Machining the O-ring Groove into the Face of Oversized Bolted Head Hydraulic Cylinders {0677, 5100, 7562} Caterpillar

Machining the O-ring Groove into the Face of Oversized Bolted Head Hydraulic Cylinders {0677, 5100, 7562}

Usage:

769C 01X

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Introduction

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Table 1
Revision	Summary of Changes in SEBF8208
23	Updated Effectivity
22	Updated Effectivity
21	Updated Effectivity
20	Updated Effectivity

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar Dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

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

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Canceled Part Numbers and Replaced Part Numbers

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

Summary

The head seal for the oversize bolted-head cylinder was the oval seal that is used in an oversize threaded-crown cylinder. The oval seal was located at the lead-in chamfer that is located at the open end of the cylinder tube. In certain applications, this oval seal could leak.

Oversized bolted-head cylinders or any bolted-head cylinder that had chronic head seal leakage can now be sealed by using an O-ring that is located at the head joint. This O-ring provides a more effective seal than the oval head seal. The groove for the stock seal is left empty.

Note: Most oversized seal kits include both the oval seal and the O-ring seal. Also, current bolted-head cylinders from the Caterpillar Reman program receive the groove for the O-ring as part of the remanufacturing process.

Note: Some cylinder assemblies have been dealer reworked to add the O-ring groove to the flange face of the head rather than the cylinder. Do not assemble a cylinder that would mate a cylinder and head both having an O-ring groove.

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Illustration 1	g01648953
Bolted head with face O-ring seal. (1) Flange (2) Groove for Face O-Ring Seal (3) Head (4) Face O-ring Seal (5) Location of Stock Seal (6) Former location of Oval Seal

Important Safety Information

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Illustration 2	g02139237

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.

Improper operation, lubrication, maintenance, or repair of this product is dangerous. Improper methods could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair of this product, until you understand 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.

Hazards are identified by a safety alert symbol. Safety alert symbols are followed by a signal word such as "Warning" that is shown below.

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Illustration 3	g01032906

The following is the meaning of this safety alert symbol:

Pay attention!
Become Alert!
Your safety is involved

The message that appears under the warning explains the hazard. The message will be written or pictorially shown.

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. Therefore, the warnings in this publication and on the product are not all inclusive. If a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar is used, ensure that all personnel around the machine are safe. Ensure that the product will not be damaged or that the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures.

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

Safety

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine.

To prevent possible injury, perform the procedure that follows before testing and adjusting the steering system.

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Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

References

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Table 2
References
Media	Title
NENG2500	"Dealer Service Tool Catalog"
SEBF8357	"General Cleaning Methods"

Equipment Needed

The O-ring groove can be machined by using several different processes and machine tools. Most machine shops will use either a horizontal mill or a lathe that is equipped with a four-jaw chuck and a steady rest. The four-jaw chuck and steady rest is used because of the need to center the cylinder assembly in the lathe when machining the different cylinder end cap configurations.

O-ring Groove Dimensions

Bolt-on head cylinder assemblies that have been honed oversize but lack the flange face O-ring groove can be reworked to add the groove. Machine new grooves according to the dimensions in Table 3. Make the groove concentric and perpendicular to the center-line of the bore. If the flange face of the cylinder assembly is damaged, the cylinder can be salvaged by machining away a maximum of 3.0 mm (0.112 inch) from the face. If the damaged face has the O-ring groove, the groove must be machined deeper by the amount removed from the flange face.

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Illustration 4	g02156051
Seal Groove Width Dimensions. Refer to Table 2 for item references and dimensions.

