SecureLift Lifting System Use Guide Nemisys

Safety General Safety Information The safety practices described in this manual are meant as guidelines for safe operation under most conditions and are meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of others results from putting into practice the correct operating procedures. Read this entire manual prior to conducting the maintenance procedures described in this manual. Signal Words Throughout this manual are statements preceded by a special attention symbol:. The symbol is used with the following signal words to attract your attention to information of special priority. Read the paragraphs carefully and make sure you understand their significance, especially the possible causes of injury or death. WARNING: A statement preceded by WARNING is information that should be acted upon to prevent serious injury or death. CAUTION: A statement preceded by CAUTION is information that should be acted upon to prevent machine or equipment damage. Additional signal words that are not preceded by the attention symbol are: IMPORTANT: A statement preceded by the word IMPORTANT is information that possesses special significance. Tip: A statement preceded by Tip is information that is handy to know and may make your job easier. Personal Safety WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. WARNING: Parts or components may be subject to unplanned movement during the installation or removal process. It is important to prevent parts from unplanned movement by tilting the bucket back slightly. Failure to follow these instructions could result in serious injury or death. WARNING: When removing points, keep the point fully supported during the entire removal process. Keep hands and arms away from all pinch points. Do not stand with feet directly under the point. Failure to follow these procedures may cause serious injury or death. WARNING: When removing intermediate adapters, keep the adapter fully supported during the entire removal process. Keep hands and arms away from all pinch points. Do not stand with feet directly under the adapter. Failure to follow these procedures may cause serious injury or death. WARNING: Lifting system should be maintained in accordance with site chain lifting system maintenance policy. WARNING: Lifting system is to only be used for the purposes outlined in this guide. WARNING: Lifting system is not to be modified in any way. 2

Table of Contents 1. Required Parts...4 2. Lifting Eye Use...5 3. Required Steps...6 4. Point Removal...7 5. Intermediate Adapter Removal...9 6. Lifting Eye Inspection...13 3

1. Required Parts Use the SecureLift Lifting System that corresponds to the size of the Nemisys Lip System as shown in the table below. Figure 1-2 SecureLift Lifting System N3SLS Figure 1-1 SecureLift size is marked on ESCO tag attached to lifting system. Nemisys Size SecureLift Model SecureLift Model The SecureLift Lifting System has: 1 long lifting eye that is used when removing or reinstalling an intermediate adapter and point together. 2 short lifting eyes that are used when: N1 N1SLS N1SLS-AU N3 N3SLS N3SLS-AU N5 N5SLS N5SLS-AU N7 N7SLS N7SLS-AU Figure 1-3 SecureLift Lifting System Size Removing or reinstalling an intermediate adapter and point together, or Removing or reinstalling a point separately. Figure 1-4 Left Long SecureLift Lifting Eye Right Short SecureLift Lifting Eye WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 4

2. Lifting Eye Use WARNING: If a part has been excessively worn to the extent that the head of a lock has been worn away and the lock collar has been damaged, the lifting system must not be used to remove that part. Before attempting to lift a part with the SecureLift Lifting System, proper installation of each eye used must be confirmed. Confirmation can be made when threading an eye into its corresponding lock collar and can be determined in one of three ways. Inspect the outside of the lifting eye to see if the threaded surface is damaged. If the threaded surface of the lifting eye is damaged, discontinue use of the lifting system (see section 6). 1. Sound: a click should be heard when the eye is fully installed and the lifting eye s latch clip engages the lock collar. 2. Feel: if the click cannot be heard, the lifting eye s latch clip engagement with the lock collar may be felt. 3. Sight: if the lifting eye s latch clip engagement with the lock collar cannot be heard or felt, a visual inspection of the eye s final position can be used to confirm proper installation. The lifting eye will have the ring of the eye perpendicular to the length of the tooth or adapter. Figure 2-1 Proper installed lifting eye orientation BUCKET The PAT ESCOCORP.COM text will be facing away from the bucket. The upper, non-threaded portion of the lifting eye body will be nearly touching the lock collar. WARNING: If lifting eye cannot be threaded into a part s lock collar far enough to achieve any of the confirmation methods listed above, the lifting system must not be used to remove that part. If a lifting eye cannot be fully threaded into a lock collar, check the following items to determine the cause. Figure 2-2 PAT ESCOIP.COM visible on properly installed lifting eyes Inspect the inside of the lock collar to see if fines or other debris in the bottom of the opening is stopping the lifting eye. If fines or other debris is found, remove it from the lock collar opening. Inspect the inside of the lock collar to see if the threaded surface is damaged. Figure 2-3 Lifting eye not fully installed (left) and fully installed (right) If the threaded surface of the lock collar is damaged, do not use the lifting system to remove that part. 5

