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Hydraulic Cylinder & Seals

TABLE OF CONTENTS

Introduction

2

Reference Items:

Identification

3

Applications

10

Oversize Cylinders, Head Seals, Chamfer Sizes

13

Seal Selection for Non-Caterpillar Equpment 20

Press In Wiper Seals 21 Snap In Wiper Seals 27 U-Cup Rod Seals 32 Buffer
Press In Wiper Seals
21
Snap In Wiper Seals 27
U-Cup Rod Seals 32
Buffer Seals
39
Head Wear Rings
44
Metal Bearings for 300 HEX
Head Seals
48
53
Piston Seals 56
Piston Wear Rings 65
Chevron Packing
77
Troubleshooting / Installation 79
Head Orientation
Bolted Head Cylinder Orientation:
85
Sorted by Cylinder Group
Bolted Head Cylinder Orientation
86
91
Remanufactured Cylinders and Rods 97
How To Use This Handbook 98
Footnotes 99
Hydraulic Cylinders & Seals Sorted By:
Machine Model:
Agricultural Tractors
100
Articulated Trucks 104
Backhoe Loaders 115
Excavators 139
Forest Machines
Front Shovel Excavators
Integrated Toolcarriers
186
191
199
Landfill Compactors 207
Motor Graders
Off-Highway Trucks
Paving Product — Asphalt Pavers
Paving Product — Cold Planers
208
231
245
249
Paving Product — Pneumatic Tired Compactors
Paving Product — Road Reclaimers / Soil Stabilizers
250
250
Paving Product — Vibratory Compactors 251
Pipelayers 251
Scrapers
253
Soil Compactors
297
Telehandlers 299
Track Loaders 300
Track-Type Tractors
Tractors
Wheel Loaders
331
367
370
Wheel Tractors
Cylinder Group Part Number
Cylinder Assembly Part Number
Rod Assembly Part Number
416
420
731
743
Standard Cylinder Bore Diameter 755
Standard Rod Diameter 769

Hydraulic Cylinder & Seals

INTRODUCTION

Caterpillar is Committed to Lowering Your Hydraulic Cylinder Repair Costs!

Caterpillar is committed to keeping your hydraulic cylinder repair costs as low as possible. That’s why we’re constantly adding to our exchange program and seal kit offering. This Cylinder and Seal Reference Guide is designed to serve as a quick reference for information regarding:

• Cylinder Seals

• Standard and Oversize Cylinders

• Remanufactured Cylinders and Rods

• Standard and Oversize Seal Kits

The first section of this reference guide provides information regarding cylinder seals. This information includes seal identification, applications, oversize seals, part numbers for each type of seal, troubleshooting when a failure occurs, and installation. The second section of this reference guide provides general information regarding Cat cylinders. This information includes the cylinder group part number, standard and oversize remanufactured cylinder part number, rod assembly part number, and standard and oversize seal kit part numbers.

Preventive maintenance is a cost-effective way to extend the life of your Cat equipment. It is important to take good care of your hydraulic cylinders, including frequent inspection for worn rod seals or other damage. The key is to catch any possible failures before they occur! This simple step can minimize unexpected downtime tremendously.

simple step can minimize unexpected downtime tremendously. Cat ® Reman Program Caterpillar’s Remanufactured

Cat ® Reman Program

Caterpillar’s Remanufactured Products program is an exchange program. For each remanufactured unit sold, the core (scratched or damaged cylinder or rod) must be returned. Even if ruptured or broken the core can qualify for partial core credit.

Cat ® Hydraulic Cylinder Seal Kits

Cat Hydraulic Cylinder Seal Kits are a quick and economical solution to leaky cylinders. One part

number provides you with all the seals necessary to

reseal a Cat cylinder of the individual seals.

at a price less than the cost

Hydraulic Cylinder & Seals

IDENTIFICATION

Seal Identification

What is a Seal?

A seal is a device which prevents the escape or passage of a fluid (liquid or gas). A hydraulic cylinder seal is used to seal two surfaces under fluctuating pressure conditions.

Hydraulic Cylinders:

The hydraulic cylinder is the tool which converts hydraulic fluid pressure into work. Even though there are many different designs of hydraulic cylinders, they are relatively similar in the way they are sealed and repaired. Because of this similarity, this guidebook will not address different types of designs. It will suffice to mention that Caterpillar manufactures three different designs: bolt-on head, threaded crown and threaded gland cylinders.

Hydraulic Cylinder Seals:

Caterpillar seals are available as either individual pieces or kits. Kits offer a convenience as well as a cost-savings, priced substantially below the sum of the individual pieces.

Caterpillar hydraulic seals can be used on other makes of cylinders. Cat also offers some of the most popular seal configurations and sizes designed solely for other makes of hydraulic cylinders.*

*Note: Check for availability in your subsidiary.

Identifying Hydraulic Cylinder Seals

Refer to the hydraulic cylinder illustration below. The seals in this Caterpillar cylinder are those typically found in hydraulic cylinders.

cylinder are those typically found in hydraulic cylinders. Use the seal pictures, cross-sections, cutaway illustrations

Use the seal pictures, cross-sections, cutaway illustrations and descriptions on the following pages to help you identify the different types of hydraulic cylinder seals.

Hydraulic Cylinder & Seals

IDENTIFICATION

1a. Press-in Wiper Seal - prevents external contaminants from entering the system. Single-lip (the lip is the projecting rim or edge of the seal) wipers clean the rod as it retracts. Double-lip wipers clean the rod as it retracts and seals oil, eliminating “weeping” (cosmetic leakage). The double-lip wipers are secured in place with a bearing mount. These urethane wipers are metal-encased for added strength. They are often referred to as “canned” wipers (metal-encased) or “J” wipers (the metal often forms a “J” shape when viewed in the cross-section).

4J8932

a “J” shape when viewed in the cross-section). 4J8932 Type A Type C Single-lip wiper Modified
Type A Type C Single-lip wiper Modified
Type A
Type C
Single-lip wiper
Modified

Type B

Double-lip wiper

Type D

Modified Single

1b. Snap-in Wiper Seal - prevents external contaminants from entering the system, but used in less severe environmental conditions and lighter duty hydraulic applications than its press-in counterpart.

5J8156
5J8156
Type Reg
Type Reg

Hydraulic Cylinder & Seals

IDENTIFICATION

The following various types of snap-in wipers are available for use on other makes of hydraulic cylinders.

“Type SHU” wipers are slotted heel, universal style urethane wipers. The slotted heel acts as a relief slot to prevent a

pressure trap occurring between the rod seal and the wiper. between two seals.

A pressure trap is excessive fluid pressure “trapped”

3E4108

trap is excessive fluid pressure “trapped” 3E4108 Type SHU “Type AN” wipers are a non-current design,
Type SHU
Type SHU

“Type AN” wipers are a non-current design, originally made for the military (AN refers to Army/Navy). This single-lip wiper is made of urethane.

3E4145

originally made for the military (AN refers to Army/Navy). This single-lip wiper is made of urethane.
Type AN
Type AN

Hydraulic Cylinder & Seals

IDENTIFICATION

“Type H” and “Type K” wipers are double-lip, urethane wipers.

3E4130

3E4153

K” wipers are double-lip, urethane wipers. 3E4130 3E4153 Type H Type K 2. Rod Seal -
K” wipers are double-lip, urethane wipers. 3E4130 3E4153 Type H Type K 2. Rod Seal -

Type H

Type K
Type K

2. Rod Seal - commonly known as a “u-cup” and performs as the primary rod seal. The u-cup is made of urethane or nitrile. The nitrile u-cup is used with a backup ring in water-glycol hydraulic systems. The backup ring prevents the seal from extruding (forced movement of a seal under pressure into the clearance between the metal parts being sealed).

5J8200

7J4824

996996

the clearance between the metal parts being sealed). 5J8200 7J4824 996996 BACKUP RING BACKUP RING Type
the clearance between the metal parts being sealed). 5J8200 7J4824 996996 BACKUP RING BACKUP RING Type
the clearance between the metal parts being sealed). 5J8200 7J4824 996996 BACKUP RING BACKUP RING Type
BACKUP
BACKUP
the clearance between the metal parts being sealed). 5J8200 7J4824 996996 BACKUP RING BACKUP RING Type

RING

the clearance between the metal parts being sealed). 5J8200 7J4824 996996 BACKUP RING BACKUP RING Type

BACKUP

RING

Type A

Type B

Type C

Hydraulic Cylinder & Seals

IDENTIFICATION

Loaded u-cups are also available for use on other makes of cylinders. The “Type E” loaded u-cup has a back-bevel lip for increased sealability.

3E4285

3E4198

a back-bevel lip for increased sealability. 3E4285 3E4198 Type D Type E Backup Ring Type F
a back-bevel lip for increased sealability. 3E4285 3E4198 Type D Type E Backup Ring Type F
Type D Type E
Type D
Type E

Backup

Ring

sealability. 3E4285 3E4198 Type D Type E Backup Ring Type F 3. Buffer Seal -acts as

Type F

3. Buffer Seal -acts as a secondary rod seal and protects the rod from sudden increases in system pressure. There are currently three types of buffer seals. Type A is a one-piece seal made of urethane. Type B is a two-piece bronze filled PTFE seal with a nitrile expander. The notched view in the cross section must face the pressure side for maximum seal performance. Type C is a two-piece urethane seal with a thermoplastic backup ring. This design allows the seal to withstand higher pressures. Type B and Type C buffer seals are designed to prevent seal extrusion and pressure trapping.

6J8631

8C3839

0996997

C buffer seals are designed to prevent seal extrusion and pressure trapping. 6J8631 8C3839 0996997 Type
C buffer seals are designed to prevent seal extrusion and pressure trapping. 6J8631 8C3839 0996997 Type
C buffer seals are designed to prevent seal extrusion and pressure trapping. 6J8631 8C3839 0996997 Type
C buffer seals are designed to prevent seal extrusion and pressure trapping. 6J8631 8C3839 0996997 Type
C buffer seals are designed to prevent seal extrusion and pressure trapping. 6J8631 8C3839 0996997 Type
C buffer seals are designed to prevent seal extrusion and pressure trapping. 6J8631 8C3839 0996997 Type

Type A

Type B

Type C

Hydraulic Cylinder & Seals

IDENTIFICATION

4. Head Wear Ring - eliminates metal-to-metal contact between the head and rod and prevents scoring (scratching) of the rod by the head.

8T0785

prevents scoring (scratching) of the rod by the head. 8T0785 4a. Bronze Bearing for 300 HEX
prevents scoring (scratching) of the rod by the head. 8T0785 4a. Bronze Bearing for 300 HEX

4a. Bronze Bearing for 300 HEX - used instead of plastic head wear ring for many 300 HEX hydraulic cylinder groups. The coated bearing is pressed into the cylinder group head and held in place with a split metal retaining ring. This bearing supports the hydraulic cylinder rod and prevents metal-to-metal contact between the head and the cylinder rod.

114-0761

contact between the head and the cylinder rod. 114-0761 5. Head Seal - a two-piece seal,
contact between the head and the cylinder rod. 114-0761 5. Head Seal - a two-piece seal,

5. Head Seal - a two-piece seal, consisting of a nitrile o-ring and a backup ring, which seals the head to the cylinder wall.

