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Hydraulic Cylinder Seal Analysis

The document provides a Reuse and Salvage Guideline for hydraulic cylinder seal failure analysis, aimed at helping Caterpillar dealers establish a parts reusability program. It emphasizes the importance of cleanliness during assembly and details common issues, root causes, and remedies related to hydraulic cylinder seal failures. Additionally, it includes safety precautions and references to other relevant Caterpillar publications for further technical guidance.

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Soubhik Bagchi
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© © All Rights Reserved
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0% found this document useful (0 votes)
151 views17 pages

Hydraulic Cylinder Seal Analysis

The document provides a Reuse and Salvage Guideline for hydraulic cylinder seal failure analysis, aimed at helping Caterpillar dealers establish a parts reusability program. It emphasizes the importance of cleanliness during assembly and details common issues, root causes, and remedies related to hydraulic cylinder seal failures. Additionally, it includes safety precautions and references to other relevant Caterpillar publications for further technical guidance.

Uploaded by

Soubhik Bagchi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

7/31/22, 12:35 PM SIS 2.

2022/05/23 Hydraulic Cylinder Seal Failure Analysis {7555, 7562} (REHS2811-27)

SMCS - 7555, 7562 i09210697 


Agricultural Tractor
All
Articulated Truck
All
Asphalt Paver
All

Backhoe Loader
All
Challenger
All
Cold Planer
All
Combine
All
Compact Track Loader
All
Compact Wheel Loader
All
Continuous Miner
All
Earthmoving Compactor
All
Excavator
All
All Mining Shovels
Forest Products
All
Integrated Toolcarrier
All
Landfill Compactor
All

Load Haul Dump


All
Material Handler
All
Mini Hydraulic Excavator
All
Motor Grader
All
Multi Terrain Loader
All
Off-Highway Truck/Tractor
All
PNEUMATIC COMPACTOR
All

Paving Compactor
All
Pipelayer
All
Road Reclaimer/Soil Stabilizer

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7/31/22, 12:35 PM SIS 2.0

All
Skid Steer Loader
All
Soil Compactor
All
Telehandler
All
Track Feller Buncher
Blount Branded
Timberking Branded
Track-Type Loader
All
Track-Type Skidder
All
Track-Type Tractor
All
Underground Articulated Truck
All
Unit Rig Mining Truck
All
Wheel Dozer
All
Wheel Feller Buncher
All
Wheel Loader
All
Wheel Skidder
All
Wheel Tractor-Scraper
All
Wheeled Excavator
All

Revision History:
Revision Summary of Changes in REHS2811 
27 Added 4 new serial number prefixes
26 Added 10 new serial number prefixes
Added 6 new serial number prefixes
25
Updated Table 2
24 Added serial number prefixes

Table 1

Introduction
© 2022 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).

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7/31/22, 12:35 PM SIS 2.0

Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional repair options or modifications to reuse and salvage
techniques and/or methods.

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System
website 2.0 (SIS web 2.0) interface.

Canceled Part Numbers and Replaced Part Numbers


This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information
System website 2.0 (SIS web 2.0) for information about canceled part numbers and replaced part numbers. NPR will provide the current part
numbers for replaced parts.

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. Ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance, or the repair procedures that are used. Ensure that the product will not be damaged or made unsafe by any
operation, lubrication, maintenance, or the repair procedures used.

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”.
Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.

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.
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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, 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.

Summary
This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. This guideline
must be used with the recommendations found in the Reuse and Salvage Guideline, SEBF8072 , "Inspection and Salvage of Hydraulic Cylinder
Components".

References
Note: Refer to the appropriate Remove and Install (R&I), Disassembly and Assembly (D&A), and Operation and Maintenance Manual (OMM) for
the part or machine of focus before initiating this inspection or procedure.

References
"Why Reuse and Salvage Parts"
Channel1
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7/31/22, 12:35 PM SIS 2.0

Special Publication
PERJ1017
"Dealer Service Tools Catalog"
Reuse and Salvage Guidelines
SEBF8072
"Inspection and Salvage of Hydraulic Cylinder Components"

Table 2

Foreword
Careful inspection of the hydraulic cylinder seals after a failure can give indications of the root cause. Document the complaint of the customer and
determine if the problem is drift, leakage, or noise. Leakage can occur at the rod seals between the cylinder head and rod or at the head seals
between the head and the tube. Leakage can also occur internally at the piston seals, between the piston and the tube. At disassembly, all seals
should be inspected for any change in appearance in comparison to new seals. All scratches, nicks, cuts, foreign particles, dimensional changes,
or color changes should be noted. The following sections describe most common problems, indications of the root causes, and remedies.

Cleanliness of hydraulic components during assembly is critical. Before assembly, clean all parts properly. All parts that will be stored prior to
assembly must be stored in a way to protect from contamination.

Nomenclature

Illustration 3 g01217895

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(1) Head O-ring seal


(2) Head seal backup ring
(3) Wear band
(4) Buffer seal
(5) U-cup seal
(6) Wiper seal
(7) Nut
(8) Piston
(9) Head
(10) Rod
(11) Piston seal expander ring
(12) Piston seal ring
(13) Wear band
Illustration 3 shows the position of all the seals, rings, and bands that will be discussed in this document. A bolted head cylinder is shown, but
threaded gland and threaded crown cylinders have the same basic seal positioning.

Rod Seal Leakage


Assembly Damage

Illustration 4 g01202321
Steel backed PTFE wear band heavily scratched by the edge of the rod.

1. Assembly Cone Not Used


Indications

A small section of the material is clipped out of the buffer seal, U-cup seal, or wiper seal ID lip.

Steel backed PTFE wear ring (used on HEX machines) is heavily scratched in one or more discrete areas. Refer to Illustration 4.
Possible Root Causes

A sharp edge, usually at the end of the cylinder rod, has clipped or scratched the seals as the head is pushed over the rod.

Remedy

The recommended practice is to use a seal guide when reassembling the head to the rod. Any metal part that comes in contact with a seal
during assembly or operation must be free of sharp edges.

Comments

The wiper seal is most commonly clipped when a guide is not used. The head lands pilot the head after the wiper goes over the rod. An
attempt to assemble the head over the rod in one motion should be made. If a jerking motion is used, there is the possibility for the wiper lip
to be caught. The wiper lip will get caught between the edge of the seal guide and the rod chamfer. All burrs and sharp edges should be
removed from the end of the rod prior to reassembly.

2. Wiper Seal Not Installed Properly


Indications

The wiper seal metal shell is dented or deformed.

Dirt enters the cylinder through the wiper seal because the lip is not in close contact with the rod.

The wiper seal is dislodged from the counter-bore.

The contacting band of the wiper seal is not uniform in width around the circumference of the seal.
Possible Root Causes

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The wiper seal was not installed properly or the seal was damaged during installation.

Remedy

A piloting, wiper seal driver should be used to install wiper seals that have a metal shell. If necessary, use a rubber mallet to tap around the
edges of the seal. The procedure will ensure proper seating of the seal against the counter-bore. Do not dent the metal shell.

Comments

An uneven contact band on the ID of the wiper indicates that the seal was not properly seated. The contact band should be seated against
the back of the counterbore. The uneven contact band could also mean that the rod was bent. Always use bearing adhesive on the OD of the
metal shell to aid in retention and eliminate the seal OD as a possible leak path. However, adhesive on any other surface of the seal, rod, or
head is not allowed.

Illustration 5 g01202423
Buffer groove damage by removing a seal with a screwdriver.

3. Damage to the Head


Indications

Upon removal of the seals, scratches or gouges are found in the seal grooves of the head.
Possible Root Causes

The seals were removed in a manner that was too aggressive. Gouges were left in the grooves by screwdrivers, chisels, or other hardened
tools. The groove surface finish was degraded beyond the ability of the seals to function properly. Refer to Illustration 5.

Remedy

Care should be taken to prevent damage to the groove when removing rod seals. Use a seal pick or other tools of low hardness to remove
the seals.

Contamination

Illustration 6 g01202426
Paint of front face of wiper seals. Paint on the lip edge indicates that the rod was probably painted.

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7/31/22, 12:35 PM SIS 2.0

Illustration 7 g01202568
Strut in which the wiper seal and the rod outboard of the seal was not masked prior to painting.

