Reuse and Salvage Guideline for Front Suspension Cylinder Housings and Heads on Off-Highway Trucks {0374, 0599, 7201} Caterpillar

Off-Highway Truck/Tractor

All

Introduction

Table 1

Revision	Summary of Changes in REHS2099
20	Updated Table 21 dimension (Y) and (JJ) for all head part numbers. Updated Table 26 line (F). Feature (T) changed to feature (U).
19	Added new serial number prefixes for New Product Introduction (NPI). Updated copyright date to 2018. Added a section to the document "793 Front Strut Suspension Housing Rib Replacement 105–3550". Updated Illustrations 47, 55, 56, and 82.
18	Added new 6E-0730 Head Repin Procedure for 793 Off Highway Truck Front Strut. Updated specifications in multiple tables, multiple Illustrations updated with dimensions.
17	Updated copyright date to 2017. Added part number 229-9609 Head and 6E-0730 Head to Table Header and Radius dimension to Row AA in Table 17.
16	Removed part number 229-9609.
15	Removed part number 6E-0730.

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Cat 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 Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may 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

Front suspension cylinder housings that have damaged seal grooves can be repaired. Repair methods include remachining and welding the seal lands on the cylinder housings for all Off-Highway trucks. This guideline does not contain instructions on sleeving for the repair of cylinder housings. Sleeving is being more fully investigated due to concerns that involve wall thickness.

This guideline provides the salvage procedures for only the cylinder housings. The procedure for salvage and the reusability for cylinder rods may be found in Guideline For Reusable Part, SEBF8072, "Inspection and Salvage of Hydraulic Cylinder Components".

This guideline contains the latest standards of engineering, which will help minimize owning and operating costs. A part can be expected to reach the next Planned Component Repair (PCR). A part that meets the specifications within this guideline and if the part is used in the same application. Use this guideline to determine whether a part should be reused. Do not install a part that is not reusable. During reconditioning, correct any condition that might have caused the original failure.

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 it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not 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 such as 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.

Service Letters and Technical Information Bulletins

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NOTICE
The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

References

Table 2

References
Media Number	Publication Type & Title
SEBD0512	Reuse and Salvage Guidelines "Caterpillar Service Welding Service Guide"
SEBF8072	Reuse and Salvage Guidelines "Inspection and Salvage of Hydraulic Cylinder Components"
SEBF8187	Reuse and Salvage Guidelines "Standardized Parts Marking Procedures"
SEBF9236	Reuse and Salvage Guidelines "Fundamentals of HVOF Spray for Reconditioning Components"
SEBF9238	Reuse and Salvage Guidelines "Fundamentals of Arc Spray for Reconditioning Components"
SEBF9240	Reuse and Salvage Guidelines "Fundamentals of Flame Spray for Reconditioning Components"
SEBF9250	Reuse and Salvage Guidelines "Thermal Spray Procedures for 776 - 793 OHT Strut Cap Pin"
SEBF9291	Reuse and Salvage Guidelines "Thermal Spray Procedures for OHT Front Struts"
SEBF9395	Reuse and Salvage Guidelines "Reuse and Salvage on 773E Assembled Front Suspension Cylinder Housings"

Tooling and Equipment

Table 3

Required Tooling and Equipment
Part Number	Description	Qty
(1)	Personal Protective Equipment (PPE)	Personal Protection
1P-3537	Dial Bore Gauge Kit	1
1U-5516	Discs (Coarse)	As needed
1U-5519	Disc Pad Holder	1
1U-7465	55 Ton Press	1
1U-9918	Inspection Stainless Steel Brush	1
4C-4804	Penetrating Oil	As needed
4C-8515	Flapper Wheel (2" x 1" 120 grit)	As needed
4C-8521	Wheel Adapter	1
4C-9616	Welding Blanket	As needed
6V-2010	Polishing Stone	1
8S-2257	Magnifying Glass	As needed
8T-5096	Dial Indicator Kit	1
8T-7765	Surface Reconditioning Pad	As needed
9U-7377(2)	Metal Marking Pen	1
222-3074	Die Grinder
222-3076	Right Angle Die Grinder	1
263-7184	Crack Detection Kit	As needed
288-4209	Paper Towel	As needed
367-9109	Digital Caliper 6 Inch	1
385-9422	Inside Micrometer Set 2-24 inch	1
448-3698	Profilometer Non-Bluetooth Feature	1
459-0184	UV Lamp Kit	1
473-8688 or 473-8689	Inside Micrometer Set 2-12 inch	1
	Inside Micrometer Set 50-300 mm	1
473-8690	Outside Electronic Micrometer Set 0-4 inch	1
473-8691	Outside Electronic Micrometer Set 2-6 inch	1
473-8692	Outside Electronic Micrometer Set 6-12 inch	1
474-3709 or 474-3710	Inside Micrometer Set 8-32 inch	1
	Inside Micrometer Set 200-800 mm	1
164-3310	Infrared Thermometer Gp	1
349-4202	Thermometer (Infrared Hand Held)	1
1U-9600	Welding Group	1

(1)	Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards.
(2)	Available in the United States only.

Prepare the Area for Inspection & Welding

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Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.

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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Illustration 3	g03721203
Typical burr removal tooling. (A) Right Angle Die Grinder (B) Die Grinder (C) ( D) ( E) Conditioning Discs, Disc Pad Holder, and Threaded Shaft (F) ( G) Flapper Wheels

• Clean all surfaces for inspection before you inspect the part. Make sure that you remove all debris, paint, and oil.

• When you move parts that require cleaning, always use a proper lifting device. This device must protect the part from damage. For the safety of the operator, all lifting devices must be inspected before use.

• During cleaning, do not damage machined surfaces.

• Use pressurized air to dry parts.

• If the component cannot be inspected immediately after cleaning, put hydraulic oil on all machined surfaces to prevent rust or corrosion. Carefully store the parts in a clean container.

• Use appropriate thread taps to chase all threaded holes.

Standardized Parts Marking

Reference: Refer to Reuse And Salvage Guideline, SEBF8187, "Standardized Parts Marking Procedures" for additional information regarding marking procedures.

Note: Use metal marking pen for all marking.

The procedure for marking includes a code that will identify the number of rebuilds and the number of hours on each rebuild.

Illustration 4	g03683915
Illustration 4 shows code (1-15). The first number (1) indicates that the component had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the component at the time of rebuild.

Illustration 5	g03683920
Typical Example of Parts Marking

Illustration 5 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 5. In this example, the gear has a total of 22,000 hours.

Measurement Techniques

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NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Measurement Tooling include precision inside and outside diameter micrometers capable of measuring four decimal places in inches or three decimal places in millimeters. Measuring tools should be calibrated using gage blocks certified to a national standard such as the National Institute of Standards and Technology (NIST).

Ensure that several sample measurements are taken at different locations on the same feature. Measure diameters of internal bores in several places to identify tapered and or oval conditions.

Internal Bore Diameters

Illustration 6	g06222292
Example of measuring bore (ID) Inside Dimension of Motor Flange. (A) Indicates the diameter of the bore. (B) Indicates the overall thickness of the material.

Take measurements at locations (A1), (A2), and (A3).

Then take measurements at locations (A4), (A5), and (A6).

To ensure adequate life of the components, this document contains precise tolerances for measurements taken on various features. Ensure that several sample measurements are taken at different locations on the same feature. Measure diameters of internal bores in six places to identify tapered and or oval conditions. Refer to Illustration 6.

Repair Procedure

Illustration 7	g06222408
Housing Type A dimensions are shown in Illustration 7. Refer to Table 4 for the identification and specific dimensions of the cylinder according to the part number. Refer to Illustrations 24,25, and 28 for designations concerning surface finishes and run-out dimensions. Refer to Illustration 25 for descriptions of the designations concerning surface textures.

Table 4

Housing Type A Required Dimensions
Assembly Part Number		4J-9030	7J-3480, 7J-8286, 8J-2322	5J-3369	9J-5476	3G-0681, 9J-2016	1U-4031
Housing Part Number		5J-3321	7J-3479	5J-3347	3G-1695	9J-3920	1U-4779, 100-7415
A	Cylinder Overall Length	219.96 ± 0.25 mm (8.660 ± 0.010 inch)	926.08 ± 0.25 mm (36.460 ± 0.010 inch)	926.08 ± 0.25 mm (36.460 ± 0.010 inch)	818.13 ± 0.25 mm (32.210 ± 0.010 inch)	926.08 ± 0.25 mm (36.460 ± 0.010 inch)	926.0 ± 0.25 mm (36.46 ± 0.010 inch)
B	Wear Band Groove Length	181.36 ± 0.13 mm (7.140 ± 0.005 inch)	181.36 ± 0.25 mm (7.140 ± 0.010 inch)	181.36 ± 0.25 mm (7.140 ± 0.010 inch)	181.36 ± 0.25 mm (7.140 ± 0.010 inch)	181.36 ± 0.25 mm (7.140 ± 0.010 inch)	188.0 ± 0.08 mm (7.40 ± 0.003 inch)
C	Location Dimension for Wear Band Groove	34.93 ± 0.25 mm (1.375 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)
D	Location Dimension for Buffer Seal Groove	20.07 ± 0.25 mm (0.790 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)
E	Buffer Seal Groove Width	10.41 ± 0.13 mm (0.410 ± 0.005 inch)	5.65 ± 0.13 mm (0.222 ± 0.005 inch)	5.65 ± 0.13 mm (0.222 ± 0.005 inch)	5.65 ± 0.13 mm (0.222 ± 0.005 inch)	5.65 ± 0.13 mm (0.222 ± 0.005 inch)	5.65 ± 0.11 mm (0.222 ± 0.004 inch)
F	Location Dimension for Wiper Seal Groove	12.7 -0.03 +0.08 mm (0.50 - 0.001 +0.003 inch)	12.7 ± 0.25 mm (0.50 ± 0.010 inch)	12.7 ± 0.25 mm (0.50 ± 0.010 inch)	12.7 ± 0.25 mm (0.50 ± 0.010 inch)	12.7 ± 0.25 mm (0.50 ± 0.010 inch)	12.7 ± 0.25 mm (0.50 ± 0.010 inch)
G	Wiper Seal Groove Width	10.16 -0.03 +0.08 mm (0.400 -0.001 +0.003 inch)	10.16 ± 0.25 mm (0.400 ± 0.010 inch)	10.16 ± 0.25 mm (0.400 ± 0.010 inch)	10.16 ± 0.25 mm (0.400 ± 0.010 inch)	10.16 ± 0.25 mm (0.400 ± 0.010 inch)	10.18 ± 0.05 mm (0.401 ± 0.002 inch)
1	OD of Housing Minor	Ø 203.12 mm (7.997 inch)	Ø 228.6 mm (9.00 inch)	Ø 228.6 mm (9.00 inch)	Ø 228.6 mm (9.00 inch)	Ø 228.6 mm (9.00 inch)	Ø 228.6 mm (9.00 inch)
2	ID of Tube Minor Diameter	N/A	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)
3	ID of Wear Band Groove	Ø 184.28 ± 0.03 mm (7.255 ± 0.001 inch)	Ø 184.28 ± 0.03 mm (7.255 ± 0.001 inch)	Ø 184.28 ± 0.03 mm (7.255 ± 0.001 inch)	Ø 184.33 ± 0.03 mm (7.257 ± 0.001 inch)	Ø 184.28 ± 0.03 mm (7.255 ± 0.001 inch)	Ø 187.5 ± 0.03 mm (7.38 ± 0.001 inch)
4	ID of Buffer Seal Lands	Ø 178.05 ± 0.03 mm (7.010 ± 0.001 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)
5	ID of Bottom Seal Land	Ø 193.68 ± 0.25 mm (7.625 ± 0.010 inch)	Ø 193.68 ± 0.25 mm (7.625 ± 0.010 inch)	Ø 193.68 ± 0.25 mm (7.625 ± 0.010 inch)	Ø 193.68 ± 0.25 mm (7.625 ± 0.010 inch)	Ø 193.68 ± 0.25 mm (7.625 ± 0.010 inch)	Ø 193.68 ± 0.25 mm (7.625 ± 0.010 inch)
6	ID of Buffer Seal Groove	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)
7	ID of Wiper Seal Groove	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)
8	ID of Tube Major Diameter	Ø203.187 mm (7.9995 inch)	Ø 228.777 ± 0.05 mm (9.007 ± 0.002 inch)	Ø 228.777 ± 0.05 mm (9.007 ± 0.002 inch)	Ø 228.854 ± 0.13 mm (9.010 ± 0.005 inch)	Ø 228.777 ± 0.05 mm (9.007 ± 0.002 inch)	Ø 228.854 ± 0.13 mm (9.010 ± 0.005 inch)

Illustration 8	g06222504
Housing Type B dimensions are shown in Illustration 8. Refer to Table 5 for the identification and specific dimensions of the cylinders according to the part number of the housing. Refer to Illustration 21 and Illustration 25 for designations concerning surface finishes and run-out dimensions. Refer to Illustration 25 for descriptions of the designations concerning surface texture.

Table 5

Housing Type B Required Dimensions
Assembly Part Number		3G-0683, 8J-8895, 4T-3235	1U-4605
Housing Part Number		9J-9279	1U-4606
A	Cylinder Overall Length	1163.32 ± 0.25 mm (45.800 ± 0.010 inch)	1438.0 ± 0.25 mm (56.61 ± 0.010 inch)
B	Wear Band Groove Length	228.6 ± 0.08 mm (9.00 ± 0.003 inch)	279.4 ± 0.08 mm (11.00 ± 0.003 inch)
C	Location Dimension for Wear Band Groove	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	54.0 ± 0.8 mm (2.13 ± 0.03 inch)
D	Location Dimension for Buffer Seal Groove	25.4 ± 0.25 mm (1.00 ± 0.010 inch)	38.0 ± 0.25 mm (1.50 ± 0.010 inch)
E	Buffer Seal Groove Width	5.64 ± 0.13 mm (0.222 ± 0.005 inch)	5.1 ± 0.13 mm (0.20 ± 0.005 inch)
F	Location Dimension for Wiper Seal Groove	20.32 ± 0.25 mm (0.800 ± 0.010 inch)	25.0 ± 0.25 mm (0.98 ± 0.010 inch)
G	Wiper Seal Groove Width	10.18 ± .05 mm (0.401 ± 0.002 inch)	12.75 ± 0.05 mm (0.502 ± 0.002 inch)
1	OD of Housing Minor	Ø 280.0 ± 1.0 mm (11.02 ± 0.04 inch)	Ø 357.8 ± 0.8 mm (14.09 ± 0.03 inch)
2	ID of Tube Minor Diameter	Ø 231.78 ± 0.25 mm (9.125 ± 0.010 inch)	Ø 282.58 ± 0.25 mm (11.125 ± 0.010 inch)
3	ID of Wear Band Groove	Ø 238.25 ± 0.05 mm (9.380 ± 0.002 inch)	Ø 289.1 ± 0.05 mm (11.38 ± 0.002 inch)
4	ID of Buffer Seal Lands	Ø 231.78 ± 0.25 mm (9.125 ± 0.010 inch)	Ø 282.58 ± 0.25 mm (11.125 ± 0.010 inch)
5	ID of Bottom Seal Land	Ø 239.73 ± 0.25 mm (9.438 ± 0.010 inch)	Ø 296.3 ± 0.25 mm (11.67 ± 0.010 inch)
6	ID of Buffer Seal Groove	Ø 245.82 ± 0.13 mm (9.678 ± 0.005 inch)	Ø 296.62 ± 0.13 mm (11.678 ± 0.005 inch)
7	ID of Wiper Seal Groove	Ø 247.7 ± 0.25 mm (9.752 ± 0.010 inch)	Ø 304.85 ± 0.08 mm (12.002 ± 0.003 inch)
8	ID of Major Diameter	Ø 308.051 ± 0.13 mm (12.128 ± 0.005 inch)	Ø 354.85 ± 0.13 mm (13.937 ± 0.005 inch)

Illustration 9	g06222547
Housing Type C dimensions are shown in Illustration 9. Refer to Tables 6,7,8, and 9 for the identification and specific dimensions for the cylinders according to the part number for the housing. Refer to Illustrations 24,25, and 28 for designations concerning surface finishes and run-out dimensions. Refer to Illustration 25 for descriptions of the designations concerning surface textures.

Table 6

Housing Type C Required Dimensions
Assembly Part Number		7J-3480, 7J-8286, 8J-2322	9J-5476	130-3921	116-3092	311-7785
Housing Part Number		9J-2424	100-7412	130-4631	134-1156	106-0818
A	Cylinder Overall Length	926.0 ± 0.25 mm (36.46 ± 0.010 inch)	818.13 ± 0.25 mm (32.21 ± 0.010 inch)	818.13 ± 0.25 mm (32.21 ± 0.010 inch)	926.0 ± 0.25 mm (36.46 ± 0.010 inch)	1438.0 ± 0.25 mm (56.61 ± 0.010 inch)
B	Wear Band Groove Length	181.36 ± 0.08 mm (7.140 ± 0.003 inch)	181.36 ± 0.25 mm (7.140 ± 0.010 inch)	181.36 ± .025 mm (7.140 ± 0.010 inch)	188.0 ± 0.08 mm (7.40 ± 0.003 inch)	279.4 ± 0.08 mm (11.00 ± 0.003 inch)
C	Location Dimension for Wear Band Groove	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	54.0 ± 0.8 mm (2.13 ± 0.03 inch)
D	Location Dimension for Buffer Seal Groove	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	38.0 ± 0.25 mm (1.50 ± 0.010 inch)
E	Buffer Seal Groove Width	5.65 ± 0.13 mm (0.222 ± 0.005 inch)	5.65 ± 0.13 mm (0.222 ± 0.005 inch)	5.65 ± 0.13 mm (0.222 ± 0.005 inch)	5.65 ± 0.11 mm (0.222 ± 0.005 inch)	5.1 ± 0.13 mm (0.20 ± 0.005 inch)
G	Wiper Seal Groove Width	15.0 ± 0.5 mm (0.59 ± 0.02 inch)	15.0 ± 0.5 mm (0.59 ± 0.02 inch)	15.0 ± 0.5 mm (0.59 ± 0.02 inch)	15.0 ± 0.5 mm (0.591 ± 0.020 inch)	16.0 ± 0.25 mm (0.63 ± 0.010 inch)
H	Seal Land Width	N/A	N/A	N/A	N/A	N/A
1	OD of Housing Minor	Ø 228.6 ± 1.0 mm (9.00 ± 0.04 inch)	Ø 228.6 ± 1.0 mm (9.00 ± 0.04 inch)	Ø 228.6 ± 1.0 mm (9.00 ± 0.04 inch)	Ø 228.6 ± 1.0 mm (9.00 ± 0.04 inch)	Ø 357.8 ± 0.8 mm (14.09 ± 0.03 inch)
2	ID of Main Tube Seal Land	N/A	N/A	N/A	N/A	N/A
3	ID of Wear Band Groove	Ø 184.32 ± 0.03 mm (7.257 ± 0.001 inch)	Ø 184.32 ± 0.03 mm (7.257 ± 0.001 inch)	Ø 184.32 ± 0.03 mm (7.257 ± 0.001 inch)	Ø 187.5 ± .03 mm (7.38 ± 0.001 inch)	Ø 289.1 ± 0.05 mm (11.38 ± 0.002 inch)
4	ID of Buffer Seal Lands	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)	Ø 282.58 ± 0.25 mm (11.125 ± 0.010 inch)
6	ID of Buffer Seal Groove	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 296.62 ± 0.13 mm (11.678 ± 0.005 inch)
7	ID of Wiper Seal Groove	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 304.85 ± 0.08 mm (12.002 ± 0.003 inch)
8	ID of Tube Minor Diameter	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)	Ø 282.58 ± 0.25 mm (11.125 ± 0.010 inch)
9	ID of Tube Major Diameter	Ø 228.85 ± 0.13 mm (9.001 ± 0.005 inch)	Ø 228.85 ± 0.13 mm (9.001 ± 0.005 inch)	Ø 228.85 ± 0.13 mm (9.001 ± 0.005 inch)	Ø 228.85 ± 0.13 mm (9.001 ± 0.005 inch)	Ø 384.13 ± 0.13 mm (11.125 ± 0.010 inch)

Table 7

Housing Type C Required Dimensions (cont.)
Assembly Part Number		4T-4756, 285-7635, 290-7232, 299-5433	335-6352, 396-9813	9T-8910, 284-8014, 295-5706	4T-5182	347-7423
Housing Part Number		101-3368	296-4017, 342-5327	105-3550	4T-4832, 106-0905	297-3134, 300-8551
A	Cylinder Overall Length	1163.32 ± 0.25 mm (45.800 ± 0.010 inch)	1163.32 ± 0.5 mm (45.800 ± 0.02 inch)	1568.0 ± 0.8 mm (61.73 ± 0.03 inch)	1493.0 ± 0.8 mm (58.779 ± 0.03 inch)	1493.0 ± 0.8 mm (58.78 ± 0.03 inch)
B	Wear Band Groove Length	228.6 ± 0.08 mm (9.00 ± 0.003 inch)	228.6 ± 0.13 mm (9.00 ± 0.005 inch)	254.41 ± 0.08 mm (10.016 ± 0.003 inch)	310.0 ± 0.08 mm (12.21 ± 0.003 inch)	310.0 ± 0.08 mm (12.21 ± 0.003 inch)
C	Location Dimension for Wear Band Groove	38.1 ± 0.8 mm (1.50± 0.03 inch)	38.1 ± 0.8 mm (1.50± 0.03 inch)	58.0 ± 0.8 mm (2.28 ± 0.03 inch)	54.0 ± 0.8 mm (2.13 ± 0.03 inch)	54.0 ± 0.8 mm (2.13 ± 0.03 inch)
D	Location Dimension for Buffer Seal Groove	25.4 ± 0.25 mm (1.00 ± 0.010 inch)	25.4 ± 0.25 mm (1.00 ± 0.010 inch)	38.0 ± 0.25 mm (1.50 ± 0.010 inch)	38.0 ± 0.25 mm (1.50 ± 0.010 inch)	38.0 ± 0.25 mm (1.50 ± 0.010 inch)
E	Buffer Seal Groove Width	5.65 ± 0.11 mm (0.222 ± 0.004 inch)	5.65 ± 0.13 mm (0.222 ± 0.005 inch)	10.5 ± 0.1 mm (0.41 ± 0.004 inch)	5.0 ± 0.13 mm (0.20 ± 0.005 inch)	5.0 ± 0.13 mm (0.20 ± 0.005 inch)
G	Wiper Seal Groove Width	16.0 ± 0.5 mm (0.63 ± 0.02 inch)	16.0 ± 0.5 mm (0.63 ± 0.02 inch)	16.5 ± 0.25 mm (0.65 ± 0.010 inch)	16.0 ± 0.5 mm (0.63 ± 0.02 inch)	16.0 ± 0.5 mm (0.63 ± 0.02 inch)
H	Seal Land Width	N/A	N/A	13.0 ± 0.5 mm (0.51 ± 0.02 inch)	N/A	N/A
1	OD of Housing Minor	Ø 280.0 ± 1.0 mm (11.02 ± 0.04 inch)	Ø 280.0 ± 1.0 mm (11.02 ± 0.04 inch)	Ø 444.5 ± 0.8 mm (17.50 ± 0.03 inch)	Ø 413.0 ± 0.8 mm (16.26 ± 0.03 inch)	Ø 413.0 ± 0.8 mm (16.26 ± 0.03 inch)
2	ID of Main Tube Seal Land	N/A	N/A	Ø 344.0 ± 0.25 mm (13.54 ± 0.010 inch)	N/A	N/A
3	ID of Wear Band Groove	Ø 238.25 ± 0.05 mm (9.380 ± 0.002 inch)	Ø 238.25 ± 0.05 mm (9.380 ± 0.002 inch)	Ø 352.61 ± 0.05 mm (13.882 ± 0.002 inch)	Ø 327.21 ± 0.05 mm (12.882 ± 0.002 inch)	Ø 327.21 ± 0.05 mm (12.882 ± 0.002 inch)
4	ID of Buffer Seal Lands	Ø 231.78 ± 0.25 mm (9.125 ± 0.010 inch)	Ø 231.78 ± 0.25 mm (9.125 ± 0.010 inch)	Ø 344.0 ± 0.25 mm (13.543 ± 0.010 inch)	Ø 320.68 ± 0.25 mm (12.625 ± 0.010 inch)	Ø 320.68 ± 0.25 mm (12.625 ± 0.010 inch)
6	ID of Buffer Seal Groove	Ø 245.82 ± 0.13 mm (9.678 ± 0.005 inch)	Ø 245.82 ± 0.13 mm (9.678 ± 0.005 inch)	Ø 360.12 ± 0.13 mm (14.178 ± 0.005 inch)	Ø 334.72 ± 0.13 mm (13.177 ± 0.0051 inch)	Ø 334.72 ± 0.13 mm (13.177 ± 0.0051 inch)
7	ID of Wiper Seal Groove	Ø 247.78 ± 0.08 mm (9.755 ± 0.003 inch)	Ø 247.78 ± 0.08 mm (9.755 ± 0.003 inch)	Ø 368.35 ± 0.08 mm (14.502 ± 0.003 inch)	Ø 342.95 ± 0.08 mm (13.501 ± 0.003 inch)	Ø 342.95 ± 0.08 mm (13.501 ± 0.003 inch)
8	ID of Tube Minor Diameter	Ø 231.78 ± 0.25 mm (9.125 ± 0.010 inch)	Ø 231.78 ± 0.25 mm (9.125 ± 0.010 inch)	Ø 350.0 ± 1.0 mm (13.78 ± 0.04 inch)	Ø 320.68 ± 0.25 mm (12.625 ± 0.010 inch)	Ø 320.68 ± 0.25 mm (12.625 ± 0.010 inch)
9	ID of Tube Major Diameter	Ø 308.05 ± 0.13 mm (12.128 ± 0.005 inch)	Ø 273.05 ± 0.09 mm (10.75 ± 0.003 inch)	Ø 409.66 ± 0.06 mm (16.128 ± 0.002 inch)	Ø 440.0 ± 0.25 mm (17.323 ± 0.009 inch)	Ø 384.22 ± 0.22 mm (15.126 ± 0.009 inch)

Table 8

Housing Type C Required Dimensions (cont.)
Assembly Part Number		1U-4777	223-4393, 264-5784, 296-0736	223-8460, 299-7982, 299-7984	223-9658, 285-7637, 290-7233	229-2378
Housing Part Number		100-7415	223-4396	223-8458	223-9656	229-2381
A	Cylinder Overall Length	926.0 ± 0.25 mm (36.46 ± 0.010 inch)	926.0 ± 0.25 mm (36.46 ± 0.010 inch)	818.13 ± 0.25 mm (32.210 ± 0.010 inch)	1116.32 ± 0.25 mm (43.800 ± 0.010 inch)	1493.0 ± 0.8 mm (58.78 ± 0.03 inch)
B	Wear Band Groove Length	188.0 ± 0.08 mm (7.40 ± 0.003 inch)	188.0 ± 0.08 mm (7.40 ± 0.003 inch)	181.36 ± 0.25 mm (7.140 ± 0.010 inch)	228.6 ± 0.08 mm (9.00 ± 0.003 inch)	310.0 ± 0.08 mm (12.21 ± 0.003 inch)
C	Location Dimension for Wear Band Groove	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)	38.1 ± 0.8 mm (1.50 ± 0.03 inch)	54.0 ± 0.8 mm (2.13 ± 0.03 inch)
D	Location Dimension for Buffer Seal Groove	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)	25.4 ± 0.25 mm (1.00 ± 0.010 inch)	38.0 ± 0.25 mm (1.50 ± 0.010 inch)
E	Buffer Seal Groove Width	5.65 ± 0.11 mm (0.222 ± 0.004 inch)	5.65 ± 0.11 mm (0.222 ± 0.004 inch)	5.65 ± 0.13 mm (0.222 ± 0.005 inch)	5.65 ± 0.11 mm (0.222 ± 0.004 inch)	5.0 ± 0.13 mm (0.20 ± 0.005 inch)
G	Wiper Seal Groove Width	15.0 ± 0.5 mm (0.59 ± 0.02 inch)	15.0 ± 0.5 mm (0.59 ± 0.02 inch)	15.0 ± 0.5 mm (0.59 ± 0.02 inch)	16.0 ± 0.5 mm (0.63 ± 0.02 inch)	16.0 ± 0.5 mm (0.63 ± 0.02 inch)
H	Seal Land Width	N/A	N/A	N/A	N/A	N/A
1	OD of Housing Minor	Ø 228.6 ± 1.0 mm (9.00 ± 0.04 inch)	Ø 228.6 ± 1.0 mm (9.00 ± 0.04 inch)	Ø 228.6 ± 1.0 mm (9.00 ± 0.04 inch)	Ø 280.0 ± 1.0 mm (11.02 ± 0.04 inch)	Ø 413.0 ± 0.8 mm (16.26 ± 0.03 inch)
2	ID of Main Tube Seal Land	N/A	N/A	N/A	N/A	N/A
3	ID of Wear Band Groove	Ø 187.5 ± 0.03 mm (7.38 ± 0.001 inch)	Ø 187.5 ± 0.03 mm (7.38 ± 0.001 inch)	Ø 184.32 ± 0.03 mm (7.257 ± 0.001 inch)	Ø 238.25 ± 0.05 mm (9.380 ± 0.002 inch)	Ø 327.21 ± 0.05 mm (12.882 ± 0.002 inch)
4	ID of Buffer Seal Lands	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 231.78 ± 0.25 mm (9.125 ± 0.010 inch)	Ø 320.68 ± 0.25 mm (12.625 ± 0.010 inch)
6	ID of Buffer Seal Groove	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)	Ø 245.82 ± 0.13 mm (9.678 ± 0.005 inch)	Ø 334.72 ± 0.13 mm (13.178 ± 0.005 inch)
7	ID of Wiper Seal Groove	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 203.2 ± 0.05 mm (8.00 ± 0.002 inch)	Ø 247.78 ± 0.08 mm (9.755 ± 0.003 inch)	Ø 342.95 ± 0.08 mm (13.502 ± 0.003 inch)
8	ID of Tube Minor Diameter	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)	Ø 180.97 ± 0.25 mm (7.125 ± 0.010 inch)	Ø 231.78 ± 0.25 mm (9.125 ± 0.010 inch)	Ø 320.68 ± 0.25 mm (12.625 ± 0.010 inch)
9	ID of Tube Major Diameter	Ø 228.85 ± 0.25 mm (9.009 ± 0.010 inch)	Ø 228.85 ± 0.25 mm (9.009 ± 0.010 inch)	Ø 228.85 ± 0.25 mm (9.009 ± 0.010 inch)	Ø 308.05 ± 0.13 mm (12.128 ± 0.005 inch)	Ø 440.00 ± 0.25 mm (17.323 ± 0.010 inch)

Table 9

Housing Type C Required Dimensions (cont.)
Assembly Part Number		229-9604, 284-8015, 295-5707	229-9872, 311-7784	298-3926
Housing Part Number		229-9606	229-9876	298-3925
A	Cylinder Overall Length	1568.0 ± 0.8 mm (61.73 ± 0.03 inch)	1438.0 ± 0.25 mm (56.61 ± 0.010 inch)	926.0 ± 0.25 mm (36.46 ± 0.010 inch)
B	Wear Band Groove Length	254.41 ± 0.08 mm (10.016 ± 0.003 inch)	279.4 ± 0.08 mm (11.00 ± 0.003 inch)	188.0 ± 0.08 mm (7.40 ± 0.003 inch)
C	Location Dimension for Wear Band Groove	58.0 ± 0.8 mm (2.28 ± 0.03 inch)	54.0 ± 0.8 mm (2.13 ± 0.03 inch)	38.1 ± 0.25 mm (1.50 ± 0.010 inch)
D	Location Dimension for Buffer Seal Groove	38.0 ± 0.25 mm (1.50 ± 0.010 inch)	38.0 ± 0.25 mm (1.50 ± 0.010 inch)	28.58 ± 0.25 mm (1.125 ± 0.010 inch)
E	Buffer Seal Groove Width	10.50 ± 0.10 mm (0.413 ± 0.004 inch)	5.10 ± 0.13 mm (0.201 ± 0.005 inch)	5.65 ± 0.11 mm (0.222 ± 0.004 inch)
G	Wiper Seal Groove Width	16.5 ± 0.25 mm (0.65 ± 0.010 inch)	16.0 ± 0.25 mm (0.63 ± 0.010 inch)	15.0 ± 0.5 mm (0.59 ± 0.02 inch)
H	Seal Land Width	13.0 ± 0.5 mm (0.51 ± 0.02 inch)	N/A	N/A
1	OD of Housing Minor	Ø 444.5 ± 0.8 mm (17.50 ± 0.03 inch)	Ø 357.8 ± 0.8 mm (14.09 ± 0.03 inch)	Ø 228.6 mm (9.0 inch)
2	ID of Main Tube Seal Land	Ø 344.0 ± 0.25 mm (13.54 ± 0.010 inch)	N/A	N/A
3	ID of Wear Band Groove	Ø 352.61 ± 0.05 mm (13.882 ± 0.002 inch)	Ø 289.10 ± 0.05 mm (11.38 ± 0.002 inch)	Ø 187.5 ± 0.03 mm (7.38 ± 0.001 inch)
4	ID of Buffer Seal Lands	Ø 344.0 ± 0.25 mm (13.543 ± 0.010 inch)	Ø 282.58 ± 0.25 mm (11.125 ± 0.010 inch)	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)
6	ID of Buffer Seal Groove	Ø 360.12 ± 0.13 mm (14.178 ± 0.005 inch)	Ø 296.62 ± 0.13 mm (11.678 ± 0.005 inch)	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)
7	ID of Wiper Seal Groove	Ø 368.35 ± 0.08 mm (14.502 ± 0.003 inch)	Ø 304.85 ± 0.08 mm (12.002 ± 0.003 inch)	Ø 203.20 ± 0.25 mm (8.00 ± 0.010 inch)
8	ID of Tube Minor Diameter	Ø 350.0 ± 1.0 mm (13.78 ± 0.04 inch)	Ø 282.58 ± 0.25 mm (11.125 ± 0.010 inch)	Ø 182.58 ± 0.25 mm (7.188 ± 0.010 inch)
9	ID of Tube Major Diameter	Ø 409.66 ± 0.06 mm (16.128 ± 0.002 inch)	Ø 384.00 ± 0.13 mm (15.118 ± 0.005 inch)	Ø 228.85 ± 0.13 mm (9.010 ± 0.005 inch)

Illustration 10	g06219478
Housing Type D dimensions are shown in Illustration 10. Refer to Table 9 for the identification and specific dimensions for the cylinders according to the part number of the housing. Refer to Illustrations 24,25, and 28 for designations concerning surface finishes and run-out dimensions. Refer to Illustration 25 for descriptions of the designations concerning surface texture.

Table 10

Housing Type D Required Dimensions
Assembly Part Number		148-9775, 191-8042, 289-8629
Housing Part Number		185-3150
A	Cylinder Overall Length	1687.0 ± 0.8 mm (66.42 ± 0.03 inch)
B	Wear Band Groove Length	254.41 ± 0.08 mm (10.016 ± 0.003 inch)
C	Location Dimension for Wear Band Groove	58.0 ± 0.8 mm (2.28 ± 0.03 inch)
D	Location Dimension for Buffer Seal Groove	38.0 ± 0.25 mm (1.50 ± 0.010 inch)
E	Buffer Seal Groove Width	10.50 ± 0.10 mm (0.41 ± 0.004 inch)
F	Location Dimension for the Wiper Seal Groove	21.0 ± 0.25 mm (0.83 ± 0.010 inch)
G	Wiper Seal Groove Width	14.5 ± 0.5 mm (0.57 ± 0.02 inch)
H	Seal Land Width	13.0 ± 0.5 mm (0.51 ± 0.02 inch)
J	Retaining Ring Groove Width	2.3 ± 0.10 mm (0.09 ± 0.004 inch)
1	OD of Housing Minor	Ø 520.0 ± 0.8 mm (20.47 ± 0.03 inch)
2	ID of Main Tube Seal Land	Ø 401.15 ± 0.25 mm (15.793 ± 0.010 inch)
3	ID of Wear Band Groove	Ø 409.76 ± 0.05 mm (16.132 ± 0.002 inch)
4	ID of Buffer Seal Lands	Ø 401.15 ± 0.25 mm (15.793 ± 0.010 inch)
5	ID of Bottom Seal Land	Ø 404.0 ± 0.05 mm (15.91 ± 0.002 inch)
6	ID of Buffer Seal Groove	Ø 417.27 ± 0.13 mm (16.428 ± 0.005 inch)
7	ID of Wiper Seal Groove	Ø 425.5 ± 0.13 mm (16.752 ± 0.005 inch)
8	ID of Tube Minor Diameter	Ø 407.1 ± 1.0 mm (16.03 ± 0.04 inch)
9	ID of Tube Major Diameter	Ø 466.81 ± 0.06 mm (18.3783 ± 0.0023 inch)

Illustration 11	g06219484
Housing Type E dimensions are shown in Illustration 11. Refer to Table 11 for the identification and specific dimensions for the cylinders according to the part number of the housing. Refer to Illustrations 24,25, and 28 for designations concerning surface texture and run-out dimensions. Refer to Illustration 25 for descriptions of the designations concerning surface texture.

Table 11

Housing Type E Required Dimensions
Assembly Part Number		334-4225, 441-5252
Housing Part Number		334-4222, 451-9205
A	Cylinder Overall Length	926.0 ± 0.5 mm (36.46 ± 0.02 inch)
B	Wear Band Groove Length	188.0 ± 0.13 mm (7.40 ± 0.005 inch)
C	Location Dimension for Wear Band Length	38.1 ± 0.25 mm (1.50 ± 0.010 inch)
D	Location Dimension for Buffer Seal Groove	21.3 ± 0.25 mm (0.839 ± 0.010 inch)
E	Buffer Seal Groove Width	10.5 ± 0.13 mm (0.413 ± 0.005 inch)
G	Wiper Seal Groove Width	15.0 ± 0.5 mm (0.59 ± 0.02 inch)
A1	Bore Length	399.5 ± 0.25 mm (15.73 ± 0.010 inch)
B1	Length	82.5 ± 0.25 mm (3.25 ± 0.010 inch)
C1	Location Dimension for second Buffer Seal Groove	65.0 ± 0.25 mm (2.56 ± 0.010 inch)
D1	Location Dimension for Wear Band	6.0 ± 0.5 mm (0.24 ± 0.02 inch)
E1	Second Wear Band Groove Length	41.4 ± 0.13 mm (1.63 ± 0.005 inch)
F1	Second Buffer Seal Groove Width	10.5 ± 0.13 mm (0.413 ± 0.005 inch)
1	OD of Housing Minor	Ø 228.6 ± 1.0 mm (9.0 ± 0.04 inch)
2	ID to Tube Minor Diameter	Ø 182.58 ± 0.25 mm (7.189 ± 0.010 inch)
3	ID of Wear Band Groove	Ø 187.55 ± 0.05 mm (7.384 ± 0.002 inch)
4	ID of Buffer Seal Lands	Ø 178.5 ± 0.1 mm (7.03 ± 0.004 inch)
6	ID of Buffer Seal	Ø 195.02 ± 0.13 mm (7.678 ± 0.005 inch)
7	ID of Wiper Seal	Ø 203.2 ± 0.25 mm (8.0 ± 0.01 inch)
1A	ID of second Wear Band	Ø 137.55 ± 0.1 mm (5.42 ± 0.004 inch)
2A	ID of second Buffer Seal Lands	Ø 178.25 ± 0.1 mm (7.02 ± 0.004 inch)
3A	ID of second Buffer Seal	Ø 195.02 ± 0.13 mm (7.68 ± 0.005 inch)
4A	ID of Tube Major Diameter	Ø 203.29 ± 0.09 mm (8.003 ± 0.003 inch)

Procedure for Machining of Front Suspension Cylinder Housings

1. Remove the tube and the gland, and then steam clean the housing.
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   Illustration 12	g03705292
   Example of a cylinder housing mounted on a horizontal boring mill.

2. Mount the cylinder housing on suitable tooling that is appropriate for heavy machining. Use a properly sized lathe or horizontal mill to make the proper cuts.
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   Illustration 13	g03705306
   Typical example for alignment of the bore of the housing to the center-line of the cutting tool.

3. The center-line of the housing bore must be on the same axis as the center-line of the machine tool.
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   Illustration 14	g06223089
   Use the proper machine tool to remove the section of the seal land (A1). Refer to Table 4 for the part number of the cylinder and related dimensions.

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   Illustration 15	g06223092
   Use the proper machine tool to remove the section of the seal land (A1). Refer to Table 5 for the part number of the cylinder and related dimensions.

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   Illustration 16	g06223095
   Use the proper machine tool to remove the section of the seal land (A1). Refer to Tables 6,8,9, and 11 for the part number of the cylinder and related dimensions.

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   Illustration 17	g06223103
   Use the proper machine tool to remove the section of the seal land (A1). Refer to Table 10 for the part number of the cylinder and related dimensions.

4. Remove one seal land. Refer to Illustration 16. Remove both of the seal lands. Refer to Illustrations 14,15, and 17. Removing the seal lands allows the weld to fill into the narrow grooves. Removing the seal lands also prevents porosity during the welding operation.

5. Machine the bore diameters enough to remove the damage. The wall thickness of the cylinder should not be reduced excessively. No bore diameter should exceed 2.03 mm (0.080 inch) of the bore diameter of the wiper seal groove. Do not machine the groove for the wear band more than 50.80 mm (2.000 inch) beyond the top of the original groove.
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   Illustration 18	g03705357
   Use 1U-9600 Welding Group to build up the machined bore.

6. Fill the machined bore with welding material. The housing should be preheated to 93 °C (200 °F) and welded with ER-70S3 Weld (Electrode). Stick welding causes a large amount of distortion due to heat. Stick welding also takes longer than welding with a wire.
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   Illustration 19	g03705363
   Housing bore after welding

7. The bore that is welded and the grooves should be made 2.54 mm (0.100 inch) to 3.18 mm (0.125 inch) smaller than the dimensions in Tables 4 through 11. This step will allow sufficient material for cleanup during the machining process.

   Note: The bore of the housing must be in alignment with the center-line of the machine tool.

8. Immediately after welding the cylinder housing cover with an insulated welding blanket to reduce the chance of hydrogen cracking. Position the cylinder on the machine tool to machine the seal grooves. Use standard feeds and speeds for the machine tool and the cutting element to produce a quality surface texture.

9. After the housing is centered in the machine tool, make light cuts initially. This action removes the rough surface of the weld. This method will establish a plane to take measurements.
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   Illustration 20	g03705367
   Refer to Illustration 7 for the locations of the dimensions and Table 4 for the machining dimensions. Refer to Illustration 24 for the specifications of the surface texture for wear ring, buffer, and wiper seal grooves. Call outs that contain letters represent surface texture. Call-outs that contain numbers represent run-out. Refer to Illustration 25 for descriptions of the designations concerning surface texture.

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   Illustration 21	g03705367
   Refer to Illustration 8 for the locations of the dimensions and Table 5 for the machining dimensions. Refer to Illustration 24 for the specifications of the surface texture for wear ring, buffer, and wiper seal grooves. Call-outs that contain letters represent surface texture. Call-outs that contain numbers represent run-out. Refer to Illustration 25 for descriptions of the designations concerning surface texture.

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   Illustration 22	g03705402
   Refer to Illustration 9 for the locations of the dimensions and Tables 6,7,8, and 9, for the machining dimensions. Refer to Illustration 24 for the specifications of the surface finishes for wear ring, buffer, and wiper seal grooves. Call-outs that contain letters represent surface finishes. Call-outs that contain numbers represent run-out. Refer to Illustration 25 for descriptions of the designations concerning surface finishes.

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   Illustration 23	g03705408
   Refer to Illustration 10 for the locations of the dimensions and Table 10 for the machining dimensions. Refer to Illustration 24 for the specifications of the surface finishes for wear ring, buffer, and wiper seal grooves. Call-outs that contain letters represent surface finishes. Call outs that contain numbers represent run-out. Refer to Illustration 25 for descriptions of the designations concerning surface finishes.

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   Illustration 24	g06339162

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   Illustration 25	g06339229

10. Machine the wear ring, the buffer seal, and the wiper seal grooves according to the dimensions in the Tables 4 through 11. Machine the grooves to have surface texture that are specified in Illustrations 20 through 25.

11. Remove all sharp edges after machining the grooves. This step will help to prevent damage to the new seals during installation. Buff the machined area with emery paper.

Procedure for Machining Seal Lands in the Middle of the Suspension Cylinder

Some front suspension cylinders feature a second set of seal lands on the middle of the front suspension cylinder. These seals hold higher pressure oil and nitrogen that the seal lands in the end. These seal lands in the middle can also be salvaged. The weld must have good fusion and no porosity or pathways for leakage.

Follow the steps as described in the"Procedure for Machining of Front Suspension Cylinder Housings". Use the following Illustrations and table to complete the salvage operation.

Illustration 26	g06223320
Use the proper machine tool to remove the section of the seal land (A1). Refer to Table 11 for the part number of the cylinder and related dimensions.

Illustration 27	g03705516
Refer to Illustration 11 for the locations of the dimensions and Table 11 for the machining dimensions. Refer to Illustration 28 for the specifications of the surface texture for wear ring, buffer, and wiper seal grooves. Call-outs that contain letters represent surface texture. Call-outs that contain numbers represent run-out. Refer to Illustration 25 for descriptions of the designations concerning surface texture.

Illustration 28	g06223334

Procedure for Machining Surface of the Mounting Flange

If pitting is present on face of mounting flange, remove 2.0 mm (0.08 inch) from the face. If pitting is still present, replace with new. After removal of pitting, use twin-wire arc spray to build up the machined surface. Refer to Reuse And Salvage Guidelines, SEBF9238, "Fundamentals of Arc Spray for Reconditioning Components". Refer to Table 12 for machining to nominal dimension.

Illustration 29	g03839096

Illustration 30	g03839170

Illustration 31	g03839337

Illustration 32	g03839365

Table 12

Mounting Flange Dimensions
Assembly Part Number	Housing Part Number	Nominal Dimension (A)	Nominal Dimension (B)	Nominal Dimension (C)	Nominal Dimension (D)
1U-4031, 1U-4777	1U-4779, 100-7415	130.0 ± 0.5 mm (5.12 ± 0.02 inch)	6.6 ± 0.25 mm (0.26 ± 0.01 inch)	R.8 ± 0.30 mm (0.03 ± 0.012 inch) X 45°	50.93 ± 0.08 mm (2.005 ± 0.003 inch)
116-3092	134-1156
3G-0681, 9J-2016	9J-3920
5J-3369	5J-3347
7J-3480, 7J-8286, 8J-2322	7J-3479
9J-5476	3G-1695, 100-7412
130-3921	130-4631
223-4393, 264-5784, 296-0736	223-4396
223-8460, 299-7982, 299-7984	223-8458
334-4225, 441-5252	334-4222, 451-9205
341-6163, 341-6164	293-8457, 451-9203
342-7915, 342-7916	347-2383, 451-9204
298-3926	298-3925	136.6 ± 0.5 mm (5.38 ± 0.02 inch)	6.6 ± 0.25 mm (0.26 ± 0.01 inch)	R.8 ± 0.30 mm (0.03 ± 0.012 inch) X 45°	50.93 ± 0.08 mm (2.005 ± 0.003 inch)
3G-0683, 8J-8895, 4T-3235	9J-9279	180.85 ± 0.5 mm (7.120 ± 0.02 inch)	6.6 ± 0.25 mm (0.26 ± 0.01 inch)	R.8 ± 0.30 mm (0.03 ± 0.012 inch) X 45°	76.33 ± 0.08 mm (3.005 ± 0.003 inch)
4T-4756, 285-7635, 290-7232, 299-5433	101-3368
223-9658, 285-7637, 290-7233	223-9656
335-6351, 335-6352, 396-9813	296-4017, 342-5327
1U-4605, 311-7785	1U-4606, 106-0818	230.0 ± 0.8 mm (9.06 ± 0.03 inch)	10.25 ± 0.25 mm (0.404 ± 0.01 inch)	R1.0 ± 0.5 mm (0.04 ± 0.02 inch) X 45°	102.0 ± 0.08 mm (4.02 ± 0.003 inch)
229-9872, 311-7784	229-9876
4T-5182	4T-4832, 106-0905	260.0 ± 0.5 mm (10.24 ± 0.02 inch)	10.25 ± 0.25 mm (0.404 ± 0.01 inch)	R1.0 ± 0.5 mm (0.04 ± 0.02 inch) X 45°	102.0 ± 0.08 mm (4.02 ± 0.003 inch)
9T-8910, 284-8014, 295-5706	105-3550
229-2378	229-2381
229-9604, 284-8015, 295-5707	229-9606
347-7423	297-3134, 300-8551
148-9775, 191-8042, 289-8629	185-3150	315.0 ± 0.5 mm (12.40 ± 0.02 inch)	10.25 ± 0.25 mm (0.404 ± 0.01 inch)	R1.0 ± 0.5 mm (0.04 ± 0.02 inch) X 45°	102.0 ± 0.08 mm (4.02 ± 0.003 inch)

Procedure for Welding of Front Suspension Cylinder Housings

Note: Repaired parts will not have the same life as the original parts.

Welding Specifications and Qualifications

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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

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NOTICE
Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Qualifications

Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal Arc Welding (SMAW) and Flux Cored Arc Welding (FCAW). Refer to Specification ANSI/AWS D1.1 for information that regards qualification requirements. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

• Oil

• Grease

• Paint

• Dirt

• Rust

• Any fluids or moisture

All welding shall be conducted on base material heated and maintained at room temperature.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Welding Electrodes and Parameters

Flux Cored Welding Electrode for the FCAW Process

Use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the manufacturer shielding gases that are specified (typically 75% argon and 25% carbon dioxide). The H8 implies that the electrode is designed to provide less than 8 ml/100 g of diffusible hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode will have the following minimum mechanical properties:

Table 13

Mechanical Properties from Flux Cored Welding Electrode That Is Classified as "ANSI/AWS A5.20 E71T-1 H8"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -18 °C (20 ft lb @ -0 °F)

The tables that follow show the recommended parameter ranges for out of position welding in the field for two different flux cored welding electrode diameters.

Table 14

Welding Parameters for Flux Cored Welding Electrode that Is 1.2 mm (0.045 inch)
Wire Feed Rate	Voltage	Amperage
7.620 - 7.784 m/min (300 - 310 ipm)	24 to 28	190 to 240

Table 15

Welding Parameters for Flux Cored Welding Electrode that Is 1.4 mm (0.052 inch)
Wire Feed Rate	Voltage	Amperage
5.080 - 6.350 m/min (200 - 250 ipm)	23 to 27	180 to 220

Note: The settings listed above are recommendations based on experience from welding in the horizontal, and vertical-up. Slight changes in the voltage and amperage may be necessary due to welding position and various formulations by different electrode manufacturers. The use of higher parameters than specified for welding in the flat position is acceptable.

Use a polarity setting of DC reverse polarity. Remove the slag after each welding pass. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld to reduce the possibility of evolving gas that is trapped in the weld. The maximum size weld per pass should be equivalent to that of a 8.0 mm (.32 inch) fillet weld.

Low Hydrogen Electrodes for the SMAW Process

As an alternative process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet the following requirements.

Table 16

Mechanical Properties of Welds from Low Hydrogen Electrodes That Are Classified as "ANSI/AWS A5.1 E7018H4R"
Tensile Strength	480 MPa (70000 psi)
Yield Strength	400 MPa (58000 psi)
Elongation	22%
Impact Toughness	27 J @ -29 °C (20 ft lb @ -20 °F)

Low hydrogen electrodes must be stored in an electrode oven at 120 °C (250 °F) when not in use. If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturer specifications.

The table that follows shows the settings for the welding current based on electrode diameter.

Table 17

Welding Parameters for Low Hydrogen Electrodes
Diameter	Amperage Rating
3.2 mm (1/8 inch)	105-155
4.0 mm (5/32 inch)	130-200
4.8 mm (3/16 inch)	200-275

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed two times the electrode diameter.

Weld Inspection Procedure

Illustration 33	g03714869
(A) Flange (B) Rib (C) Housing

1. Thoroughly clean the front suspension cylinder to remove any dirt, oil, and grease prior to inspection.
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   Illustration 34	g03714546
   Example of applied liquid dye penetrant to ribs to housing, ribs to flange, flange to housing vertical welds, and axial belly welds that run the length of the flange to tube.

2. Use liquid dye penetrant (PT) or magnetic particle (MT) to identify a crack.

   • All ribs-to-flange welding

   • All ribs-to-housing welding

   • Flange-to-housing
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   Illustration 35	g03714839
   Example of crack at flange to housing. Weld repair is not permissible,

3. Defects or cracks in the parent material of the housing that are less than 2 mm (0.079 inch) deep may be ground or sanded out of the parent material of the housing. If the defect or crack in the housing is greater than 2 mm (0.079 inch) in depth DO NOT REUSE the housing.
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   Illustration 36	g03714849
   (D) Rib-to-flange welding

4. Weld repairs are acceptable on rib-to-flange (D) welding.
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   Illustration 37	g03714880
   (E) Rib-to-housing welding

5. Weld repairs are acceptable on rib-to-housing (E) welds only if cracks are observed in three or fewer than three ribs. If cracks are observed in more that three ribs, weld repair is not permissible as the weld repair usually deforms the housing past a point of usability.
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   Illustration 38	g03714894
   (F) Flange-to-housing outside vertical welding

6. If cracks are observed in flange-to-housing outside vertical welding, weld repair is not permissible. DO NOT REUSE
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   Illustration 39	g03714907
   (G) Axial belly welding

7. If cracks are observed on axial belly (G) welds, weld repair is not permissible. DO NOT REUSE

8. If cracks are noticed in other areas of the front suspension cylinder housing, weld repair is not permissible. DO NOT REUSE

Welding Preparation / Repair

Illustration 40	g00008666

IF WELDING ON ASSEMBLED STRUTS AND STRUTS THAT ARE ON THE MACHINES, PLEASE REFER TO SEBF9395 , "Reuse and Salvage on 773E Assembled Front Suspension Cylinder Housings"

1. Remove all oil, grease, paint, and dirt from the damaged surface. Also, remove surface oxides from the area being repaired.

   Note: Good cleaning and surface preparation are important to ensure a good quality of repair.

2. Protect all machined surfaces, from sparks or spatter produced by the weld removal, welding, chipping, and/or grinding operations.

3. When the base metal temperature is below 0° C (32.0° F), metal must be preheated to at least 16° C (60.8° F). This minimum temperature must be maintained throughout the procedure to reduce the chance of weld distortion, minimize the heat generated by the welding procedure.

4. Caution should be used to avoid excessive removal of the surrounding base material. Areas that are gouged by air carbon arc torch shall be later ground and cleaned prior to welding to remove all carbon absorption or contamination.

5. Gouged areas requiring rewelding shall have a root radius of not less than 5 mm (0.20 inch) and a Single V - 60° included angle joint preparation to allow the welder reasonable access to reinstate the weld.

6. Use liquid dye penetrant (PT) or magnetic particle (MT) to inspect the gouged and ground area to ensure that the crack has been removed before welding commences.

7. Orient the front suspension cylinder so weld can be repaired in 1F or 2F position.

8. Repair the prepared groove utilizing the recommendations provided in the"Welding Electrodes and Parameters" section. Weld to 12 mm (0.472 inch) fillet size and ensure with weld fillet gauge.

9. Grind weld to blend a smooth transition between rib and flange.

10. After repair is complete, check for the correct internal dimensions of the housing in which can be deformed by welding. Refer to Table 8 for dimensions.

793 Front Strut Suspension Housing Rib Replacement 105–3550

Illustration 41	g06329369
793 105-3550 Housing As (front strut housing lower rib supports) (1).

Some front suspension housings on 793 trucks may exhibit cracking on the four lowest ribs (1). Refer to Illustration 41 for the location of the ribs. The cracked ribs require repair before the part may be placed back in to service. The procedure that follows will provide one method of salvage.

Illustration 42	g06328423
(2) Crack originated at the housing to rib weld, then propagated through the rib.

Illustration 43	g06328475
(3) Cracked rib to flange fillet welds.

1. Inspect the housing for cracks on the lower ribs using Liquid (Dye) Penetrant Testing or Dry Magnetic Particle Testing. The cracks usually originate in the rib to housing weld and propagate across the rib. Other weld cracking may occur, for example in the rib to flange area fillet welds. Refer "Crack Detection Methods" at the end of this document for Liquid (Dye) Penetrant Testing or Dry Magnetic Particle Testing instructions.

2. If one rib is found cracked proceed to step 3. If no ribs are found cracked, no further action is required in this section.

3. Remove all paint around the ribs at the housing and flange areas.

4. Perform steps 1 through 7 in the"Procedure for Machining of Front Suspension Cylinder Housings"with in this document.

5. Remove the 4 lowest ribs by air carbon arc gouging out the welds. Refer to , SEBD0512 , "Caterpillar Service Welding Guide".

6. Use an angle grinder to remove excess weld material to match the contour of the housing.

7. Ensure that the cracks do not penetrate the housing. If cracks penetrate the housing and are more than 2 mm (0.08 inch) deep, the cracks should not be removed by grinding. Weld repair is not permissible. DO NOT REUSE THE HOUSING.

8. Machine the replacement ribs from plate steel such as: ASTM A572 Grade 42 or 50. Alternative steels include: EN10025-2 Grade S275J2, S275K2, S355J2, or S355K2. If one of these steel types cannot be obtained, steel with a carbon content less than 0.3% and a carbon equivalent less than 0.5% may be used. The minimum yield strength of the steel shall be 290 MPa (42000 psi).
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   Illustration 44	g06328529
   Rib support for 793 front suspension housing.

9. Refer to Illustration 44 and Table 18 for specifications on how to fabricate the replacement rib.
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   Table 18

   793 Replacement Rib Dimensions
   Callout	Dimension
   A	327 mm (12.87 inch)
   B	156 mm (6.14 inch)
   C	3X 3 ± 0.5 mm (0.1181 ± 0.02 inch) X 45° TYP
   D	16 mm (0.63 inch)
   E	346 mm (13.62 inch)
   F	333 mm (13.11 inch)
   G	187 mm (7.36 inch)
   H	49 mm (1.93 inch)
   J	R 222.3 mm (8.75 inch)
   K	R 222.3 mm (8.75 inch)
   L	R 25 mm (0.984 inch)

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   Illustration 45	g06329369
   (1) Rib supports to be replaced.

10. Locate and clamp the four ribs in place on the housing. The ribs are 101.6 ± 1.5 mm (4.0 ± 0.06 inch) apart and 23.5 ± 1.5 mm (0.925 ± 0.06 inch) from the edge of the flange. Refer to Illustration 45.

11. Tack weld the ribs with six tacks on each rib. Place two tack welds on the rib to housing and one tack weld on the rib to flange. Tack welds should be at the corners of the ribs, not along the middle of the edge of the ribs.

12. Preheat the housing flange to 150° C (302° F). Weld the ribs to the flange with a 12 mm (0.47 inch) fillet in three passes. The inter-pass temperature should remain between 150° C (302° F) and 250° C (482° F). The weld passes should be done in the order specified in Illustration 46. Reference SEBD0512Reuse and Salvage Guideline, "Caterpillar Service Welding Guide".
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    Illustration 46	g06329396
    Weld pass order.

13. Preheat the housing tube to 150° C (302° F). Weld the ribs to the housing with a 12 mm (0.47 inch) fillet in three passes. The inter-pass temperature should remain between 150° C (302° F) and 250° C (482° F). The weld passes should be done in the order specified in Illustration 46. Reference , SEBD0512Reuse and Salvage Guideline, "Caterpillar Service Welding Guide".

14. Remove any weld spatter on the housing, flange, and ribs.

15. Machine the mounting flange flat according to the "Procedure for Machining Surface of the Mounting Flange" listed in , REHS2099 if necessary.

16. Perform steps 8 through 11 in the"Procedure for Machining of Front Suspension Cylinder Housings"within this document. Steps 8 through 11 will finish inside the bore to complete the wear band and seal grooves.

17. Remachine the bolt spot faces on the housing 73.02 ± 0.8 mm (2.87 ± 0.03 inch).

18. Perform any other repairs needed.

793 Rib Replacement Welding Electrodes and Parameters

Note: The hydrogen content of the welding consumable should be lower than or equal to 5 mL (0.17 oz) of hydrogen per 100 gram (3.5 ounce) of weld metal.

For example: E71T-12MJH4 indicates an electrode that provides 4 mL (0.136 oz) of hydrogen per 100 gram (3.5 ounce) of weld metal when stored and used as specified by the manufacturer.

Electrode Requirements for the Flux Cored Arc Welding (FCAW)

Use the Flux Cored Arc Welding (FCAW) process with a welding electrode that meets (ANSI/AWS A5.20) E71T-1MJH4, E71T-9MJH4 , or E71T-12MJH4 and the manufacturer shielding gases that are specified (typically 75% argon and 25% carbon dioxide).

Electrodes that have an H5 designator are also acceptable.

The table that follows shows the recommended parameter ranges for out of position welding in the field for two different flux cored welding electrode diameters. Refer to table 19 for (FCAW) electrode specifications.

Table 19

Flux-Cored Arc Welding (FCAW) 75% Ar - 25% CO 2
Electrode Diameter	AWS Class/ Spec. A5.20	Amps (DCEP) Voltage (V)	Wire Feed Speed
Ø 1.2 mm (0.045 inch)	E71T-1MJH4 E71T-9MJH4 E71T-12MJH4	190–240 A 24–28 V	7620 - 10,160 mm/min (300 -.400 ipm)
Electrode Diameter	AWS Class/ Spec.	Amps (DCEP) Voltage (V)	Wire Feed Speed
Ø 1.4 mm (0.052 inch)	E71T-1MJH4 E71T-9MJH4 E71T-12MJH4	180-220 A 23–27 V	5,080 - 6,350 m/min (200- 250 ipm)
Minimum Preheat	Maximum Interpass	Post Heat Treatment
150° C (302° F)	250° C (482° F)	Slow Cool with insulated blanket
Notes	Ensure that all electrodes are kept dry according to manufacturing recommendations. Do not expose electrodes to any contaminants such as grease, oil, water, or any other possible sources of moisture. Use temperature indicating crayon to ensure that preheat temperature is in accordance with the procedure.

Note: The settings listed above are recommendations based on experience from welding in the horizontal, vertical, and overhead positions. Slight changes in the voltage and amperage may be necessary due to welding position and various formulations by different electrode manufactures. the use of higher parameters than specified for welding in the flat position is acceptable.

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld to reduce the possibility of evolving gas that is trapped in the weld. The maximum size weld per pass should be equivalent to that of 8 mm (0.31 inch) fillet weld.

Electrode requirements for SMAW (Shielded Metal Arc Welding) Process

As an alternative process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet the following requirements.

ANSI/AWS A5.1 E7018-1 H4R meets the requirements for allowable hydrogen content.

Low hydrogen electrodes must be stored in an electrode oven at 250° C (482° F). If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturer specifications.

Refer to Table 20 for the settings of the welding current based on electrode diameter.

Table 20

Shielded Metal Arc Welding (SMAW)
Electrode Diameter	AWS Class/ Spec.	Amps (DC+)
3.2 mm (1/8 inch)	E7018-1 (H4R) 250° C (482° F)	105–155 A
4.0 mm (5/32 inch)	E7018-1 (H4R)	130-200 A
4.8 mm (3/16 inch)	E7018-1 (H4R)	200–275 A
Preheat	Maximum Inter-pass	Post Heat Treatment
150° C (302° F)	250° C (482° F)	Slow Cool with insulated blanket
Notes	Ensure that all electrodes are kept dry according to manufacturing recommendations. Do not expose electrodes to any contaminants such as grease, oil, water, or any other possible sources of moisture.

Front Strut Suspension Cylinder Head Repair (All Off Highway Trucks Except 793)

Illustration 47	g06330254
(A) Fillet

During repairs to the front suspension cylinder group, closely inspect the stub shaft on the cylinder head. Under extreme service, the stub shaft may fatigue. The stub shaft may also fracture in the area of the fillet of the stub shaft.

Note: The following salvage procedures cannot be used if the plate of the cylinder head is cracked. Replace any cylinder head with cracks in the plate.

Inspection

1. Steam clean the head prior to inspection to remove grease and other materials from the surface. Use a wire brush to remove any remaining scale or oxidation.
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   Illustration 48	g03705541
   Application of penetrating oil

2. Spray an inspection grade penetrating oil on the surface around the fillet. Start at the stub shaft and extend the coverage outward. Refer to Illustration 48.

3. Leave the cleaner on the surface of the head for 2 to 3 minutes. By using an absorbent cloth or a clean towel, remove the cleaner from the head. There should not be any visible signs of the cleaner on the surface.

4. Spray a dye penetrant developer around the same areas that were sprayed with the cleaner. Refer to Illustration 49.
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   Illustration 49	g03705546
   Application of developer

5. If cracks are present, the penetrating oil that is trapped in the crack will leak through the developer. The penetrating oil will make the fracture visible. Refer to Illustration 50.

Illustration 50	g03705550
The dye penetrant cleaner that is trapped in the crack will leak through the dye penetrant developer.

Heads which have cracks at the fillet of the stub shaft can be salvaged. The stub shaft must be removed. A new stub shaft must be machined and installed on the head.

Illustration 51	g06037472
Dimensions for machining and fitting a new stub shaft to the head

Head Repair Specifications

Table 21

Dimensions Required To Machine New Stub Shaft
Assembly Part Number	3G-0683, 8J-8895	4T-4756, 285-7635, 290-7232, 299-5433	299-5433	223-9658, 285-7637, 290-7233	335-6351	335-6352	299-7982, 299-7984
Head Part Number	8J-9937	9T-6243, 102-6340	299-5434	223-9652	342-5329	335-6353	303-5967
V	Ø 82.42 ± 0.08 mm (3.2449 ± 0.0032 inch)
W	6.5 ± 0.5 mm (0.256 ± 0.0197 inch X 15°)
X	134.9 ± 0.5 mm (5.31 ± 0.0197 inch)						105.0 ± 0.5 mm (4.1339 ± 0.0197 inch)
Y	219.12 mm (8.627 inch)						156.2 mm (6.149 inch)
Z	225.42 ± 0.25 mm (8.8748 ± 0.0098 inch)						165.5 ± 0.5 mm (6.5157 ± 0.0197 inch)
AA	R25.4 ± 0.5 mm (1.000 ± 0.0197 inch)	R25.0 ± 1.0 mm (0.9843 ± 0.0394 inch)				R50 ± 1 mm (1.968 ± 0.039 inch)	R25.0 ± 1.0 mm (0.9843 ± 0.0394 inch)
CC	R13.0 mm (0.5118 inch)						N/A
DD	Ø 142.5 mm (5.6102 inch)						Ø 117.0 mm (4.6063 inch)
EE	Ø 142.37 mm (5.6051 inch)						Ø 116.87 mm (4.6012 inch)
FF	12.7 mm (0.5000 inch X 45°)
GG	38.0 ± 0.5 mm (1.4961 ± 0.0197 inch)						28.5 ± 0.5 mm (1.1220 ± 0.0197 inch)
HH Centering Pilot Only	N/A	Ø 22.5 mm (0.8858 inch) 65.0 mm (2.5591 inch) Deep 1-8-2B Thd 48.0 mm (1.8898 inch) Deep
JJ	31.7 mm (1.248 inch)						19.2 mm (0.756 inch)
Dimensions Required To Machine New Stub Shaft continued
Assembly Part Number	229-9604, 284-8015, 295-5707		229-2379	4T-5182, 347-7423	1U-4605, 311-7785	229-9872, 311-7784	334-4225, 441-5252	341-6163, 342-7915, 342-7916
Head Part Number	229-9609		229-2385	4T-4838	1U-4618, 9T-9993	229-9880	342-9372	350-0210, 350-0211
V	Ø 101.47 ± 0.08 mm (3.995 ± 0.003 inch)				Ø 82.42 ± 0.08 mm (3.245 ± 0.003 inch)			69.88 ± 0.08 mm (2.751 ± 0.003 inch)
W	6.0 ± 0.5 mm (0.2362 ± 0.0197 inch) X 30°						6.5 ± 0.5 mm (0.256 ± 0.0197 inch) x 15°
X	124.0 ± 0.5 mm (4.8819 ± 0.0197 inch)				122.0 ± 0.5 mm (4.8031 ± 0.0197 inch)		130.4 ± 0.5 mm (5.1339 ± 0.0197 inch)	89.5 ± 0.5 mm (3.5236 ± 0.0197 inch)
Y	238.7 mm (9.398 inch)				200.7 mm (7.902 inch)		183.1 mm (7.208 inch)	137.2 (5.402 inch)
Z	270.0 ± 0.5 mm (10.6299 ± 0.0197 inch)				232.0 ± 0.5 mm (9.13 ± 0.02 inch)		190.9 ± 0.5 mm (7.52 ± 0.02 inch)	150.0 ± 0.5 mm (5.91 ± 0.02 inch)
AA	R25.0 ± 0.5 mm (0.98 ± 0.02 inch)		R13.0 ± 1.0 mm (0.51 ± 0.04 inch)		R25.0 ± 0.5 mm (0.98 ± 0.02 inch)		R25.0 ± 1.0 mm (0.98 ± 0.04 inch)
BB	N/A		30° ± 1°		N\A
CC	R32.0 mm (1.26 inch)				R24.0 mm (0.95 inch)		N/A
DD	Ø 223.0 mm (8.78 inch)				Ø 163.0 mm (6.42 inch)		117.0 mm (4.61 inch)	129.0 mm (5.08 inch)
EE	Ø 222.88 mm (8.775 inch)				Ø 162.87 mm (6.412 inch)		116.87 mm (4.601 inch)	128.87 mm (5.074 inch)
FF	12.7 mm (0.50 inch) X 45°
GG	58.0 ± 0.5 mm (2.28 ± 0.02 inch)						28.5 ± 0.5 mm (1.12 ± 0.02 inch)
HH Centering Pilot Only	Ø 22.5 mm (0.89 inch) 63.0 mm (2.48 inch) Deep 1-8-2B Thd 48.0 mm (1.89 inch) Deep						Ø 22.5 mm (0.86 inch) 65.0 mm (2.56 inch) Deep 1-8-2B Thd 48.0 mm (1.89 inch) Deep
JJ	26.7 mm (1.051 inch)						20.7 mm (0.815 inch)	15.7 mm (0.618 inch)

Note: The following salvage procedures cannot be used if the plate of the cylinder head is cracked. Replace any cylinder head with cracks in the plate.

1. Place the head into a good quality lathe. Position the head so that you can work on the stub shaft. The lathe should be capable of holding close tolerances. Use a dial indicator to make sure that the head is square with the cutting tool.

2. Use feeds and use speeds that are appropriate for the lathe. Make an extra light cut for cleanup. Make the cut 0.05 mm (0.0012 inch) to 0.13 mm (0.0051 inch).
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   Illustration 52	g03705593
   Head after the recess for the stub shaft or the pilot bore is machined.

3. Machine the recess for the pilot bore in the head. Use dimensions (EE) and (GG) in Table 21. There is an interference fit between the recess for the pilot bore and the base of the stub shaft.
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   Illustration 53	g03705598
   Cut a 45° chamfer at the top of the recess for the stub shaft.

4. Machine a chamfer at the top of the recess for the stub shaft. The chamfer should be cut at a 45° angle. The chamfer (FF) should also be at least 12.70 mm (0.5000 inch) long.

5. By using "SAE4130" steel, machine the stub shaft to the provided dimensions. Refer to Table 21. The base of the stub shaft must be sized for an 0.13 mm (0.0051 inch) interference fit with the recess for the stub shaft. The radii (AA) and (CC) must be smooth to prevent concentrations of stress.