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Table 3
Seal Part Numbers and Machining Dimensions
Nominal Bore Diameter	O-ring Part Number	Groove Diameter (A)	Groove Width (B)	Groove Depth (C)	Radius (D)
76.20 mm (3.000 inch)	5P-2931	87.12 ± 0.51 mm (3.430 ± 0.020 inch)	2.40 ± 0.05 mm (0.094 ± 0.002 inch)	1.32 ± 0.05 mm (0.052 ± 0.002 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
88.90 mm (3.500 inch)	4F-4097	101.95 ± 0.51 mm (4.014 ± 0.020 inch)	3.53 ± 0.08 mm (0.139 ± 0.003 inch)	1.95 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.10 mm (0.016 ± 0.004 inch)
95.25 mm (3.750 inch)	7X-5494	106.30 ± 0.51 mm (4.185 ± 0.020 inch)	2.40 ± 0.05 mm (0.095 ± 0.002 inch)	1.33 ± 0.05 mm (0.052 ± 0.002 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
101.60 mm (4.000 inch)	9X-7357	112.52 ± 0.50 mm (4.431 ± 0.019 inch)	2.40 ± 0.05 mm (0.095 ± 0.002 inch)	1.33 ± 0.05 mm (0.052 ± 0.002 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
107.95 mm (4.250 inch)	6S-3002	121.00 ± 0.50 mm (4.764 ± 0.020 inch)	3.53 ± 0.08 mm (.139 ± 0.003 inch)	1.96 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
114.30 mm (4.500 inch)	9X-7566	127.35 ± 0.51 mm (5.014 ± 0.020 inch)	3.53 ± 0.08 mm (.139 ± 0.003 inch)	1.96 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
120.00 mm (4.724 inch)	133-0128	136.00 ± 0.50 mm (5.350 ± 0.020 inch)	3.53 ± 0.08 mm (.139 ± 0.003 inch)	1.96 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
120.65 mm (4.750 inch)	3F-5792	136.45 ± 0.50 mm (5.372 ± 0.02 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
127.00 mm (5.000 inch)	131-3716	137.92 ± 0.50 mm (5.430 ± 0.020 inch)	2.40 ± 0.05 mm (0.094 ± 0.002 inch)	1.33 ± 0.05 mm (0.052 ± 0.002 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
133.35 mm (5.250 inch)	2D-8009	149.15 ± 0.50 mm (5.872 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
139.70 mm (5.500 inch)	9X-7358	152.76 ± 0.50 mm (6.015 ± 0.020 inch)	3.53 ± 0.08 mm (0.138 ± 0.003 inch)	1.96 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
140.00 mm (5.512 inch)	2K-8257	155.50 ± 0.50 mm (6.122 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
152.40 mm (6.000 inch)	8T-6404	165.46 ± 0.50 mm (6.514 ± 0.020 inch)	3.53 ± 0.08 mm (0.138 ± 0.003 inch)	1.95 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
158.75 mm (6.250 inch)	9X-7391	171.81 ± 0.50 mm (6.764 ± 0.020 inch)	3.53 ± 0.08 mm (0.138 ± 0.003 inch)	1.96 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
160.00 mm (6.299 inch)	9D-8042	176.15 ± 0.50 mm (6.935 ± 0.020 inch)	3.53 ± 0.08 mm (0.138 ± 0.003 inch)	1.96 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
165.10 mm (6.500 inch)	9D-8042	179.17 ± 0.50 mm (7.054 ± 0.020 inch)	3.53 ± 0.08 mm (0.138 ± 0.003 inch)	1.95 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