5H8848

- a two-piece seal, consisting of a nitrile o-ring and a backup ring, which seals the
- a two-piece seal, consisting of a nitrile o-ring and a backup ring, which seals the

Hydraulic Cylinder & Seals

IDENTIFICATION

6. Piston Seal - a two-piece seal, consisting of a piston ring and an expander, which prevents oil transfer between the rod end of the cylinder and the cap end. The piston seal is usually made of Teflon, with nylon available for pressures greater than 3000 psi (20,670 kpa). The various shaped expanders are nitrile. Type 4 consists of a teflon piston ring with a nitrile rubber expander. Type 5 consists of a rubber expander surrounded by bronze filled Teflon on both sides. Type 6 is a urethane u-cup seal used in single acting cylinders.

8T6213

urethane u-cup seal used in single acting cylinders. 8T6213 Type 4 Type 1 Type 2 Type
urethane u-cup seal used in single acting cylinders. 8T6213 Type 4 Type 1 Type 2 Type

Type 4

Type 1

Type 2

used in single acting cylinders. 8T6213 Type 4 Type 1 Type 2 Type 5 Type 3
used in single acting cylinders. 8T6213 Type 4 Type 1 Type 2 Type 5 Type 3

Type 5

single acting cylinders. 8T6213 Type 4 Type 1 Type 2 Type 5 Type 3 Type 6

Type 3

Type 6

7. Piston Wear Ring - supports and centers the piston to prevent metal-to-metal contact between the piston and the cylinder wall.

5J7942

contact between the piston and the cylinder wall. 5J7942 Chevron Packing - used as gland packing
contact between the piston and the cylinder wall. 5J7942 Chevron Packing - used as gland packing

Chevron Packing - used as gland packing in place of rod seals for high pressure applications. This non-current seal is made of a multi-compounded material (usually cotton duck cloth and nitrile). It is often referred to as V-Packing, the shape formed by its cross-section. The end adapters can be tightened down, making the seal adjustable.

4F8420

can be tightened down, making the seal adjustable. 4F8420 PACKING GLAND HEAD CHEVRON ROD PACKING (STACKED
PACKING GLAND HEAD CHEVRON ROD PACKING (STACKED V-RINGS)
PACKING
GLAND
HEAD
CHEVRON ROD PACKING
(STACKED V-RINGS)

PRESS IN OR SNAP IN WIPER

Hydraulic Cylinder & Seals

APPLICATIONS

Seal Applications

Hydraulic cylinder seals perform their functions under difficult conditions, being constantly subjected to friction and

wear.

performance. The following guidelines will assist you in choosing the best seal for an application when more than one

design or material is offered.

It is important, therefore, to have the best seal design and material to achieve maximum seal life and

General:

• Hydraulic cylinder seals beginning with a “3E” prefix are designed for use in other than Caterpillar hydraulic cylinders.

• Use nitrile rubber (a synthetic, oil-resistant elastomer). An elastomer is any synthetic or natural material with resilience sufficient to return to its original shape after distortion.

• Do not use urethane (a very tough, abrasion-resistant synthetic elastomer) in water-glycol hydraulic systems.

Wipers:

• Follow proper installation procedures for the double-lip, press-in wiper to achieve maximum seal performance (see Seal Installation section).

• Do not use double-lip wipers with loaded u-cup rod seals.

Rod Seals:

• When using a nitrile u-cup in high pressure hydraulic systems, a backup ring is needed to prevent the u-cup from extruding out of its groove.

• The lips of the u-cups should always face the pressure.

• Loaded u-cups and “Type B” loaded u-cups are interchangeable. The "Type B" loaded u-cup, because of its back- bevel lip, will provide better sealability at lower pressures.

Updated Rod Seals:

Most kits listed in this handbook contain new-design rod seal part numbers. If the rod seals in your kit do not match the part numbers listed in the parts book, refer to the following chart to see if a “missing” seal has been replaced by an improvied seal.

Rod Seal Part Number Changes - Chart 1

Rod

New Step

Former

New Double-Lip

Former

Size

Buffer

Ring Buffer

Wiper

Single-Lip Wiper

U-Cup Seal

1.50

8C9122

6J9733

8C9131

4J8979

5J8150

1.62

8C9117

4T0486

4T0488

1.75

8C9123

6J9178

8C9132

4J8980

5J8175

1.88

4T6778

4T6777

4T6898

2.00

8C9124

6J6917

8C9133

1K6981

5J8200

2.25

8C9125

5J3616

8C9134

4J3515

5J8225

2.38

8C9138

6J6916

6J3892

5J8238

2.50

8C3839

5J3620

8C3840

1K6982

5J0964

2.75

8C3841

6J6553

8C3842

1J3540

5J8275

3.00

8C9126

6J6915

8C5218

2J1411

5J8300

3.25

8C9121

6J7167

8T8389

6J4169

5J8325

3.50

8C9127

6J6736

8C5219

4J8981

5J8350

3.75

8C9128

8J6070

8C9135

8J6069

5J8375

4.00

8C9129

8J4627

8C5220

7J5673

5J8400

4.50

8C9144

3G8507

3J4458

6J1450

6.75

8C9145

3G8506

8C9146

3J4460

3G4627

7.00

8C9130

9J2495

8C9136

2J4779

6J1700

Hydraulic Cylinder & Seals

APPLICATIONS

Buffer Seals:

• Use Caterpillar designed buffer seals in conjunction with u-cups in Caterpillar hydraulic cylinders.

• The slope or notch of the buffer seal must face the pressure (toward the piston) to avoid creating a pressure trap.

Do not use Caterpillar’s two-piece Teflon buffer seals with loaded u-cups; too little lubrication or a pressure trap may occur.

Head Wear Ring:

• Head wear rings are used in all current production Caterpillar hydraulic cylinders. Some seal kits may not include a head wear ring if the cylinder did not originally have a wear ring groove. Machining a groove for a wear ring may be appropriate if a Caterpillar non-current cylinder or another make of cylinder will benefit from a wear ring.