6. After the stub shaft is machined, de-burr all sharp edges. Break all the sharp edges on the recess for the stub shaft. Thoroughly clean the machined surfaces on both parts after de-burring. Make sure that the recess for the stub shaft is free from dust and machine oil.

7. Place the head in a 55 ton hydraulic press. When full pressure is supplied, the supports must be strong enough to avoid the material from deflecting. Position the base of the stub shaft in the recess, and press until the stub shaft is fully seated.

8. Preheat the plate and the stub shaft to 260° ± 28°C (500° ± 50°F) to prepare for welding.
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   Illustration 54	g03705602
   Reconditioned head after the stub shaft is welded in place.

9. Weld the stub shaft in place and make the first weld pass at the root of the chamfer around the stub shaft. Then make two more passes to fill the remaining groove. Use ER-70S3 Wire (Electrode) to weld the plate and the stub shaft together.

10. Allow the plate and the stub shaft to cool slowly after welding. Then remove the scale and inspect the area around the weld.

793 Front Strut Suspension Cylinder Head Repair

Illustration 55	g06330256

During repairs to the front suspension cylinder group, closely inspect the stub shaft on the cylinder head. Under extreme service, the stub shaft may fatigue. The stub shaft may also fracture in the area of the fillet of the stub shaft.

Note: The following salvage procedure cannot be used if the plate of the suspension cylinder head is cracked. Replace any suspension cylinder head with cracks in the plate.

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Illustration 56	g06330277
Front suspension strut cylinder head nomenclature (A1) Stub Shaft (A2) Plate

1. Steam clean the head prior to inspection. Ensure that all grease, dirt, debris, and paint has been removed from the suspension cylinder head. Use a wire brush to remove any remaining scale or oxidation. Grease, dirt, debris, and paint can hinder the inspection, machining, and welding process that are listed in this procedure.
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   Illustration 57	g03705541
   Application of dye Penetrating Oil

2. Spray an inspection grade dye Penetrating Oil on the surface around the fillet. Start at the stub shaft and extend the coverage outward. Refer to Illustration 57.

3. Allow the dye Penetrating Oil to remain on the surface for 3 minutes. Use an absorbent cloth or paper towel to remove the dye Penetrating Oil from the head. There should not be any visible signs of the dye penetrant cleaner on the surface.
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   Illustration 58	g03705546
   Application of Developer

4. Spray a developer on the same surface areas that were sprayed with the cleaner. Refer to Illustration 58.
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   Illustration 59	g03705550
   Dye Penetrating Oil that is trapped in the crack will leak through the Developer.

5. If cracks are present, the Penetrating Oil that is trapped in the crack will leak through the developer. The Penetrating Oil will make the fracture visible. Refer to Illustration 59. Suspension Cylinder Heads that have cracks at the fillet of the stub shaft can be salvaged. The stub shaft must be removed. A new stub shaft must be machined and installed in the head.

   Note: The following salvage procedure cannot be used if the plate of the suspension cylinder head is cracked. Replace any suspension cylinder head with cracks in the plate.

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   Illustration 60	g06213894
   Suspension cylinder head lathe position

6. Install the front suspension cylinder head in to a suitable lathe. Position the head so you can work on the stub shaft. The lathe should hold close tolerances. Use a dial indicator to ensure that the suspension cylinder head is square with the cutting tool. Refer to Illustration 60 for proper orientation.
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   Illustration 61	g06213931
   (A) Stub shaft removal

7. For first-time repair of the Front Strut Suspension Cylinder Head, the recess for the pilot bore diameter is to be 223 mm (8.779 inch). The depth of the recess for the pilot bore is to be 50.8 ± 0.5 mm (2 ± 0.02 inch).

8. Remove the stub shaft. Use appropriate feeds and speeds for the lathe.
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   Illustration 62	g06214092

9. Machine the recess for the pilot bore in the head. The depth of the recess is 50.8 ± 0.5 mm (2 ± 0.02 inch). Refer to Illustration 62.
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   Illustration 63	g06214125

10. Feature (B) illustrates the separation between the previous stub shaft material and the plate. Ensure that all the previous stub shaft material has been removed and an extra 0.25 mm (0.010 inch) to 0.51 mm (0.020 inch) of plate material. Refer to Illustration 63.
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    Illustration 64	g06214145

11. Machine the (C) chamfer at the top of the recess of the plate for the stub shaft. The chamfer is to be cut at a 45° angle. Refer to Table Number 26 for the chamfer dimension. Refer to Illustration 64.
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    Illustration 65	g06214238

12. Mount in the lathe an equivalent to one of the following types of steel: 4140 Heat Treated Stress Relieved (HTSR), 42CrMo4, SCM440, or 42CrMo solid steel cylindrical stock 228.60 mm (9 inch) O.D. x 285.75 mm (11.25 inch) in length. Refer to Illustration 65.
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    Illustration 66	g06214242

13. Turn down a 150 mm (5.905 inch) length of the cylindrical stock to a diameter wide enough to create a 0.25 mm (0.010 inch) interference fit with the recess for the pilot bore in the machined head. [X + 0.25 mm (0.010 inch)]. X represents the inside diameter of the bore in the plate. For example where: X = 222.75 mm (8.770 inch) + 0.25 mm (0.010 inch) = 223 mm (8.780 inch). The result of the calculation will create an interference fit of 0.25 mm (0.010 inch). Refer to Illustration 66. Refer to Table 26 for dimensions.
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    Illustration 67	g06214285

14. Cut the chamfer into the cylindrical stock. The chamfer is to be cut at a 15° angle. Refer to Table 26 for the stub shaft chamfer dimension.
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    Illustration 68	g06214550

15. Place the plate on a brick lined or fire-proof table supported by three steel blocks. Refer to Illustration 68.
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    Illustration 69	g06214554
    Use an Infrared Thermometer Group to verify temperature

16. Place a (1) propane or oxygen acetylene torch under the plate to heat the plate to 315° C (600° F). Wrap the plate with weld blankets prior to operation of the propane or oxygen acetylene torch. Refer to Illustration 69.
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    Illustration 70	g06214645

17. Remove the top weld blanket to expose the recess bore of the plate only. Vacuum the recess bore of the plate to remove any debris. Ensure that the temperature is at or above 315° C (600° F). Refer to Illustration 70.
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    Illustration 71	g06214657

18. Lift the stub shaft with a magnetic lifting device. Lower the stub shaft in to the recess bore of the plate. Turn the stub shaft clockwise and counterclockwise to ensure that the stub shaft has seated to the bottom of the recess bore of the plate. Refer to Illustration 71.

    Note: The stub shaft is not to be heated prior to installation in to the recess bore of the plate. The stub shaft is to remain at room temperature.

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    Illustration 72	g06214664

19. Cover the plate and stub shaft with weld blankets and heat with a propane or oxygen acetylene torch to 260° C (500° F). Refer to Illustration 72.
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    Illustration 73	g06214670

20. Ensure the temperature of the stub shaft and plate are at 260° C (500° F). Tack weld the stub shaft to the plate in four places. Each weld tack is to be placed 90° apart. Tack weld the stub shaft to the plate in four extra places. Each ofthefouradditional tack welds are to be placed 90° apart in between the previous four tack welds. To equal a total of eight tack welds.
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    Illustration 74	g06218106
    Join the weld tacks

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    Illustration 75	g06218111
    First weld pass is completed, joining all the weld tacks to encompass the complete circumference of the stub shaft.

21. Join the weld tacks at the root of the chamfer around the complete circumference of the stub shaft. Refer to Illustrations 74 and 75. Refer to Table 22 for weld specifications.
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    Table 22

    Shielded Metal Arc Welding (SMAW)
    Electrode Diameter	AWS Class/Spec.	Amps (DCEP) Voltage
    2.4 mm (1/8 inch)	E7018 A5.1	120 A 36

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    Illustration 76	g06218116
    2 weld passes applied to complete second root pass

22. The second pass consists of two weld passes. Refer to Illustration 76. Refer to Table 23 for weld specifications.
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    Table 23

    Shielded Metal Arc Welding (SMAW)
    Electrode Diameter	AWS Class/Spec.	Amps (DCEP) Voltage
    4.0 mm (5/32 inch)	E7018 A5.1	150 A 36

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    Illustration 77	g06218121
    Third root pass

23. The third pass consists of one pass. Refer to Illustration 77. Refer to Table 24 for weld specifications.
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    Table 24

    Shielded Metal Arc Welding (SMAW)
    Electrode Diameter	AWS Class/Spec.	Amps (DCEP) Voltage
    4.8 mm (3/16 inch)	E7018 A5.1	200 A 36

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    Illustration 78	g06218126
    2 weld passes applied to complete fourth cap pass

24. The fourth cap pass consists of two weld passes. Refer to Illustration 78. Refer to Table 25 for weld specifications.
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    Table 25

    Shielded Metal Arc Welding (SMAW)
    Electrode Diameter	AWS Class/Spec.	Amps (DCEP) Voltage
    4.8 mm (3/16 inch)	E7018 A5.1	200 A 36

25. Cover the stub shaft and plate (front suspension cylinder head) with weld blankets. Allow the strut head to cool slowly. Remove any scale and inspect the weld area after the strut head has reached room temperature.
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    Illustration 79	g06218431
    Lathe rough cut

26. Install the front suspension cylinder head in to a good quality lathe. Position the head so that you can work on the stub shaft. The lathe should hold close tolerances. Use a dial indicator to ensure that the head is square with the cutting tool. Refer to Illustration 79 for proper orientation.

27. Initiate the rough cut of the front suspension cylinder head. Refer to Table 26 for dimensions.
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    Illustration 80	g06218480
    Final machining cut

    Note: Illustration 80 is for illustrative purposes only. Refer to Illustration 82 and Table 26 for head geometry.

28. Initiate the final cut of the front suspension cylinder head. The top of the strut plate has been turned down a minimal amount to remove weld spatter and reduce stress risers. Refer to Table 26 for dimensions.
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    Illustration 81	g06218866
    Stub shaft dimension prior to installation in to plate.

29. Illustration 81 calls-out the dimensions needed to machine the stub shaft prior to installation in to the plate. Refer to Table 26 for the (final cut) dimensions.
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    Illustration 82	g06332903
    Front suspension cylinder head dimensions (final cut)

30. Refer to Illustration 82 for the call-outs of the (final cut) dimensions of the front suspension cylinder head. Refer to Table 26 for the (final cut) dimensions.
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    Table 26

    Dimensions Required to Machine the Front Suspension Cylinder Head for 793 Off Highway Truck
    Assembly Part Number	9T-8910 284-8014 295-5706
    Head Part Number	6E-0730
    D	285.75 mm (11.250 inch)
    E	50.8 ± 0.25 mm (2.0 ± 0.010 inch)
    F	Feature "U" plus 0.25 mm (0.010 inch) for interference fit
    G	19 ± 0.25 mm (0.74803 ± 0.010 inch) X 15°
    H	270.00 ± 0.508 mm (10.630 ± 0.020 inch)
    J	124 ± 0.5 mm (4.881 ± 0.020 inch) surface finish of Ra 1.6 µm (63 µin)
    K	101.473 ± 0.0762 mm (3.995 ± 0.003 inch)
    L	6 ± 0.5 mm (0.236 ± 0.020inch) X 30°
    M	Ø 22.5 mm (0.89 inch) 63.0 mm (2.48 inch) Deep 1-8-2B Thd 48.0 mm (1.89 inch) Deep
    N	R75 ± 0.5 mm (2.952 ± 0.020 inch) surface finish of Ra 1.6 µm (63 µin)
    P	R32 ± 0.5 mm (1.259 ± 0.020inch)
    R	Radius center located 111.5 ± 0.5 mm (4.389 ± 0.020 inch) from center-line
    S	17.78 ± 0.25 mm (0.70000 ± 0.010 inch) x 45°
    T	58 ± 0.5 mm (2.283 ± 0.02 inch)
    U	First rework should be 223 mm (8.779 inch) Bore Diameter. For each additional rework increase the diameter of the bore by 0.25 mm (0.010 inch) to 0.51 mm (0.020 inch).
    V	50.8 ± 0.5 mm (2.0 ± 0.020 inch)

31. Remove any rough edges or burrs after (final cut) machining.

32. Paint only the exterior of the front suspension cylinder head. Do not paint the interior, apply rust preventative to the interior of the front suspension cylinder head.