3. Required Steps Prior to performing the work in other sections of this guide, you must perform the following steps. 1. Secure the machine in accordance with your site s safety procedures. 2. Rest the bucket with the teeth 5-10 above the horizontal. Figure 3-1 Proper tooth angle Tip: Tooth angle can be determined by referencing the flat on the nose and intermediate adapter. 3. Hang the SecureLift Lifting System assembly from the hoist in accordance with your site s safety procedures. Figure 3-2 Flat feature for tooth angle estimation 6

4. Point Removal 1. Clean any soil fines from the lock hole in the top of the point and the space between the point and the intermediate adapter. 2. Remove the fines cap from the lock. 3. Insert the appropriate hex bit (see Figure 4-3 below) into the lock and turn counter-clockwise until the point lock is removed. Figure 4-1 Clean fines from lock hole Nemisys Hex Bit in. mm N1 5/8 16 N3 3/4 19 N5 3/4 19 N7 7/8 22 Figure 4-3 Hex bit selection Figure 4-2 Remove the fines cap Figure 4-4 Remove lock with hex bit WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 7

4. Insert a short lifting eye into the point lock and rotate clockwise until there is a hard stop with an audible click. Tip: If the lifting eye is difficult to thread into the lock by hand, a pry bar inserted through the lifting eye can be used to make turning easier. 5. Use a pry bar to separate the point from the intermediate adapter and then remove the point with a hoist. 6. Taking care to avoid unexpected part movement, safely remove lifting system from point using reverse of installation steps. Figure 4-5 Insert short lifting eye into point lock Click Figure 4-6 Rotate clockwise until you hear an audible click Figure 4-7 Use pry bar to remove point 8 Figure 4-8 Remove point with hoist

5. Intermediate Adapter Removal Note: The point and intermediate adapter must be removed as a single unit, even if the point is to be reinstalled on a new intermediate adapter. Note: Only one intermediate adapter lock should be removed at a time and a short lifting eye should be immediately installed in its place. The process can then be repeated for the second lock. 1. Clean any soil fines from the lock hole in the top of the point, the lock holes on the sides of the intermediate adapter, and the space between the intermediate adapter and the rear nose. Figure 5-1 Clean fines from point lock hole 2. Remove the fines caps from the locks. Figure 5-2 Clean fines from adapter lock holes Figure 5-3 Remove fines cap from the point WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 9 Figure 5-4 Remove fines caps from the adapter

3. Insert the appropriate hex bit (see Figure 5-5 below) into the point lock and turn counter-clockwise until the lock is removed. Nemisys Hex Bit in. mm N1 5/8 16 N3 3/4 19 N5 3/4 19 N7 7/8 22 Figure 5-5 Hex bit selection Figure 5-6 Remove lock with hex bit 4. Insert the long lifting eye into the point lock and rotate clockwise until there is a hard stop with an audible click. 5. Insert the hex bit into one of the intermediate adapter locks and turn counter-clockwise until the lock is removed. Figure 5-7 Insert long assembly lifting eye Click Figure 5-8 Rotate clockwise until you hear an audible click 10 Figure 5-9 Turn intermediate adapter locks counter clockwise

6. Insert a short lifting eye into the intermediate adapter lock and rotate clockwise until there is a hard stop with an audible click. 7. Repeat lock removal and short lifting eye installation steps for second intermediate adapter lock. Figure 5-10 Insert short lifting eye Click Figure 5-11 Rotate clockwise until you hear an audible click Figure 5-12 Complete lifting system installation WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 11

8. Use grab hooks to shorten lifting system chains, removing slack. This maintains the correct orientation during removal and prevents binding on the nose. WARNING: Hooks are to only be used for shortening lifting system s chain legs. 9. Using a pry bar and a hoist, remove the point and intermediate adapter as a single unit. 10. Taking care to avoid unexpected part movement, safely remove lifting system from point and adapter using the reverse of installation steps. Note: If the point is to be reinstalled, first install a new intermediate adapter using the cast lifting eye, then install the original point onto the new intermediate adapter using a short lifting eye. Installation of the point is the reverse of removal. Figure 5-13 Shorten lifting system chains with grab hooks Note: If the intermediate adapter is to be reinstalled, it must be moved as a single unit with the point, regardless of whether the point is new or reused. Figure 5-14 Use pry bar to remove point and adapter together Figure 5-15 Remove point and adapter with hoist 12

6. Lifting Eye Inspection WARNING: If at any time, a lifting eye is found to have cracks or surface deformation, the attached lifting system must be removed from service and replaced. Following the chain lifting system inspection interval for your site, perform the following lifting eye inspection every time a SecureLift Lifting System is inspected. Visually inspect each of the lifting system s three lifting eyes. If any part of a lifting eye (eye ring, body, or threads) has cracks or surface deformations, the lifting system must be removed from service and replaced. Thread each lifting eye into a new lock collar in a matching size Nemisys point or adapter (remove lock for this test and replace afterward). If any lifting eye s latch clip engagement with the lock collar cannot be heard or felt, the lifting system must be removed from service and replaced. 13

NOTES: