reporting of structural inspections with
focus on the highlighted areas shown at the following pages. In case of any crack has been
identified by visual inspection appropriate testing methods shall be used to verify exact
crack propagation or defects/conclusions (e.g. local repair welding).

Drawings are generic in origin and are constructed only to give an overview of the
component under inspection. Where required or necessary add notes or sketches to
emphasize the inspectors point more clearly.
Use this form to report the following conditions:

Damages
Cracked Welds
Cracked Plates / Castings
Faulty Workmanship
Repair Recommendations
In-field Repairs

To ensure warranty coverage, these forms have to be sent as attachment via SIMSi.
In case no cracks have been found, please complete and transmit first page only.

Reporting in SIMSi / Dealer Claim systems

Dealer Claim system (including
SIMSi
CLAIMSi)
PART CAUSING FAILURE SP7760 SP7760
or PART NUMBER (Substitute Part-No.) (Substitute Part-No.)
753H 753H
GROUP NUMBER
(SMCS Code) (SMCS Code)

COMMENTS / FINDINGS Struc.Insp. Struc.Insp.

PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

NOTE: Warranty claims, submitted later than 1st Jan. 2014 are to be claimed by submission
through applicable Caterpillar Warranty Claim System. All incidents must be reported by
SIMSi.

Procedure
First clean the critical areas thoroughly using cleaning agents and either high pressure or
steam cleaner. A close visual inspection must be done to determine whether there are any
suspect areas. If any suspect areas have been found additional testing is required:

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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.
The ellipses and arrows on attached sketches indicate the most critical welding connections
or other areas (e.g. stoppers, access holes, etc.) to be checked visual on a regular base.

1. Select the sketch that represents the structural component under inspection.
2. Note the problem, defect, or concern of the customer.
For related crack reporting use the designated area to sketch the characteristics
of the crack development more in detail.
3. Note the action required and the inspectors recommendation for repair.
4. Record the response of customer and evaluation of the inspection.
5. Inform about all local repairs indicating if temporary or permanent.
6. Attach photos of the damage and if repairs completed to this report.

Testing Methods
VI Visual Inspection
Most of the cracks can be already identified by visual inspection due to splintered paint and
rust development.

PT Liquid Penetrant Testing (Testing method for cracks developing from surface)
Consider that indication by dye penetrant testing is limited to cracks developing within
surface.
A dye penetrant kit is available from Caterpillar Global Mining HMS GmbH

Cleaner HMS SAP Part-No. 4014472 / Legacy HMS Part-No. 0552304

Penetrant HMS SAP Part-No. 4014471 / Legacy HMS Part-No. 0552301
Developer HMS SAP Part-No. 4221579 / Legacy HMS Part-No. 0552302

MT Magnetic Particle Testing

(Testing method for cracks developing from or directly underneath surface)
Consider that indication is limited to crack development at or close to surface and the
possible influence of particular deviations (e.g. surface roughness, pseudo identification at
corners, broadly separation, intensive rounding at corners, etc.).

UT Ultrasonic Testing (testing method for possible cracks inside material or welding)
Consider that an initial pulse and reflections from back wall are related to the test method
and select the test probe (vertical or angular transceiver) according to material and
expected orientation of defect (flaw, crack, inclusion).

Structural Repairs
All structural repairs are to be carried out in accordance to Welding Procedures of
Caterpillar Global Mining HMS GmbH, described in Service Manual Welding, which is
part of Technical Documentation delivered with each machine.

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Overview
Choose the appropriate page and complete the inspection. Once completed the report has
to contain the following pages:

1. Front cover of Report

2. Related component page 5 up to page 28
3. Additional Description page 29
4. Required Repair Information page 30
Note:
Keep also attention of wear & crack status on all mechanical stoppers at attachment!
Be sure to include all photographs of damaged and repaired structures.

The latest release of this document can be downloaded from our web-
portal www.bucyrus-hex.de.

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Shovel attachment

TriPower TriPower Boom FOPS

Triangle Bar
weer
Cabin Module

Stick

Bucket
Backwall
Superstructure
Bucket
Front Undercarriage

Backhoe attachment

Boom

FOPS

Cabin Module

Stick

Linkage

Toggle

Backhoe
Super-
Undercarriage structure

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1) Undercarriage

Specific for 6015/6015FS

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 Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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2) Superstructure

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 Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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2.1) Hydraulic Tank

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 Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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2.2) Fuel Tank

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 Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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3) Boom (Front Shovel)

For latest design with manhole check visually also critical areas from inside in
case of any crack development detected from outside.

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 Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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3.1) TriPower Triangle
Two different versions of TriPower Triangles are available:
a) casted design radius area must be checked
b) welded design area of welding seams must be checked

a) casted design: check radius area

b) welded design: check area of welding seams

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 Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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3.2) TriPower Bar

welded design: check area of welding seams

Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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4) Stick (Front Shovel)

For latest design with manhole check visually also critical areas from inside in
case of any crack development detected from outside.

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 Comments: sketch of defect detail

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 Photos / Attachments submitted: No Yes, no of pages:

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5) Face Shovel Back Wall

Check also if back wall is affected by rock damages!

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 sketch of defect detail
Comments:

Photos / Attachments submitted: No Yes, no of pages:

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6) Face Shovel Front Shell

sketch of defect detail

Comments:

Photos / Attachments submitted: No Yes, no of pages:

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7) Backhoe Boom (General)

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8) Backhoe Boom (latest design e.g. 6060)

For latest design with manhole check visually also critical areas from inside in
case of any crack development detected from outside

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 Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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9) Backhoe Stick

Check also if lower chord is affected by rock damages!

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 Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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10) Toggle Linkage (Backhoe)

sketch of defect detail

Comments:

Photos / Attachments submitted: No Yes, no of pages:

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11) Backhoe

sketch of defect detail

Comments:

Photos / Attachments submitted: No Yes, no of pages:

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12) Fuel Tank

Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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13) Cabin Module

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 Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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14) FOPS (Falling Object Protection Structure) on Cabin

FOPS: check for cracks in area of fixation points and crane hooks

Comments: sketch of defect detail

Photos / Attachments submitted: No Yes, no of pages:

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Additional Description:

Additional sketch:

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Required Repair Information

Company Name:

Address:

City:

Country:

Phone:

Fax:

Contact:

Date of repair:

Completed by:

Manhours:

Currency:

Rate per hour:

Material Cost:

Total Cost:

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