Measuring Bores and Installing Seals in Standard and Oversized Hydraulic Cylinders

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Reuse And Salvage Guidelines

Measuring Bores and Installing Seals in Standard and Oversized Hydraulic Cylinders
{5100, 7562}
Media Number -SEHS8630-09 Publication Date -03/04/2013 Date Updated -03/04/2013
i05295229
Measuring Bores and Installing Seals in Standard and

Oversized Hydraulic Cylinders{5100, 7562}
SMCS - 5100; 7562
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Introduction
Table 1
Revision Summary of Changes in SEHS8630
09 Updated Effectivity.
06 - 08 Updated Effectivity.
Removed reference to canceled tooling 8T-9011 Component Cleaner

05
Added Introduction and Important Safety Information
© 2013 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.
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 form for feedback in
the Service Information System. To address an urgent issue, use the following resources to
communicate your request to Caterpillar Repair Process Engineering:
• Caterpillar Dealer Technical Communicator
• Dealer Solution Network
• Caterpillar Technical Representative
• Knowledge Network
Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on
SIS for information about canceled part numbers and replaced part numbers. NPR will provide the
current part numbers for replaced parts
Summary
This instruction provides the necessary procedure for measuring the cylinder bore to determine if
the dimension is inch or metric. This instruction helps decide whether the bore requires standard
or oversize seals and the procedure for installing the seals.
Since there is the possibility that the cylinder bore could have been honed oversized, determine a
tube bore size prior to installing new seals. Also, many cylinders from Caterpillar and other
suppliers are designed using metric dimensions. Knowing if the bore is inch or metric, new,
standard, or oversize when selecting and installing seals is important.
If you are not certain of the bore size, examine the tube for one or more of the following:
• A plate attached to the O.D. of the tube near the open end. The plate will have raised
characters indicating the oversize amount along with an "0R" part number.
• Characters stamped into the casting at the closed end of the tube that indicate the oversize
amount.
You will have to measure the bore of the cylinder if the previous two methods of identification are
not present.
Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by
recognizing potentially hazardous situations before an accident occurs. A person must be alert to
potential hazards. This person should also have the necessary training, skills, and tools to perform
these functions properly. Safety precautions and warnings are provided in this instruction and on
the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or
to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a
potential hazard. Therefore, the warnings in this publication and the warnings that are on the
product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is
not recommended by Caterpillar is used, ensure that the procedure is safe for you and for other
people to use. Ensure that the product will not be damaged or be made unsafe by the operation,
lubrication, maintenance, or the repair procedures.
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 1 g00008666
This safety alert symbol means:
Pay attention!
Become alert!
Your safety is involved.
The message that appears under the safety alert symbol explains the hazard.
Operations that may cause product damage are identified by "NOTICE" labels on the product and
in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential
hazard. The safety information in this document and the safety information on the machine
are not all inclusive. Determine that the tools, procedures, work methods, and operating
techniques are safe. Determine that the operation, lubrication, maintenance, and repair
procedures will not damage the machine. Also, determine that the operation, lubrication,
maintenance, and repair procedures will not make the machine unsafe.
The information, the specifications, and the illustrations that exist in this guideline are based on
information which was available at the time of publication. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes
can affect the service that is given to the product. Obtain the complete, most current information
before you start any job. Caterpillar dealers can supply the most current information.
Safety
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.
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.
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, NENG2500, "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
Table 2
Media Number Title
NENG2500 "Dealer Service Tool Catalog"
Determining the Bore Size

First measure the cylinder bore and convert the measured diameter to inches or metric. This
procedure will help you to determine whether the bore is inch or metric, or if the cylinder is using
standard or oversized seals. Refer to the following list and the following table.
English (Inch) Cylinders

• The bore diameters of English (inch) cylinders increase in size by nominal values of 0.250
inch. (Examples 7 inch, 7.25 inch, 7.5 inch, 7.750 inch)
• New English (inch) cylinders from the factory have bores that are no larger than 0.005
inches larger than the nominal size. (Examples: 7.005 inches, 7.255 inches, 7.505 inches,
7.755 inches)
• New English (inch) cylinders can be honed up to 0.010 inches over the new (nominal) size
and still use standard-size seals. (Examples 7.010 inches, 7.260 inches, 7.510 inches, 7.760
inches)
• English (inch) size cylinders can be honed 0.030 inches over the standard nominal size and
be resealed by using oversized seals. (Examples : 7.030 inches, 7.280 inches, 7.530 inches,
7.780 inches)
• Once the cylinder has been honed 0.030 inches over the standard nominal size, the cylinder
can be honed an additional 0.010 inches and use oversized seals. Once the bore size has
reached 0.040 inches over the standard nominal size, the cylinder must be retubed or
replaced.
Note: Check the availability of oversized seal kits before honing your cylinder bore oversized.
Metric Cylinders
• The bore diameters of metric cylinders increase in size by nominal values of 5 mm or 10
mm. (Examples: 115 mm, 120 mm, 130 mm, 140 mm)
• New metric cylinders from the factory have bores that are no larger than 0.10 mm larger
than the nominal size. (Examples 115.10 mm, 120.10 mm, 130.10 mm, 140.10 mm)
• New metric cylinders can be honed up to 0.254 mm over the new (nominal) size and still
use standard-size seals. (Examples 115.254 mm, 120.254 mm, 130.254 mm, 140.254 mm)
• Metric size cylinders can be honed 0.762 mm over the standard nominal size and be
resealed by using oversized seals. (Examples 115.762 mm, 120.762 mm, 130.762 mm,
140.762 mm)
Note: Check the availability of oversized seal kits before honing your cylinder bore oversized.
Bore Sizes Chart