170.00 mm (6.693 inch)	9X-7725	187.50 ± 0.50 mm (7.382 ± 0.020 inch)	3.53 ± 0.08 mm (0.138 ± 0.003 inch)	1.96 ± 0.08 mm (0.077 ± 0.003 inch)	0.40 ± 0.05 mm (0.016 ± 0.002 inch)
177.80 mm (7.000 inch)	5J-2383	198.98 ± 0.50 mm (7.834 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
180.00 mm (7.087 inch)	5J-2383	196.50 ± 0.50 mm (7.736 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
184.15 mm (7.250 inch)	5J-2383	198.98 ± 0.50 mm (7.834 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
190.50 mm (7.500 inch)	3J-0634	211.68 ± 0.50 mm (8.334 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
196.85 mm (7.750 inch)	3J-0634	209.47 ± 0.50 mm (8.247 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
200.00 mm (7.874 inch)	5P-3092	225.00 ± 0.50 mm (8.858 ± 0.020 inch)	7.40 ± 0.20 mm (0.291 ± 0.008 inch)	3.95 ± 0.20 mm (0.156 ± 0.008 inch)	1.60 ± 0.40 mm (0.063 ± 0.016 inch)
209.55 mm (8.250 inch)	4K-6804	224.38 ± 0.50 mm (8.834 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
215.90 mm (8.500 inch)	1T-0132	241.22 ± 0.50 mm (9.496 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
220.00 mm (8.661 inch)	1M-9015	253.92 ± 0.50 mm (9.997 ± 0.020 inch)	9.35 ± 0.25 mm (0.368 ± 0.010 inch)	5.25 ± 0.20 mm (0.207 ± 0.008 inch)	1.60 ± 0.40 mm (0.063 ± 0.016 inch)
234.95 mm (9.250 inch)	5S-3676	253.92 ± 0.50 mm (9.997 ± 0.020 inch)	4.75 ± 0.13 mm (0.187 ± 0.005 inch)	2.64 ± 0.13 mm (0.104 ± 0.005 inch)	0.80 ± 0.20 mm (0.030 ± 0.007 inch)
254.00 mm (10.000 inch)	3S-3074	276.15 ± 0.50 mm (10.872 ± 0.020 inch)	7.40 ± 0.20 mm (0.291 ± 0.008 inch)	3.95 ± 0.20 mm (0.156 ± 0.008 inch)	1.60 ± 0.40 mm (0.063 ± 0.016 inch)
266.70 mm (10.500 inch)	5P-2236	288.85 ± 0.50 mm (11.372 ± 0.020 inch)	7.40 ± 0.20 mm (0.291 ± 0.008 inch)	3.95 ± 0.20 mm (0.156 ± 0.008 inch)	1.60 ± 0.40 mm (0.063 ± 0.016 inch)
279.40 mm (11.000 inch)	130-9108	310.50 ± 0.50 mm (12.224 ± 0.0197 inch)	7.40 ± 0.20 mm (0.291 ± 0.008 inch)	3.95 ± 0.20 mm (0.156 ± 0.008 inch)	1.60 ± 0.40 mm (0.063 ± 0.016 inch)
292.10 mm (11.500 inch)	6V-3263	314.25 ± 0.50 mm (12.372 ± 0.020 inch)	7.40 ± 0.20 mm (0.291 ± 0.008 inch)	3.95 ± 0.20 mm (0.156 ± 0.008 inch)	1.60 ± 0.40 mm (0.063 ± 0.016 inch)
317.50 mm (12.500 inch)	130-9109	360.50 ± 0.50 mm (14.193 ± 0.020 inch)	7.40 ± 0.20 mm (0.291 ± 0.008 inch)	3.95 ± 0.20 mm (0.156 ± 0.008 inch)	1.60 ± 0.40 mm (0.063 ± 0.016 inch)
330.20 mm (13.000 inch)	130-9109	360.50 ± 0.50 mm (14.193 ± 0.020 inch)	7.40 ± 0.20 mm (0.291 ± 0.008 inch)	3.95 ± 0.20 mm (0.156 ± 0.008 inch)	1.60 ± 0.40 mm (0.063 ± 0.016 inch)
342.90 mm (13.500 inch)	130-9110	381.50 ± 0.50 mm (15.020 ± 0.020 inch)	7.40 ± 0.20 mm (0.291 ± 0.008 inch)	3.95 ± 0.20 mm (0.156 ± 0.008 inch)	1.60 ± 0.40 mm (0.063 ± 0.016 inch)