Crack Detection Methods

There are seven major crack detection methods or Non-Destructive Testing (NDT) listed in this section: Visual Surface Inspection (VT), Liquid Penetrant Testing (PT), Dry / Wet Magnetic Particle Testing (MPT), Ultrasonic Testing (UT), Radiographic Testing (RT), and Eddy-Current Testing (ET).

Crack detection methods or NDT is methods for testing components for cracks without damaging the component. VT, PT, Dry/ Wet, and MPT are methods recommended. There may be more than one acceptable crack detection method for the testing of a given part, although PT is the most versatile. For example, the PT method can be used when testing smooth machined components such as shafts, gear teeth, and splines, but using the Wet MPT is more accurate. Refer to Table 27 for advantages and disadvantages and Table 28 for standards and requirements for these NDT methods.

Table 27

Crack Inspection Method Advantages vs. Disadvantages
Inspection Method	Advantages	Disadvantages
Visual Surface Inspection (VT)	- Least expensive - Detects most damaging defects - Immediate results - Minimum part preparation	- Limited to surface-only defects - Requires inspectors to have broad knowledge of welding and fabrication in addition to NDT
Liquid Penetrant (PT)	- Inexpensive - Minimal training - Portable - Works on nonmagnetic material	- Least sensitive - Detects surface cracks only - Rough or porous surfaces interfere with test
Dry Magnetic Particle (MT)	- Portable - Fast/Immediate Results - Detects surface and subsurface discontinuities	- Works on magnetic material only - Less sensitive than Wet Magnetic Particle
Wet Magnetic Particle (MT)	- More sensitive than Liquid Penetrant - Detects subsurface as much as 0.13 mm (0.005 inch)	- Requires Power for Light - Works on magnetic parts only - Liquid composition and agitation must be monitored

Table 28

Applicable Crack Detection Standards
Type	Standard	Acceptance Criteria	Recommended Practice	Minimum Required Personnel Qualifications
Visual Surface Inspection (VT)	EN-ISO 5817 AWS D1.1	EN-ISO 5817 - Level B AWS D1.1 - Table 6.1	ANSI-ASNT SNT-TC-1A	EN-ISO 9712
Liquid Penetrant Testing (PT)	EN-ISO 3452 ASTM E165	EN-ISO 23277 AWS - D1.1	ANSI-ASNT SNT-TC-1A	EN-ISO 9712
Magnetic Particle Testing (MT)	EN-ISO 17638 ASTM E709	EN-ISO 23278 - Level 1 AWS D1.1 - Table 6.1	ANSI-ASNT SNT-TC-1A	EN-ISO 9712
Ultrasonic Testing (UT)	EN-ISO 17640 - Level B AWS D1.1	EN-ISO 11666 Technique 2 - Level 2 AWS D1.1 - Class A - Table 6.3	ANSI-ASNT SNT-TC-1A	EN-ISO 9712
Eddy Current Testing (ET)	EN-ISO 15549 ASTM E426	EN-ISO 20807	ANSI-ASNT SNT-TC-1A	EN-ISO 9712
Radiographic Testing (RT)	EN-ISO 5579 ASTM E94	EN-ISO 10657-1	ANSI-ASNT SNT-TC-1A	EN-ISO 9712

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NOTICE
Regardless of which crack detection method is used, ensure the instructions furnished with the detection equipment are followed closely when checking any component. Failure to do so may cause inaccurate results or may cause injury to the operator and/or surroundings.

Visual Surface Inspection (VT)

Illustration 83	g06085008
Example of Visual Inspection Tools (A) Flashlight or adequate light source (B) Magnifying eye loupe (C) Tape measure or other measuring device (D) Inspection mirror (E) Weld size inspection gauges

Components and welds that are to be inspected using PT, MT, or UT shall first be subject to visual inspection (VT). Visual Inspection is often the most cost-effective inspection method and requires little equipment as seen in Illustration 83. It is suggested that at a minimum personnel performing Visual Inspection are either trained to a company standard or have sufficient experience and knowledge about the components being inspected. It is also suggested that personnel performing visual inspections take some type of eyesight test regularly.

Liquid Penetrant Testing (PT)

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

• Penetrant: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrant indications.

• Wire Brush: Removes dirt and paint.

• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure

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Illustration 84	g06107074
Typical example of pre-cleaning area.

1. Preclean inspection area. Spray on cleaner / remover to loosen any scale, dirt, or any oil. Wipe the area to inspect with a solvent dampened cloth to remove remaining dirt and allow the area to dry. If there is visible crack remove paint using paint remover or wire brush.
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   Illustration 85	g06107081
   Typical example of applying penetrant.

2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to soak. After the penetrant has been allowed to soak, remove the excess penetrant with clean, dry wipe.
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   Illustration 86	g06107088
   Typical example of removing excess penetrant.

3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
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   Illustration 87	g06107094

4. Before using developer, ensure that the developer is mixed thoroughly by shaking can. Hold thecan approximately 8-12 inches away from part, apply an even, thin layer of developer over the area being inspected. A few thin layers are a better application method than one thick layer.
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   Illustration 88	g06084042
   Typical example of cracks found during a liquid penetrant examination.

5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines in white developer background, refer to Illustration 88. Clean the area of application of the developer with solvent cleaner.

Dry Magnetic Particle Testing (MT)

Materials and Equipment Required

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 89	g06085930
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (C) Dry powder bulb.

1. Dry magnetic powder shall be of high permeability and low retentively and of suitable sizes and shapes to produce magnetic particle indications. The powder shall be of a color that will provide adequate contrast with the background of the surface being inspected.

2. Dry magnetic particles shall be stored in suitable containers to resist contamination such as moisture, grease, oil, non-magnetic particles such as sand, and excessive heat. Contaminants will manifest in the form of particle color change and particle agglomeration. The degree of contamination will determine further use of the powder.

3. Dry magnetic powder shall be tested in accordance with ASTM E709 Section 18 (Evaluation of System Performance/Sensitivity) when not performing.

4. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

5. Check dry powder blower routinely to ensure that the spray is a light, uniform, dust-like coating of the dry magnetic particles. Blower should also have sufficient force to remove excess particles without disturbing those particles that are evidence of indications.

6. All equipment shall be inspected at a minimum of once a year or when accuracy is questionable.

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and other contaminants.

2. Apply the magnetic field using the yoke against the faces and inside diameter of each bore.

3. Simultaneously apply the dry powder using the dry powder blower.

4. Remove excess powder by lightly blowing away the dry particles.

5. Continue around the entire circumference of each bore. Position the yoke twice in each area at 1.57 rad (90°) to ensure that multiple directions of the magnetic field are created.

6. Observe particles and note if any clusters of particles appear revealing an indication.

7. Record the size and shape of any discontinuities or indications found.

Wet Magnetic Particle Testing (MT)

Materials and Equipment

Refer to Tooling and Equipment Table 3 for part numbers.

Illustration 90	g06085937
(A) Indications shown by magnetic particle testing. (B) Typical electromagnetic yoke. (D) UV Lamp used in wet magnetic particle inspection process.

Illustration 91	g06003178
Pear Shaped Centrifuge Tube

1. Wet magnetic particles are fluorescent and are suspended in a vehicle in a given concentration that will allow application to the test surface by spraying.

2. Concentration:

   1. The concentration of the suspended magnetic particles shall be as specified by the manufacturer and be checked by settling volume measurements.

   2. Concentrations are determined by measuring the settling volume by using an ASTM pear shaped centrifuge tube with a 1 mL (0.034 oz) stem with 0.05 mL (0.0017 oz) 1.0 mL (0.034 oz) divisions, refer to Illustration 91. Before sampling, the suspension shall be thoroughly mixed to assure suspension of all particles, which could have settled. A 100 mL (3.40 oz) sample of the suspension shall be taken and allowed to settle for 30 minutes. The settling volume should be between 0.1 mL (0.0034 oz) and 0.25 mL (0.0085 oz) in a 100 mL (3.40 oz) sample.

   3. Wet magnetic particles may be suspended in a low viscosity oil or conditioned water.

   4. The oil shall have the following characteristics:

      • Low viscosity not to exceed 50 mSt (5.0 cSt) at any temperature at which the vehicle is to be used.

      • Low inherent fluorescence and be non-reactive.

   5. The conditioning agents used in the conditioned water shall have the following characteristics:

      • Impart good wetting characteristics and good dispersion.

      • Minimize foaming and be non-corrosive.

      • Low viscosity shall not exceed a maximum viscosity of 50 mSt (5.0 cSt) at 38° C (100° F).

      • Non-fluorescent, non-reactive, and odorless.

      • Alkalinity shall not exceed a pH of 10.5.

3. Equipment should include a "U" shaped electromagnetic yoke made from highly permeable magnetic material, which has a coil wound around the yoke. This coil carries a magnetizing current to impose a localized longitudinal magnetic field into the part. The magnetizing force of the yoke is related to the electromagnetic strength and can be tested by determining the lifting power of a steel plate. The yoke shall have a lifting force of at least 4.5 kg (10 lbs).

Procedure

1. Ensure surface to be inspected is dry and free from oil, grease, sand, loose rust, mil scale, paint, and any other contaminants.

2. Apply the magnetic field using the yoke against the surface in the area to be inspected.
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   Illustration 92	g03536210

3. For case hardened and ground surfaces:

   • Due to the sensitivity required to locate the grinding cracks, inspection of case hardened and ground surfaces require that the yoke is applied so that the magnetic field is 1.57 rad (90°) to the expected direction of the indications. Also, due to the increased sensitivity resulting when the yoke is energized, the yoke is not moved until the evaluation is completed in the first direction. An AC yoke shall be used. See Illustration 92 for an example of yoke placement.

4. Visually inspect for indications of discontinuities using the proper illumination.

5. Record the size and shape of any discontinuities found.

Ultrasonic Testing (UT)

Refer to Tooling and Equipment Table 3 for part numbers.

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NOTICE
All personnel involved in ultrasonic examinations shall be qualified to Level 2 in accordance to standards stated in Table 28.

1. Ultrasonic testing (UT) is a method of Non-Destructive Testing (NDT) using short ultrasonic pulse waves (with frequencies from 0.1-15 MHz up to 50 MHz) to detect the thickness of the object. Ultrasonic testing consists of an ultrasound transducer connected to a diagnostic machine and passed over the object being inspected.

2. There are two methods of receiving the ultrasound waveform from the transducer: reflection and attenuation.

   a. Reflection - Ultrasonic pulses exit the transducer and travel throughout the thickness of the material. When the sound waves propagate into an object being tested, the waves return to the transducer when a discontinuity is discovered along the sonic path. These waves continue and reflect from the back surface of the material to project the thickness of the material.

   b. Attenuation - A transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Any discontinuities or other conditions within the medium will reduce the amount of sound transmitted, revealing the presence of the imperfections.

Eddy Current Testing

Illustration 93	g06090873
Eddy-current testing

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NOTICE
All personnel involved in Eddy Current examinations shall be qualified to Level 2 in accordance to standards stated in Table 28.

Eddy-current testing (ET) is a Non-Destructive Testing (NDT) method in which eddy-current flow is induced in the test object. Changes in the flow caused by variations in the specimen are reflected in to a nearby coil or coils for subsequent analysis by suitable instrumentation and techniques. Major applications of eddy-current testing are surface inspection and tubing inspections.

Radiographic Testing

Illustration 94	g06090892
Radiographic Testing

All personnel involved in radiographic examinations shall be qualified to Level 2 in accordance to standards stated in Table 28.

Illustration 95	g00008666

This process is dangerous. Only qualified personnel and test equipment should be appointed to perform this type of testing.

Radiographic testing (RT) is a Non-Destructive Testing (NDT) method in which short wavelength of electromagnetic radiation is used to penetrate materials to find hidden discontinuities such as cracks. In radiographic testing, the test object is placed between the radiation source and the film, or x-ray detector. The electromagnetic radiation will penetrate the thickness of the test object and, when all the way through, will project onto the film any indications that have been in the path of the radiation waves.