R&I Cilindro Hydracrowd

12/29/22, 10:03 AM SIS 2.
2022/12/12 Hydraulic Cylinder - Remove and Install - HydraCrowd (M0069644-49)
SMCS - 5101, 5362, 7562 i09692353
Removal Procedure
PIP
Required Tools
Tool Part Number Part Description Qty
A
B
-
-
Pail
Cables 1.5 inch
1
-
202 025
-
1
2 4
C - Pressure Gauge 1
13: /12/2 417

D - Four part bridle 1
E 189-0863 Shackle As 3
Table 1
0
M0 :38- 3 9
0 6
© 2 964 3:00 0
Hot hydraulic oil under high pressure can remain in the
components of the hydraulic system or the power train system
0
Cat 2 C2 4
after the engine has been stopped. The uncontrolled release of
the hydraulic oil can cause sudden machine movement and can
also result in the following conditions:
e r a
Burns
Con pilla terpi

The penetration of body tissue
fide r: llar
Other personal injury
Death
ntia Inc
If hydraulic oil penetrates body tissue, the injury must be treated
.
immediately by a doctor who is familiar with this type of injury.
lG
Use a board or a piece of cardboard to check for a hydraulic oil
leak. Make sure that all of the attachments have been lowered to
ree
the ground and that all trapped pressure has been released from
the hydraulic system and the power train system. Also, make
n
sure that the hydraulic oil is cool before the removal of any
components or lines. Remove the hydraulic oil filler cap only
when the engine is stopped and the filler cap is cool enough to
touch with your bare hand.
Cylinders equipped with lock valves can remain pressurized for

very long periods of time, even with the hoses removed.
Failure to relieve pressure before removing a lock valve or

disassembling a cylinder can result in personal injury or death.
Ensure all pressure is relieved before removing a lock valve or

disassembling a cylinder.
NOTICE
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, PERJ1017, "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.
https://sis2.cat.com/#/print-preview/service/%257B%2522title%2522%253A%2522Hydraulic%2520Cylinder%2520-%2520Remove%2520and%2520Install%2520-%2520HydraCrowd%2520(M0069644-49)%2522%2… 1/9
12/29/22, 10:03 AM SIS 2.0
Note: When removing pins there is the possibility of a sudden release of stored energy, which could result in damage to the electric shovel. Note
the ratchet-lever hoist and safety sling securing the pins have the proper support to release the load and that personnel are out of the line of fire.
Note: Hydraulic hoses must be depressurized before disconnecting from the sleeve. The hydraulic fluid is under high pressure and could spray out
with enough force to penetrate exposes skin.
Note: Ensure that you have constant radio contact with the crane operators when equipment parts are moved with the mobile crane. Many of these
lifts are "blind" and radio communication helps to prevent accidents such as dropped loads, which could cause serious injury or equipment
damage.
Note: When working at heights, use approved fall protection, man, lifts, and stepladders.
Note: Put identification marks on the hose assemblies, the tube assemblies, and the wire harnesses for installation purposes. Plug all open ports,
the hose assemblies, and the tube assemblies to prevent fluid loss and prevent contaminants from entering the system.
Illustration 1 g06088807
1. Park the Shovel straight ahead with the dipper centered between the crawlers.
2. Dump a load of loose material in front of the dipper.
3. Use the HMI in the cab to bypass the limits.

Note: Use caution when moving shovel components, including the cylinder, when the limits are bypassed.
4. Position dipper (2) with cylinder arrangement (1) fully extended and dipper (2) heeled on the ground.
Note: Ensure that there is sufficient clearance to remove the guide bushings and the crowd position sensor cable (transducer).
Note: Never attempt to remove the hydraulic cylinder and sleeve if the dipper has been detached or removed from the dipper handle.
5. Prepare the machine for maintenance, perform voltage shutdown.
a. For (S/N: ER6 and ER8) machines refer to Testing and Adjusting Machine Preparation  for the correct procedure.
b. For (S/N: R3R and R3F) machines refer to Operation and Maintenance Manual Prepare the Machine for Maintenance  for the correct
procedure.
12/29/22, 10:03 AM SIS 2.0
Note: Do not allow the cable to snap back into the housing because recoil could cause damage resulting in component failure.
Note: The cable is under tension and must be fully supported before disconnecting.
6. Disconnect crowd position sensor cable (5) from the back of dipper handle (6).
7. Start up the shovel.
8. Use the HMI in the cab to bypass the limits.

Note: Use caution when moving shovel components, including the cylinder, when the limits are bypassed.
9. Position dipper teeth (10) into the ground to position dipper (9) to rest on top of the load of material. Move the shovel forward until dipper
handle (8) becomes vertical. Avoid boom (7) jacking.
Personal injury can result from hot oil spray.
Make sure all attachments have been lowered, oil is cool and the
pressure has been released from the hydraulic system before
removing any components or lines.
Be sure there is no pressure in the tubing before it is

disconnected from the fitting.
Do not allow hot oil or components to contact skin.
10. Attach Tooling (C) (not shown) to the hoses to check the hydraulic system pressure.
a. The pressure hoses should be 690 kpa (100 psi)
b. The return hoses should be 207 kpa (30 psi)
Note: This initial position will ensure that the boom is not jacked.
12/29/22, 10:03 AM SIS 2.0
15. Use Tooling (A) to recover the draining oil from the tubes. Use the test port (X) connection points at the saddle block to drain the pressure and
return hoses to zero energy.
16. Connect the auxiliary hydraulic hose to the main tank and transfer the hydraulic oil until the auxiliary tank oil level is at 25 percent.
17. Reconnect the auxiliary hydraulic hose.
18. Switch to the auxiliary power system.
19. Use suitable man lift to access the cylinder head.
20. Install Tooling (E) and Tooling (B). Attach a suitable crane to Tooling (B). The weight of cylinder (1) is approximately 11340 kg (25000 lb).
12/29/22, 10:03 AM SIS 2.0
21. Remove bolts (11). Remove pin retainers (12) on both sides of the dipper handle.
22. Use a suitable lifting device to remove pin (13). The weight of pin (13) is approximately 277 kg (610 lb). Remove pin (13).
23. Use the auxiliary system to adjust the cylinder and remove tension from pin (13).
Note: Pin (13) may shift suddenly when pin (13) is fully removed from the dipper handle. An extra suitable lifting device may be necessary
safely control to pin (13). Stay clear of pin (13) while removing pin (13).
24. Use the auxiliary system to retract the cylinder.
25. Disconnect the auxiliary system.
26. Disconnect pilot hose assembly (14) and hose assembly (15) from cylinder manifold (16). Cap open ends of hose
assemblies. Remove connector (X) from the cylinder manifold port.
27. Install plug assembly (17) to cover the open port on the cylinder manifold. Install cap (18) to end of the tube assembly on the cylinder
manifold.
12/29/22, 10:03 AM SIS 2.0
28. Remove bolts (19), flanges (20), and tube assembly (21).
29. Install shipping flanges (22), shipping cover (23), and bolts (24) to the cylinder manifold port.
30. Remove bolts (24) and disconnect tube (25) from cylinder manifold (16).
12/29/22, 10:03 AM SIS 2.0
31. Install shipping flanges (26), shipping cover (27), and bolts (28) to the cylinder manifold port.
32. Use suitable slings to secure return hose assemblies (18) and pressure hose assemblies (20) to the boom to control position.
33. Remove clips (28). Disconnect harness assembly from box (30) and electronic control module (31).
34. Remove bolts (32), washers (33), and harness assembly (29) from box (30).
12/29/22, 10:03 AM SIS 2.0
35. Mark the alignment of the cylinder sleeve (Z) and the end cap (Y) for installation purposes.
36. Remove bolts (34), washers (35), and nuts (36).
37. Using a suitable crane, lift cylinder assembly (1) and the end cap out of the handle and cylinder sleeve. The weight of cylinder (1) is
approximately 11340 kg (25000 lb).
Note: Raise the cylinder high enough to clear the boom suspension ropes and boom point sheaves.
38. Position cylinder assembly (1) vertical until comes closer to the ground.
Note: Ensure that the hydraulic cylinder assembly is not touching the ground.
Note: Do not place the cylinder rod on the ground and then lower the cylinder assembly. Damage to the cylinder can occur.
12/29/22, 10:03 AM SIS 2.0
39. Position cylinder assembly (1) horizontally.
Note: This step may require a critical lift plan at some sites.
40. Lower the cylinder assembly (1) onto suitable cribbing. The weight of cylinder (1) is approximately 11340 kg (25000 lb)
41. Inspect hydraulic cylinder assembly (1). Replace any worn or damaged parts if needed. Refer to Reuse & Salvage Guidelines, M0076021 ,
"Inspection and Reuse Guideline of the HydraCrowdTM Single Piston Cylinder for Certain 7495 Models".
Installation Procedure
1. Verify that the machine is prepared for maintenance.
a. For (S/N: ER6 and ER8) machines refer to Testing and Adjusting Machine Preparation  for the correct procedure.
b. For (S/N: R3R and R3F) machines refer to Operation and Maintenance Manual Prepare the Machine for Maintenance  for the correct
procedure.
2. Install cylinder assembly (1) in the reverse order of removal.
a. Apply clean hydraulic oil to the threads of bolts (34). Tighten bolts (34) to a torque of 1844 ± 184 N·m (1360 ± 135 lb ft).
b. Tighten bolts (24) to a torque of 460 N·m (339 lb ft).
c. Tighten bolts (19) to a torque of 240 N·m (177 lb ft).
d. Tighten bolts (11) to a torque of 651 N·m (480 lb ft).
PIP-10254417
2022/12/29
13:03:26-03:00
i06848102
© 2022 Caterpillar Inc.
Caterpillar:
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12/29/22, 10:03 AM SIS 2.

2022/12/12 Hydraulic Cylinder - Remove and Install - HydraCrowd (M0069644-49)

SMCS - 5101, 5362, 7562 i09692353

13: /12/2 417

Con pilla terpi

Cylinders equipped with lock valves can remain pressurized for

Failure to relieve pressure before removing a lock valve or

Ensure all pressure is relieved before removing a lock valve or

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Dispose of all fluids according to local regulations and

2. Dump a load of loose material in front of the dipper.

3. Use the HMI in the cab to bypass the limits.

5. Prepare the machine for maintenance, perform voltage shutdown.

7. Start up the shovel.

8. Use the HMI in the cab to bypass the limits.

Personal injury can result from hot oil spray.

Be sure there is no pressure in the tubing before it is

Do not allow hot oil or components to contact skin.

a. The pressure hoses should be 690 kpa (100 psi)

b. The return hoses should be 207 kpa (30 psi)

17. Reconnect the auxiliary hydraulic hose.

18. Switch to the auxiliary power system.

19. Use suitable man lift to access the cylinder head.

24. Use the auxiliary system to retract the cylinder.

25. Disconnect the auxiliary system.

36. Remove bolts (34), washers (35), and nuts (36).

2. Install cylinder assembly (1) in the reverse order of removal.

b. Tighten bolts (24) to a torque of 460 N·m (339 lb ft).

c. Tighten bolts (19) to a torque of 240 N·m (177 lb ft).

d. Tighten bolts (11) to a torque of 651 N·m (480 lb ft).

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