Reuse and Salvage Guideline for Unit Rig Mining Truck Hydraulic Steering Cylinders{0374, 0599, 0732, 4303} Caterpillar

Unit Rig Mining Truck: All

Off-Highway Truck/Tractor:

CAT MT4400D AC (S/N: MH41-UP; MT41-UP)

CAT MT5300D AC (S/N: MN51-UP; MT51-UP)

Introduction

© 2015 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This guideline enables dealers and dealer customers to benefit from cost reductions made possible through an established parts reusability and salvage program. Every effort has been made to provide the most current information known to Caterpillar Inc. Since the company makes ongoing product changes and product improvements, this guideline must be used with the latest technical information. Using the latest technical information available from Caterpillar ensures that such changes and improvements are incorporated where applicable.

For questions or additional information concerning this guideline, submit a feedback form in the Service Information System web site. To address an urgent need, use the following to forward your request to Caterpillar Repair Process Engineering:

• Cat Dealer Technical Communicator

• Global Dealer Solution Network

• Cat Technical Representative

• Knowledge Network

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Summary

Often, the replacement of worn or damaged hydraulic cylinder components with new parts is not the best repair option. After being reconditioned and/or salvaged, original parts can be expected to give normal performance and life.

This guideline includes inspection and cleaning processes, dimensional data, and references for repair options.

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Rerodding, straightening, or welding any steering cylinder rod, bowl cylinder rod, or front suspension cylinder rod could result in injury or death. If any of these rods are broken or cracked, the rods must be replaced with a REMAN rod or a new rod. These rods can be ground and plated with chrome if the recommended Caterpillar process that is identified in this document is used.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that the procedure is safe for you and for other people to use. Ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Safety

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the steering system.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

References

Description and Location

The steering cylinders are two-way hydraulic cylinders mounted on the front axle. The base end of the cylinder is attached to the front axle beam through a self-aligning bushing assembly. The rod end is attached to the steering arm on the ends of the axle assembly with a separate clevis assembly through a self-aligning bushing in the steering arm.

Illustration 3	g03747819
Steering Cylinder Assembly (1) Outer Tube Assembly (2) Cylinder (Piston) Rod (3) Piston (4) Setscrew (5) Stuffing Box (6) Rod Wiper (7) Rod Seal (8) O-ring (9) Rod Buffer Seal (10) Rod Wear Guide (11) O-ring Seal (12) Backup Ring (13) Capped T-seal (14) Piston Wear Guide (15) Capscrew (16) Hardened Flat washer (A) 190.5 mm (7.5 inch) (B) 101.6 mm (4.0 inch) (C) 88.9 mm (3.5 inch)

Illustration 4	g03747997
Steering Cylinder Assembly (Part Number 84092E) (1) Outer Tube Assembly (2) Piston Rod (3) Piston (4) Piston Nut (5) Bearing (6) Retainer (7) Wear Ring (8) Secondary Wiper (9) U-cup Seal (10) Backup Ring (11) O-ring (12) Backup Ring (13) Wiper Scraper (14) Wear Ring (15) Teflon Piston Seal (16) Seal Expander (17) O-ring (18) Nylon Plug (19) Bronze Plug (20) Socket Head Capscrew (21) Button Head Capscrew (22) Lockwasher

Illustration 5	g03748204
Steering Cylinder Assembly (Part Number 84092K) (1) Outer Tube Assembly (2) Piston Rod (3) Piston (4) Piston Nut (5) Bearing (6) Wear Ring (7) Secondary Wiper (8) U-cup Seal (9) Backup Ring (10) O-ring (11) Backup Ring (12) Wiper Scraper (13) Wear Ring (14) Teflon Piston Seal (15) O-ring (16) Nylon Plug (17) Bronze Plug (18) Socket Head Capscrew (19) Button Head Capscrew (20) Lockwasher

Illustration 6	g03826639
442-3555 Steering Cylinder (1) Outer Tube As (2) Rod As (3) Setscrew (4) Wear Ring (5) Piston Seal (6) Wear Ring (7) O-ring (8) O-ring (9) Backup Ring (10) Wiper Seal (11) Secondary Wiper Seal (12) U-cup Seal (13) Wear Ring

Maintenance and Adjustment

Periodic maintenance should include the following steps:

1. Clean both cylinders associated with linkage and hydraulic hoses. Inspect for wear, leakage, and damage. Repair or replace as required.

2. Verify that all cylinder mounting components are installed and in good repair, and are properly lubricated. Repair or replace as required.

   1. On trucks equipped with an expander pin, verify that both of the capscrews securing the expanders are properly torqued. Also verify that there is no evidence of rotation or wear in the pin assembly or self-aligning bushing bore.

      Note: If either of the capscrews or the pin assemblies is found to be loose, the assembly should be disassembled, inspected, and repaired. Then the capscrews should be reinstalled and torqued.

