21 May Precision Field Machining: CLIMAX CM6200 and LM6200 Restore 7495 Carbody to OEM Specs
In the demanding world of surface mining, where productivity hinges on the reliable operation of massive equipment, precision repairs are not just important—they are mission-critical. The TOMCO Group of Companies recently demonstrated the exceptional capabilities of CLIMAX portable machining solutions during a carbody repair project on a Caterpillar 7495 electric rope shovel. By deploying the CLIMAX CM6000 Circular Mill and LM6200 Gantry Linear Mill, TOMCO delivered a repair that restored the carbody to OEM specifications, reducing downtime and safeguarding performance in the field.
The Challenge: Restore a Massive Carbody to OEM Specs
The Caterpillar 7495 shovel is a workhorse in the mining sector, with its carbody serving as the structural foundation for the machine’s entire rotating assembly. Years of continuous service in punishing environments can lead to wear on critical surfaces such as the side frames, shear ledge, and swing gear mounting surfaces. Any deviation from flatness or concentricity in these areas can jeopardize operational integrity.
TOMCO was tasked with bringing these surfaces back to specification, a project that required not only precision but also the ability to work on a massive scale. That’s where CLIMAX’s field machining and portable milling machines proved indispensable.
The CM6000 Circular Mill: Precision on a Massive Scale
To re-machine the swing gear mounting surface, TOMCO utilized the CLIMAX CM6000 Circular Mill. Known for its rigid modular design and powerful milling capabilities, the CM6000 delivered exceptional results even on the massive 7495 carbody.
- Scope of Work: Milling a circular path on the swing gear mount
- Diameter: Machined out to a 190-inch diameter
- Key Features Used: Rigid base, modular design, and high torque drive system
The CM6000 ensured a precisely machined mounting surface, critical for smooth gear engagement and long-term operational integrity of the rotating assembly.
Note: While the CM6000 performed exceptionally on this project, CLIMAX has since introduced the CM6200 Circular Mill—our next-generation solution that builds upon the CM6000 platform. The CM6200 features enhanced rigidity, simplified setup, and expanded range options, making it the go-to solution for today’s most demanding field machining challenges.
The LM6200 Gantry Mill: Versatility Meets Performance
To tackle the side frame and shear ledge surfaces, TOMCO brought in the CLIMAX LM6200 Gantry Mill—one of the most powerful and versatile portable milling machines available. Its ability to mill large flat surfaces both horizontally and vertically made it ideal for restoring structural geometry to the massive steel frames.
- Horizontal Travel: 16 feet to span the entire side frame length
- Vertical Travel: A massive 106-inch ram allowed vertical machining without repositioning
- Precision: Enabled extremely flat and aligned surfaces across long spans
Whether tackling uneven shear ledges or worn side frames, the LM6200 delivered tight tolerances and a surface finish that met or exceeded OEM requirements.
The Result: Like-New Performance
Thanks to TOMCO’s expertise and the CLIMAX equipment, the Caterpillar 7495 carbody was returned to OEM tolerances without the need for costly disassembly or transportation to a repair shop. These field machining solutions significantly reduced machine downtime and associated costs, keeping mining operations running smoothly.
Why CLIMAX: Trusted in the Field
TOMCO’s success is another strong endorsement of CLIMAX’s engineering excellence. Our portable milling machines are designed for real-world industrial conditions, where accuracy, portability, and durability are non-negotiable. From high-precision circular milling to expansive gantry milling, the CM6000 and LM6200 continue to set the standard for heavy equipment repair in mining and beyond.
For more information on our milling solutions, visit www.climaxportable.com or contact your CLIMAX sales representative.