• The location of the wear ring in the head will vary according to the space available for the groove. In some Caterpillar heads, the ring is positioned between the wiper seal and the u-cup seal; other Cat ® heads may have the ring located after the buffer seal. When repairing other makes of cylinders which do not use a buffer seal, the ring may be located after the rod seal.

• If a wear ring is too wide for the groove but is the correct thickness, the width of the wear ring can be cut down to fit the width of the groove. The clearance between the groove width and the wear ring should not exceed 0.010 inches (0.25 mm).

Metal Bearing for 300 HEX:

• Many 300 HEX hydraulic cylinder groups include a steel backed, coated bronze bearing in the cylinder group head instead of the plastic split wear ring used in other Cat machine hydraulic cylinder groups.

• These metal bearings can be reused when the cylinder group is being resealed if they are not damaged. If the bearing is broked, it should be removed and replaced. If the bearing coating is scratched, or worn through to the underlying metal, the bearing should be removed and replaced. The coating on new bearings is approximately 0.04mm thick.

• Metal bearings are serviced separately and are NOT part of Cat hydraulic cylinder seal kits available to reseal 300 HEX cylinder groups. Since metal bearings can be reused if not severly damaged, their exclusion from seal kits prevents customers from paying for bearings they may not use. If bearings are damaged and need to be replaced, they need to be ordered separately in addition to the appropriate seal kit. Refer to “Metal Bearings for 300 HEX” chart for a list of bearings and retaining rings.

Head Seals:

• Use nitrile o-rings with temperatures from -29° F to 225° F continuous or 250° F intermittent (-34° C to 107° C continuous or 121° C intermittent).

• When repairing a cylinder assembly which has a chamfer , remember that an oval head seal can be used in the chamfer if the required size head seal (O-ring and backup ring) is not offered.

Piston Seals:

• Teflon ® piston seal rings with nitrile expanders are available for use with system pressures under 3000 psi.

piston seal rings with carboxylated nitrile rubber (abrasion-resistant form of nitrile rubber) expanders are designed for use in hydraulic systems where pressures are equal to or exceed 3000 psi. The nylon piston seal will also offer better resistance to extrusion.

• Never trim piston seals to make installation easier. The sealability depends on the tight interference fit. Trimming any amount off the seal will cause it to leak.

• Loaded u-cups can be used as piston seals on other makes of hydraulic cylinders provided they do not have a back-bevel lip (Type B). When using loaded u-cups as piston seals, be sure to face the lips of the seals away from each other. This will prevent pressure traps from occurring. Never install two Type B loaded u-cups on a piston as lubricant will not reach the second seal, causing it to fail.

Nylon

Hydraulic Cylinder & Seals

APPLICATIONS

Piston Wear Rings:

• Caterpillar threaded gland cylinders and the 966 lift cylinders have the piston wear ring positioned away from the piston nut; all other Cat cylinders have the piston wear ring located closest to the nut or bolt.

• If a wear ring is too wide for the groove but is the correct thickness, the width of the wear ring can be cut down to fit the width of the groove. The clearance between the width of the groove and the wear ring should not exceed 0.010 inch (0.25 mm).

Hydraulic Cylinder & Seals

OVERSIZE CYLINDERS

Oversize Cylinders, Head Seals, Chamfer Sizes

Depending on operating pressure, Caterpillar offers oversize remanufactured cylinders of 0.76 and 1.52 mm (.030 and .060 in) for three types of Caterpillar cylinders: threaded-gland, threaded-crown, and bolted-head. All three types of oversize cylinders use standard size rod seals, but use oversize piston seals and wear rings. Oversize piston seals and wear rings differ from the standard seals only by their increase in size. Remember that pistion seals will not seal if the ends are trimmed to make installation easier (See Piston Seals). The three types of cylinders differ in the method used to seal the head to the cylinder. These are covered in the following sections.

Oversize Identification

After a cylinder has been honed oversize, it must be identified as having an oversize bore. One identification method is to stamp “.030 OS” or “.060 OS” on the tube OD close to its open end. If possible, locate stamp so it can be read after cylinder is installed on machine.

Another method of identifying oversize cylinders is to stamp the amount of oversize on the metal tag which identifies the cylinder group part number. The stamp should be a minimum of 6.4 mm (.25 in) high.

Cylinders that have been remanufactured by Caterpillar have a metal tag welded to the outside of the cylinder tube. The tag indicates the part number and oversize designation of the cylinder. The oversize designation is also stamped into the casting at the closed end of the cylinder.

Oversize Threaded-Gland Cylinder

The head seal for the oversize threaded-gland cylinder is the standard O-ring and back-up ring. See Illustration 1.

is the standard O-ring and back-up ring. See Illustration 1. Illustration 1. Threaded gland with standard

Illustration 1. Threaded gland with standard head seal.

18. Head seal.

Hydraulic Cylinder & Seals

OVERSIZE CYLINDERS

Oversize Threaded-Crown Cylinder

The head seal for the oversize threaded-crown cylinder is an oval cross-section seal that locates in the lead-in chamfer at the open end of the cylinder. The O-ring and back-up ring groove in the head is left empty. See Chart 2 for part numbers.

Chart 2 Oversize Seals

Standard

Oversize

Bore Size

Head Seal

2.50

8C4889

2.75

8C4890

3.00

8T8367

3.25

8C4891

3.50

8T8368

3.75

8T8369

4.00

8T8370

4.25

8T8371

4.50

8T8372

4.75

8T8373

5.00

8T8374

5.25

8T8375

5.50

8T8376

6.00

8T8377

6.25

8T8378

6.50

8T8379

7.00

8T8380

7.25

8T8381

7.50

8C0553

7.75

8C4892

8.25

8T8382

8.50

8C4893

9.25

8T8383

10.00

8C4895

10.25

8C4896

10.50

8C4897]

11.50

8C4898

10.25 8C4896 10.50 8C4897] 11.50 8C4898 Illustration 2. Threaded crown with oval seal. 19. Oval

Illustration 2. Threaded crown with oval seal. 19. Oval seal.