   2. On trucks equipped with the straight pins, verify that the pins, nuts, and related hardware are properly installed and secured.

      Note: There should be no evidence of rotation or wear in the pin assembly or self-aligning bushing bore. If wear is found, the assembly should be disassembled, inspected, repaired and then assembled again.

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NOTICE
Since the truck engine must be running to perform this adjustment, be sure that the truck is parked in a SAFE POSITION with the park brakes appropriately set prior to beginning maintenance. Also be sure never to place yourself in a dangerous position near moving parts.

3. Purge any air from the cylinders as follows:

   1. Start the engine and allow to charge the accumulator system fully.

   2. Rotate the steering wheel from the full right to the full left positions and back until the entire steering system is free from air.

   3. Stop the engine.

Inspection and Repair

The disassembled cylinders may be serviced as follows:

1. Clean all metal components with clean solvent. Dry with compressed air.

2. Inspect the components for excessive wear, scorning, and scratches. Repair or replace as required.

   Note: Refer to Special Instruction, SEBF8072, "Inspection and Salvage of Hydraulic Cylinder Components".

3. Table 3 lists the critical dimensions for the Unit Rig Mining Truck steering cylinders.
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   Table 3

   84092K (MH)	SAP 1452452	431-6015 Cylinder As
   (1)	Cylinder Bore	152.4 + 0.076 - 0.00 mm (6.00 + 0.003 - 0.00 inch)
   (2)	Rod OD	88.77300 ± 0.00508 mm (3.495 ± 0.0002 inch)
   (3)	Piston OD	150.495 ± 0.127 mm (5.925 ± 0.005 inch)
   84092F (MM)	SAP 1467008	472-5035 Cylinder As
   (1)	Cylinder Bore	114.3 + 0.076 - 0.00 mm (4.5 + 0.003 - 0.00 inch)
   (2)	Rod OD	63.373 ± 0.005 mm (2.495 ± 0.0002 inch)
   (3)	Piston OD	113.665 ± 0.025 mm (4.475 ± 0.001 inch)
   29089 (MJ)	SAP 1452502	472-5023 Cylinder As
   (1)	Cylinder Bore	139.725 ± 0.025 mm (5.501 ± 0.001 inch)
   (2)	Rod OD	139.294 ± 0.025 mm (5.484 ± 0.001 inch)
   (3)	Piston OD	73.025 mm (2.875 inch)
   84092J (MJ)	SAP 1452480	472-5036 Cylinder As
   (1)	Cylinder Bore	146.075 ± 0.025 mm (5.751 ± 0.001 inch)
   (2)	Rod OD	145.415 ± 0.025 mm (5.725 ± 0.001 inch)
   (3)	Piston OD	74.625 mm (2.938 inch)
   84092E (MH)	SAP 4012120
   (1)	Cylinder Bore	152.4 + 0.076 - 0.00 mm (6.0 + 0.003 - 0.00 inch)
   (2)	Rod OD	88.773 ± 0.005 mm (3.495 ± 0.0002 inch)
   (3)	Piston OD	150.495 ± 0.127 mm (5.925 ± 0.005 inch)
   84092G (MP)	SAP 1454758
   (1)	Cylinder Bore	177.8 + 0.076 - 0.00mm (7.0 + 0.003 - 0.00inch)
   (2)	Rod OD	101.524 ± 0.005 mm (3.997 ± 0.0002 inch)
   (3)	Piston OD	177.165 ± 0.025 mm (6.975 ± 0.001 inch)
   84092M (MP)	SAP 4012121
   (1)	Cylinder Bore	177.8 + 0.076 - 0.00mm (7.0 + 0.003 - 0.00inch)
   (2)	Rod OD	101.524 ± 0.005 mm (3.997 ± 0.0002 inch)
   (3)	Piston OD	177.165 ± 0.025 mm (6.975 ± 0.001 inch)
   84092N (MN, MR)	SAP 1543193	442-3555 Cylinder As
   (1)	Cylinder Bore	190.5 + 0.102 - 0.00 mm (7.5 + 0.004 - 0.00 inch)
   (2)	Rod OD	101.575 ± 0.005 mm (3.999 ± 0.0002 inch)
   (3)	Piston OD	190.068 ± 0.05 mm (7.483 ± 0.002 inch)

4. Inspect the condition of the self-aligning bushing in the end of the outer body tube. If required, replace as follows:

   1. Remove the internal retaining ring.

   2. Remove the self-aligning bushing assembly by a suitable mean.

   3. Inspect the condition of the bushing bore in the outer tube assembly. The bushing bore should be free of damage and in good repair. Remove any burrs or nicks.

   4. Install the new bushing assembly, securing with internal snap ring.

5. Inspect the removed seals, wiper rings, and so on, Note and damage or abnormal appearances. If found, determine the cause and correct prior to beginning of reassembly process.

   Note: Caterpillar recommends that all seals and O-rings be discarded and replaced with new components during each assembly.