Table 3
Inch and Metric Bore Sizes
Inch Bore Metric Bore 0.25 mm (0.010 inch)

Size Size Oversized Bore Dimension 0.76 mm (0.030 inch)
Oversized Bore Dimension
2.250
-
inches 57.40 mm (2.260 inch) 57.91 mm (2.280 inch)
2.500
-
2.750
-
3.000
-
3.250
-
3.500
-
- 90 mm
90.25 mm (3.553 inch) 90.76 mm (3.573 inch)
3.750
inches - 95.50 mm (3.760 inch) 96.01 mm (3.780 inch)
- 100 mm
100.25 mm (3.947 inch) 100.76 mm (3.967 inch)
4.000
-
4.250
-
- 110 mm
110.25 mm (4.340 inch) 110.76 mm (4.360 inch)
4.500
- 115 mm
115.25 mm (4.537 inch) 115.76 mm (4.557 inch)
- 120 mm
120.25 mm (4.734 inch) 120.76 mm (4.754 inch)
4.750
-
- 125 mm
125.25 mm (4.9312 inch) 125.76 mm (4.951 inch)
5.000
130 mm
130.25 mm (5.128 inch) 130.76 mm (5.148 inch)
5.250
-
5.500
-
- 140 mm
140.25 mm (5.521 inch) 140.76 mm (5.541 inch)
- 150 mm
150.25 mm (5.916 inch) 150.76 mm (5.935 inch)
6.000
-
6.250
160 mm
160.25 mm (6.309 inch) 160.76 mm (6.329 inch)
6.5000 - 165.35 mm (6.510 inch) 165.86 mm (6.530 inch)
- 170 mm
170.25 mm (6.703 inch) 170.76 mm (6.723 inch)
7.000
-
- 180 mm
180.25 mm (7.097 inch) 180.76 mm (7.116 inch)
7.250
-
7.500
- 190 mm
190.25 mm (7.4903 inch) 190.76 mm (7.510 inch)
7.750 -
200 mm
200.25 mm (7.884 inch) 200.76 mm (7.904 inch)
8.250
-
8.500
220 mm
220.25 mm (8.671 inch) 220.76 mm (8.691 inch)
9.250 -
10.00
-
10.250
-
10.500
-
11.000
-
11.500
12.250
-
12.500
13.000
-
13.250
-
14.250
-
14.750
-
16.750
Measuring Examples
• The measured bore size is 158.93 mm (6.257 inch) in diameter. This bore is not metric
because this measurement is not close to the standard or oversized metric diameter as found
in the chart. This cylinder is English (inch) with a standard bore size of 6.250 inches. The
bore is oversized 0.007 inches and the cylinder is not new because it is more than 0.005
inches larger than the standard (nominal) size. This cylinder can still be honed up to 0.003
inches more in diameter and use the standard seals.
• The measured bore size is 165.86 mm (6.530 inch). The bore is not metric because the bore
is more than 0.10 mm larger than the standard (nominal) bore size of 165 mm. This bore is a
6.500 inch cylinder that has been honed exactly 0.030 inches oversized. This cylinder will
still use the oversized seals.
• The measured bore size is 120.76 mm (4.754 inch). This bore could be metric because the
bore is exactly 0.76 mm (0.030 inch) oversized for a metric cylinder. However, this bore is a
new English (inch) bore. The bore is less than 0.005 inches larger than the standard nominal
bore size of 4.750 inches. This bore can be honed up to 4.760 inches and still use standard
seals.
• The measured bore size is 160.02 mm (6.300 inch). This bore is metric because the bore
diameter is too large to be an oversized English (inch) cylinder and too small to be a new
English (inch) cylinder. Also, this bore is less than 0.10 mm larger than the standard
(nominal) 160 mm bore.
Head Seal Locations
D8T TRACK-TYPE TRACTOR J8B00001-UP (MACHINE) POWERED BY C15 ... Page 10 of 14
Threaded gland with standard head seal
The head seal for the oversize threaded gland cylinder is the standard O-ring and back-up ring (1).
Threaded crown with oval seal
The head seal for the oversize threaded-crown cylinder is an oval cross-section seal (2) that locates
in the lead-in chamfer at the open end of the cylinder. The O-ring and back-up ring groove (A) in
the head is left empty
Formerly, the head seal for the oversize bolted-head cylinder was the same oval seal (6) that is
used in an oversize threaded-crown cylinder. The oversize bolted-head cylinder is now sealed at
the head joint (3) by an O-ring (4). This O-ring (4) provides a more effective seal than the oval
head seal. The groove (5) for the stock seal is left empty.
Seal Installation Information