Hydraulic Cylinder & Seals

OVERSIZE CYLINDERS

Cylinder Assembly Chamfer Dimensions

Oversize threaded crown cylinders are sealed by using an oval head seal that locates in the lead-in chamfer of the cylinder bore. After the cylinder has been honed, compare the chamfer to the specifications in Illustration 4. Note: Chamfers that do not meet specifications will cause leaks. If the chamfer is too deep, it can be shortened by machining a maximum of 3.0 mm (.12 in) from the end of cylinder tube (2). If the end of the cylinder is machined, during assembly, check to make sure the crown can be fully threaded onto the cylinder and the threads do not bottom before the head is seated against the cylinder. If the chamfer is not concentric with the cylinder bore, the chamfer must be re-machined so that it is concentric and perpendicular to the bore.

Chamfer Dimensions for Oval Head Seals

to the bore. Chamfer Dimensions for Oval Head Seals Illustration 4.   Chamfer Dimensions Item

Illustration 4.

 

Chamfer Dimensions

Item

Dimension

E

Standard bore

F

0.76 (.030) oversize

G

1.52 (.060) oversize

H

9.7 (.38) max. on standard size bore

J

8.1 (.32) max. on 0.76 (.030) oversize bore

K

6.4 (.25) max. on 1.52 (.060) oversize bore

L

15°

Item

Description

2

Tube

3

Head

19

Oval Head Seal

21

Rod

Hydraulic Cylinder & Seals

OVERSIZE CYLINDERS

Cylinders that Cannot Use Oval Head Seals

Some cylinders cannot accept oval head seals. These cylinders use heads that have a “relief” machined into the square corner where the oval head seal normally locates. Because of the relief, the oval head seal will not fill the cavity and seal the joint. If the cylinder uses a head listed in Column A, it should not be oversized. Instead, offer the customer the retube option through your shop or a Caterpillar Remanufactured Standard Cylinder. If the cylinder uses a head listed in Column B, the cylinder may be honed oversize and oversize seals used.

Oval Head Seals – Chart 3

 

Column A

Effective “In”

Cylinder

Former

Column B

Change Level

Group

Relieved

Current Non-

of Current

No.

Head

Relieved Head

Head

3G2221

9J1747

9T3968

9

3G2221

1U1807

9T3968

9

3G2222

9J1747

9T3968

9

3G2222

1U1807

9T3968

9

3G4598

9J3379

9T3509

11

3G4599

9J3379

9T3509

9

3G5712

9J3379

9T3509

3

6J7810

6J7804

9T6541

5

7J1487

9J0499

9T5896

4

7J1488

9J0499

9T5896

4

 

Group Cancelled

&

Replaced by

8J5779

8J5780

4T7585

8J6337

8J6225

9T6543

4

8J6338

8J6225

9T6543

4

9J3632

9J3626

9T3501

4

1U1766

9J3379

9T3509

5

1U1767

9J3379

9T3509

5

1U1771

3G4415

9T3509

3

 

Group Cancelled

&

Replaced by

1U4679

8J5780

Multiple Numbers

Hydraulic Cylinder & Seals

OVERSIZE CYLINDERS

Oversize Bolted-Head Cylinder

Formerly, the head seal for the oversize bolted-head cylinder was the same oval seal that is used in an oversize threaded-crown cylinder. The oversize bolted-head cylinder is now sealed at the head joint by an O-ring which provides a more effective seal than the oval head seal. An oversize bolted-head cylinder that has successfully operated with the oval seal may be re-sealed without machining the O-ring groove into the flange face. However, it is recommended that the oval seal be replaced by the flange face O-ring seal. Most oversize seal kits include both the oval seal and the O-ring seal in order to accommodate re-seal requirements of both former and current designed cylinders. Caterpillar’s current remanufactured oversize cylinders (bolted-head type) have the O-ring groove machined into the flange face of the cylinder assembly.

machined into the flange face of the cylinder assembly. Illustration 3. Bolted head with face O-ring

Illustration 3. Bolted head with face O-ring seal. 20. Face O-ring seal.

New Groove Dimensions for O-ring Part Numbers

Oversize bolted-head cylinders that lack the flange face o-ring groove can be reworked to add the groove. Recommended dimensions for the cylinder o-ring face seal grooves have been modified to increase the nominal compression of the o-ring face seal. Recommended groove widths have increased and groove depths have decreased. Recommended groove diameters have not changed. O-ring face seal part numbers also have not

changed. The recommended o-ring face seal part numbers and o-ring face seal groove dimensions are listed in Chart

4. Refer to Illustration 5 for clarification.

Dealers who salvage cylinder assemblies of bolted-head cylinder groups by honing the bore oversize will need to use the new dimension recommendations to machine grooves for o-ring face seals. Bolted head cylinder assemblies already having o-ring face seal grooves should not be re-worked to the new groove dimensions.

Note: Some cylinder assemblies have been dealer re-worked to add an 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.

would mate a cylinder and head both having an o-ring groove. A. Groove Diameter B. Groove

A. Groove Diameter

B. Groove Width

C. Groove Depth

D. Radius

Illustration 5. Seal Groove Width Dimensions See Chart 4 for item reference and dimensions.

Hydraulic Cylinder & Seals

OVERSIZE CYLINDERS

Seal Part Numbers and Machining Dimensions

Chart 4 Seal Part Numbers and Groove Dimensions

Cyl. Nominal

O-ring Face Seal Part No.

Groove

Groove

Groove

Bore Dia.

Dia. (A)

Width (B)

Depth (C)

Radius (D)

76.20

5P2931

87.12 ± 0.50 (3.430 ± .020)

2.40 ± 0.05 (.094 ± .002)

1.33 ± 0.05 (.052 ± .002)

0.4 ± 0.05 (0.16 ± .002)

(3.000)

88.90

4F4097

101.96 ± 0.05 (4.014 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.016 ± .004)

(3.500)

95.25

7X5494

106.30 ± 0.50 (4.185 ± .020)

2.40 ± 0.05 (.094 ± .002)

1.33 ± 0.05 (.052 ± .002)

0.4 ± 0.05 (.016 ± .002)

(3.750)

101.60

9X7357

112.52 ± 0.50 (4.430 ± .020)

2.40 ± 0.05 (.094 ± .002)

1.33 ± 0.05 (.052 ± .002)

0.4 ± 0.05 (.016 ± .002)

(4.000)

107.95

6S3002

121.00 ± 0.50 (4.764 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.016 ± .004)

(4.250)

114.30

9X7566

127.36 ± 0.50 (5.014 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.016 ± .004)

(4.500)

120.00

1330128

136.00 ± 0.50 (5.354 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.016 ± .004)

(4.720)

120.65

3F5792

136.45 ± 0.50 (5.372 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(4.750)

127.00

1313716

137.92 ± 0.50 (5.430 ± .020)

2.40 ± 0.05 (.094 ± .002)

1.33 ± 0.05 (.052 ± .002)

0.4 ± 0.05 (.016 ± .002)

(5.000)

133.35

2D8009

149.15 ± 0.50 (5.872 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(5.250)

139.70

9X7358

152.76 ± 0.50 (6.014 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.0.016 ± .004)

(5.500)

140.00

2K8257

155.50 ± 0.50 (6.122 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.020 ± .008)

(5.510)

152.40

8T6404

165.46 ± 0.50 (6.514 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.016 ± .004)

(6.000)

158.75

9X7391

171.81 ± 0.50 (6.764 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.016 ± .004)

(6.250)

160.00

9D8042

176.15 ± 0.50 (6.935 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.016 ± .004)

(6.300)

165.10

9D8042

179.17 ± 0.50 (7.054 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.016 ± .004)

(6.500)

170.00

9X7725

187.50 ± 0.50 (7.382 ± .020)

3.53 ± 0.08 (.139 ± .003)

1.95 ± 0.08 (.077 ± .003)

0.4 ± 0.10 (.016 ± .004)

(6.690)

177.80

5J2383

198.98 ± 0.50 (7.834 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(7.000)

180.00

5J2383

196.50 ± 0.50 (7.736 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(7.090)

184.15

5J2383

198.98 ± 0.50 (7.834 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(7.250)

190.50

1J2176

211.68 ± 0.50 (8.334 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(7.500)

196.85

1J2176

209.47 ± 0.50 (8.247 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(7.750)

200.00

5P3092

225.00 ± 0.50 (8.858 ± .020)

7.40 ± 0.20 (.291 ± .008)

3.95 ± 0.20 (.155 ± .008)

1.6 ± 0.40 (.063 ± .016)

(7.87)

209.55

4K6804

224.38 ± 0.50 (8.834 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(8.250)

215.90

1T0132

241.22 ± 0.50 (9.496 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(8.500)

220.00

1M9015

253.92 ± 0.50 (9.997 ± .020)

9.35 ± 0.25 (.368 ± .010)

5.20 ± 0.25 (.207 ± .006)

1.6 ± 0.40 (.063 ± .016)

(8.66)

234.95

5S3676

253.92 ± 0.50 (9.997 ± .020)

4.75 ± 0.13 (.187 ± .005)

2.64 ± 0.13 (.104 ± .005)

0.8 ± 0.20 (.031 ± .008)

(9.250)

Hydraulic Cylinder & Seals

OVERSIZE CYLINDERS

Chart 4 Seal Part Numbers and Groove Dimensions

Cyl. Nominal

O-ring Face Seal Part No.

Groove

Groove

Groove

Bore Dia.

Dia. (A)

Width (B)

Depth (C)

Radius (D)

254.00

3S3074

276.15 ± 0.50 (10.872 ± .020)

7.40 ± 0.20 (.291 ± .008)

3.95 ± 0.20 (.155 ± .008)

1.6 ± 0.40 (.063 ± .016)

(10.000)

266.70

5P2236

288.85 ± 0.50 (11.372 ± .020)

7.40 ± 0.20 (.291 ± .008)

3.95 ± 0.20 (.155 ± .008)

1.6 ± 0.40 (.063 ± .016)

(10.500)

279.40

1309108

310.50 ± 0.50 (12.224 ± .020)

7.40 ± 0.20 (.291 ± .008)

3.95 ± 0.20 (.155 ± .008)

1.6 ± 0.40 (.063 ± .016)

(11.00)

292.10

6V3263

314.25 ± 0.50 (12.372 ± .020)

7.40 ± 0.20 (.291 ± .008)

3.95 ± 0.20 (.155 ± .008)

1.6 ± 0.40 (.063 ± .016)

(11.50)

317.50

1309109

360.50 ± 0.50 (14.193 ± .020)

7.40 ± 0.20 (.291 ± .008)

3.95 ± 0.20 (.155 ± .008)

1.6 ± 0.40 (.063 ± .016)

(12.50)

330.20

1309110

381.50 ± 0.50 (15.020 ± .020)

7.40 ± 0.20 (.291 ± .008)

3.95 ± 0.20 (.155 ± .008)

1.6 ± 0.40 (.063 ± .016)

(13.00)