Rod Seal Installation
Illustration 5
1. Install buffer seal (2) by hand. The sealing lip of the buffer seal should face the pressure
side of the cylinder. The seal will take on a kidney shape during installation. Then, install
the back-up ring (3). The backup ring should be installed closest to the rod eye end. Make
sure that you do not twist the back-up ring.
2. Install the U-cup seal (6) next. Install the U-cup seal by hand. The "U" of the U-cuped seal
should face toward the piston.
3. The head wear ring (1) is rigid and the wear ring is split to aid in assembly. Compress head
wear ring (1) and slide the head wear ring down into position until the wear ring snaps into
place.
a. Use the following procedure to install wiper seal (8) .
Note: The wiper seal (8) can be a press-in style that uses a metal shell or the wiper
seal can be a snap-in style. The snap-in style does not require the use of bearing
mount compound.
b. Scuff the surface of the counterbore in the head as well as the outside diameter of the
wiper seal's (8) metal shell with emery cloth.
c. Clean the counterbore in the head and the outside diameter of the wiper seal metal
shell with 6V-1541 Quick Cure Primer . Clean the counterbore and the metal shell
until neither of the components discolor a clean white towel.
Note: The metal shell of the wiper seal is coated with a corrosion inhibitor. This
coating may prevent proper bonding of the wiper seal to the cylinder head if the
inhibitor is not removed. After cleaning, do not touch the counterbore or the metal
shell because the oil from your fingers may prevent a good bond. Handle the seal by
the lip only.
d. Apply 6V-1541 Quick Cure Primer on the counterbore and the metal shell. Allow the
primer to dry. The primer will dry in approximately 30 seconds.
e. Apply 7M-7456 Bearing Mount Compound evenly but do not apply the Bearing
Mount Compound excessively. Apply Bearing Mount Compound to the counterbore
and to the metal shell. Do NOT allow the Bearing Mount Compound to contact the
sealing lip.
f. Press wiper seal (8) into the cylinder head. Refer to Item (B) to make sure that the
marking "THIS SIDE OUT" on the seal is toward the rod end. Ensure that the seal is
firmly seated against the bottom of the counterbore. Wipe away any excess Bearing
Mount Compound. Allow Bearing Mount Compound to dry for 15 minutes before
assembling the hydraulic cylinder.
4. Assemble the oval seal (7) or the O-ring (4) and back-up ring (5), depending on the
application.
Note: The O-ring (4) should always face the pressure side of the cylinder and back-up ring
(5) should be located on the rod eye side.
Piston Seal Installation
1. Install expander ring (3) first. Do not twist the expander ring during installation. Use a small
screwdriver to work the expander ring around piston (2) and into the groove.
2. Install piston seal ring (4) on top of expander ring (3). Seal ring (4) is split and can be
installed by hand.
3. The piston wear ring (1) is rigid and is split to aid in assembly. Expand wear ring (1) and
slide over piston (2) until wear ring (1) snaps into position.
Installation of the Head onto the Rod
Illustration 7
1. Lubricate the rod (1) and the seals with clean hydraulic oil.
2. Install a seal guide (2), if available. The seal guide (2) is a cone shaped tool that is used to
open the seals that are located in the head. The seal guide ensures that the seals will slide
onto the rod without damage. The seal guide also serves to align the seals.
3. Push the head (3) over the rod by using one quick motion.
Copyright 1993 - 2013 Caterpillar Inc. Mon May 6 23:50:59 EST 2013
All Rights Reserved.
Private Network For SIS Licensees.

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D8T TRACK-TYPE TRACTOR J8B00001-UP (MACHINE) POWERED BY C15 E...

Product: TRACK-TYPE TRACTOR

Reuse And Salvage Guidelines

Measuring Bores and Installing Seals in Standard and

Agricultural Tractor: All

Wheel Loader: All

Removed reference to canceled tooling 8T-9011 Component Cleaner

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

Canceled Part Numbers and Replaced Part Numbers

Important Safety Information

Improper operation, lubrication, maintenance or repair of this product

Do not operate or perform any lubrication, maintenance or repair on

This safety alert symbol means:

Your safety is involved.

Sudden movement of the machine or release of oil under pressure can

To prevent possible injury, perform the procedure that follows before

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

NENG2500 "Dealer Service Tool Catalog"

Determining the Bore Size

English (Inch) Cylinders

Bore Sizes Chart

Inch Bore Metric Bore 0.25 mm (0.010 inch)

6.5000 - 165.35 mm (6.510 inch) 165.86 mm (6.530 inch)

Head Seal Locations

Threaded gland with standard head seal

Threaded crown with oval seal

Seal Installation Information

a. Use the following procedure to install wiper seal (8) .

Piston Seal Installation

Installation of the Head onto the Rod

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