342.90

1309110

381.50 ± 0.50 (15.020 ± .020)

7.40 ± 0.20 (.291 ± .008)

3.95 ± 0.20 (.155 ± .008)

1.6 ± 0.40 (.063 ± .016)

(13.50)

Hydraulic Cylinder & Seals

SEAL SELECTION FOR NON-CATERPILLAR EQUIPMENT

Seal Selection for Non-Caterpillar Equipment

Caterpillar seals can be used on other than Caterpillar equipment. The following section will help you identify which seal is necessary for your repair.

help you identify which seal is necessary for your repair. How to Select the Correct Seals:

How to Select the Correct Seals:

• For cylinders used on other than Caterpillar equipment, measure the components using the following procedure.To find the correct replacement seal size, the seal groove dimensions in the iron itself should always be measured. Measuring a used seal can give false dimensions due to distortion in size from wear. The hydraulic cylinder illustration below calls out the iron dimensions required to identify the proper size replacement seal.

 

Diameter of Rod (R)

Groove

Groove

Seal Type

or Cylinder Bore (B)

Width

Diameter

Rod Wiper:

R

A

C

Rod Seal:

R

D

E

Buffer Seal

R

F

G

Head Wear Ring:

R

H

I

Head Seal:

B

J

K

Piston Seal:

B

L

M

Piston Wear Ring:

B

N

O

Should seal replacement be requested by a customer over-the-counter rather than through the service shop, measure the seal’s outside diameter at four equally-spaced areas around the seal. Take the average of these measurements to determine the seal’s outside diameter. Repeat this procedure with the seal’s inside diameter and width (height) to determine seal replacement size.

Use the tables in the following sections to find the right seal for your customer’s repair.

Hydraulic Cylinder & Seals

PRESS-IN WIPER SEALS

Press-In Wiper Seals

& Seals PRESS-IN WIPER SEALS Press-In Wiper Seals     A B   ROD   GROOVE
   

A

B

 

ROD

 

GROOVE WID. (± .02 in)

GROOVE DIA.

DIAMETER

PART

SEAL

(in)

(mm)

NUMBER

TYPE

(in)

(mm)

(in)

(mm)

1.00

25.40

7K1864

URETHANE

 

0.31

7.92

1.50

38.20

1.25

31.75

2H1746

NITRILE

A

0.28

7.00

1.75

44.50

 

3E4160

URETHANE

A

0.31

7.92

1.75

44.45

4J8982

URETHANE

A

0.28

7.00

1.75

44.50

1.37

34.92

3E4159

URETHANE

A

0.31

7.92

1.88

47.63

 

5M9736

NITRILE

A

0.41

10.52

2.10

53.46

1.50

38.10

3E4161

URETHANE

A

0.31

7.92

2.00

50.80

 

4J8979

URETHANE

A

0.43

11.00

2.25

57.15

5P0091

NITRILE

A

0.25

6.35

2.00

50.90

9J4037

NITRILE

A

0.43

11.00

2.25

57.15

8C9131

URETHANE

B

0.43

11.00

2.25

57.15

1.63

41.28

4T0486

URETHANE

A

0.33

8.50

2.13

53.98

1.75

44.40

1506739

URETHANE

C

0.43

11.00

2.44

62.07

1.75

44.45

3E4162

URETHANE

A

0.31

7.92

2.25

57.15

 

4J8980

URETHANE

A

0.43

11.00

2.44

61.90

5P0092

NITRILE

A

0.25

6.35

2.25

57.25

7J6932

URETHANE

 

0.31

7.94

2.25

57.25

8C9132

URETHANE

B

0.43

11.00

2.44

61.90

8J5817

NITRILE

A

0.43

11.00

2.44

61.90

1.77

44.95

1410713

URETHANE

D

0.28

7.00

2.16

54.97

1.83

46.50

0993929

URETHANE

A

0.33

8.35

2.52

64.02

1.87

47.62

4T6777

URETHANE

A

0.43

11.00

2.56

65.07

 

9X3565

URETHANE

B

0.43

11.00

2.56

65.07

1.89

47.90

1163393

URETHANE

A

0.33

8.35

2.52

64.02

2.00

50.75

1433670

URETHANE

C

0.43

11.00

2.69

68.42

2.00

50.80

1K6981

URETHANE

A

0.43

11.00

2.69

68.23

 

3E4164

URETHANE

A

0.31

7.92

2.50

63.50

5P0093

NITRILE

A

0.25

6.35

2.50

63.60

7J8277

NITRILE

A

0.43

11.00

2.69

68.23

8C9133

URETHANE

B

0.43

11.00

2.69

68.23

9D6583

URETHANE

A

0.25

6.35

2.50

63.60

Hydraulic Cylinder & Seals

PRESS-IN WIPER SEALS

Press-In Wiper Seals

& Seals PRESS-IN WIPER SEALS Press-In Wiper Seals     A B   ROD   GROOVE
   

A

B

 

ROD

 

GROOVE WID. (± .02 in)

GROOVE DIA.

DIAMETER

PART

SEAL

(in)

(mm)

NUMBER

TYPE

(in)

(mm)

(in)

(mm)

2.03

51.50

0996995

URETHANE

A

0.33

8.35

2.72

69.02

2.12

53.93

1506745

URETHANE

C

0.43

11.00

2.88

73.20

2.13

53.98

4T6125

URETHANE

A

0.43

11.00

2.88

73.03

 

9X3567

URETHANE

B

0.43

11.00

2.88

73.03

2.22

56.50

0961884

URETHANE

A

0.33

8.35

2.91

74.02

2.25

57.15

5J3937

URETHANE

A

0.29

7.35

3.13

79.38

 

3E4165

URETHANE

A

0.31

7.92

2.75

69.85

4J3515

URETHANE

A

0.43

11.00

3.00

76.13

7J8278

NITRILE

A

0.43

11.00

3.00

76.13

8C9134

URETHANE

B

0.43

11.00

3.00

76.13

9D6584

URETHANE

A

0.25

6.35

2.75

69.95

5H1513

URETHANE

A

0.51

12.83

3.25

82.55

2.36

59.85

931433

URETHANE

D

0.16

4.15

2.96

75.12

2.37

60.32

6J3892

URETHANE

A

0.43

11.00

3.12

79.35

 

9J1319

NITRILE

A

0.43

11.00

3.12

79.35

9X7259

URETHANE

B

0.43

11.00

3.12

79.35

2.42

61.50

957102

URETHANE

D

0.44

11.30

3.12

79.21

2.50

63.45

1506751

URETHANE

C

0.43

11.00

3.26

82.75

2.50

63.50

1K6982

URETHANE

A

0.43

11.00

3.25

82.55

 

3E4166

URETHANE

A

0.31

7.92

3.00

76.20

5P0065

NITRILE

A

0.31

7.92

3.01

76.33

7J8273

NITRILE

A

0.43

11.00

3.25

82.55

8C3840

URETHANE

B

0.43

11.00

3.25

82.55

1B0936

NITRILE

A

0.51

12.91

3.54

89.99

2.63

66.68

1U4021

URETHANE

A

0.43

11.00

3.37

85.72

 

9X3569

URETHANE

B

0.43

11.00

3.37

85.72

2.75

69.80

1491488

URETHANE

C

0.55

14.00

3.76

95.49

2.75

69.85

931434

URETHANE

D

0.16

4.15

3.35

85.15

 

8C3842

URETHANE

B

0.55

14.00

3.75

95.27

1J3540

URETHANE

A

0.55

14.00

3.75

95.27

3E4168

URETHANE

A

0.31

7.92

3.25

82.55

7J8274

NITRILE

A

0.55

14.00

3.75

95.27

Hydraulic Cylinder & Seals

PRESS-IN WIPER SEALS

Press-In Wiper Seals

& Seals PRESS-IN WIPER SEALS Press-In Wiper Seals     A B   ROD   GROOVE
   

A

B

 

ROD

 

GROOVE WID. (± .02 in)

GROOVE DIA.

DIAMETER

PART

SEAL

(in)

(mm)

NUMBER

TYPE

(in)

(mm)

(in)

(mm)

2.75

69.85

9H6079

NITRILE

A

0.54

13.70

3.75

95.27

3.00

76.15

1433671

URETHANE

C

0.55

14.00

4.01

101.92

3.00

76.20

2J1411

URETHANE

A

0.55

14.00

4.00

101.67

 

3E4170

URETHANE

A

0.31

7.92

3.50

88.90

5P0064

NITRILE

A

0.31

7.92

3.51

89.03

5P4061

URETHANE

A

0.41

10.52

3.75

95.27

8C5218

URETHANE

B

0.55

14.00

4.00

101.67

8J0249

NITRILE

A

0.55

14.00

4.00

101.67

3.06

77.70

1659285

URETHANE

B

0.43

11.00

3.71

94.23

3.14

79.85

960854

URETHANE

D

0.16

4.15

3.75

95.15

3.21

81.50

7Y5115

URETHANE

A

0.33

8.35

3.90

99.02

3.25

82.50

1537558

URETHANE

C

0.55

14.00

4.26

108.16

3.25

82.55

3E4173

URETHANE

A

0.31

7.92

3.88

98.43

 

6J4169

URETHANE

A

0.55

14.00

4.25

107.95

7J7732

NITRILE

A

0.55

14.00

4.25

107.95

8T8389

URETHANE

B

0.55

14.00

4.25

107.95

3.26

82.70

1659286

URETHANE

B

0.43

11.00

3.91

99.23

3.41

86.50

0931441

URETHANE

A

0.33

8.35

4.10

104.02

3.50

88.85

1433672

URETHANE

C

0.55

14.00

4.51

114.57

 

3E4176

URETHANE

A

0.31

7.92

4.13

104.78

1J2150

NITRILE

A

0.54

13.70

4.50

114.32

4J8981

URETHANE

A

0.55

14.00

4.50

114.32

7J8276

NITRILE

A

0.55

14.00

4.50

114.32

8C5219

URETHANE

A

0.55

14.00

4.50

114.32

3.65

92.70

1140645

URETHANE

A

0.33

8.50

4.29

109.03

 

1659288

URETHANE

B

0.43

11.00

4.30

109.23

3.75

95.25

8J6069

URETHANE

A

0.55

14.00

4.75

120.65

 

9J1325

NITRILE

A

0.55

14.00

4.75

120.65

8C9135

URETHANE

B

0.55

14.00

4.75

120.65

3.80

96.50

0960059

URETHANE

A

0.33

8.35

4.49

114.02

4.00

101.55

1389740

URETHANE

A

0.31

8.00

4.50

114.24

Hydraulic Cylinder & Seals

PRESS-IN WIPER SEALS

Press-In Wiper Seals

& Seals PRESS-IN WIPER SEALS Press-In Wiper Seals     A B   ROD   GROOVE
   

A

B

 

ROD

 

GROOVE WID. (± .02 in)

GROOVE DIA.

DIAMETER

PART

SEAL

(in)

(mm)

NUMBER

TYPE

(in)

(mm)

(in)

(mm)

4.00

101.55

1433673

URETHANE

C

0.55

14.00

5.01

127.23

4.00

101.60

3E4177

URETHANE

A

0.31

7.92

4.63

117.48

 

7J5673

URETHANE

A

0.55

14.00

5.00

127.00

7Y4667

URETHANE

A

0.39

10.00

4.76

121.02

3G2650

NITRILE

A

0.55

14.00