1. Paint Contamination
Indications

The front face of the wiper seal is painted to the wiper lip edge. Paint overspray is found on the rod in a location that will enter the seals
during operation.

Other indications are pieces of paint adhering to the inner diameter of the rod seals. Refer to Illustration 6.
Possible Root Causes

The wiper seal and/or rod was not properly masked during painting of the cylinder.

Remedy

Before painting, protect the entire front face of the wiper seal and the section of the rod that will contact the seal.

Comments

Small paint chips cause leakage by getting between the sealing lip of the U-cup seal and the rod. The U-cup lip edge must be clean of any
contaminant to function at maximum efficiency.

Illustration 8 g01202384
Metallic particles are shown embedded in the piston seal ring. These particles cause leakage by scratching the U-cup sealing lip.

Illustration 9 g03361763
The scratches in the U-cup lip were caused by metallic contamination.

Illustration 10 g03361764
Fine scratches are shown on the sealing lip of the U-cup. Small scratches will result in noticeable leakage.

2. Metallic Contamination
Indications

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Small, medium sized axial scratches are found across the sealing lip of the U-cup. Scratches that match are often found on the buffer
and wiper seals. Refer to Illustrations 9 and 10.

Shiny metal flakes and chips are embedded in the wear bands and in the sides of the plastic piston seal ring. Refer to Illustration 8.

The rod is scratched in one or more places. The scratches are straight running the length of the rod stroke.
Possible Root Causes

Metal contaminants were not removed from the system before the contaminants migrated to the cylinders. The contaminants may have been
the by-product of the manufacturing process, wear, or the result of repairs. The contaminants damage the rod seals.

Remedy

Replace wearing components. Always replace the wear bands and piston seal during resealing because these components act as particle
traps. The system cleanliness may improve after a cylinder reseal if the contamination was the result of manufacturing cleanliness instead of
system wear. Replace any rod with scoring or a nick deep enough to be felt with a fingernail.

Comments

There is nothing in the rod seals that can scratch a rod. However, rod seals and wear bands can hold hard particles against the rod resulting
in long axial scratches. These scratches may then damage the U-cup seal. A single fine scratch on the ID of the U-cup seal can result in a
noticeable leak.

Illustration 11 g03361768
The cylinder rod was lightly scored by aluminum oxide contaminants that were trapped by the head wear band.

3. Dirt Contamination
Indications

Heavy scratches or wear is found on the ID of the rod seals.

Large amounts of dirt are found between the seals and around the wear bands.

The rod is scored to varying degree. Refer to Illustration 11.


Possible Root Causes

The wiper seal was damaged or improperly assembled, and dirt is entering the cylinder.

The head was not properly cleaned prior to resealing.

Bent cylinder rods cause uneven wear of the wiper seal or a loss of lip to rod contact pressure on one side of the seal.

Nonmetallic contaminants were built into the cylinder or other hydraulic components.
Remedy

Ensure proper assembly of the wiper seal. Thoroughly clean the head and pay close attention to the inside of the seal grooves prior to
resealing. Straighten or replace any bent rod according to the guidelines in the Special Instruction, SEBF8072 , "Inspection and Salvage of
Hydraulic Cylinder Components".

Comments

A small amount of fine dirt or dust behind the wiper seal is to be expected after long service. The area behind the wiper is dead space and
system contamination will not result unless the buildup is heavy. The U-cup or buffer seal may have black oil around the OD after a period of
service. This material is a combination of small wear particles from the head wear band and chrome from the rod. This material does not
contribute to seal failures.

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Illustration 12 g01202682
Buffer seal destroyed by hydrolysis. Note the leathery "skin" on the outside of the part.

Illustration 13 g01203199
Head oval seal destroyed by hydrolysis.

4. Water Contamination (Hydrolysis)


Indications

Any of the rod seals, but especially the buffer, is cracked and brittle.

The seal has large pieces missing from the sealing edge.

Material can be scratched off the seal with a fingernail.


Possible Root Causes

Water or coolant has contaminated the hydraulic oil. Cooler failure is possible if the machine is water to oil cooled. Water can condense on
tank walls. Water may also reach higher concentrations around the rod seals. The higher concentration of water is due to low oil flow around
the seals.

Remedy

If the oil sample indicates water in the oil, change the oil. Use hydrolysis resistant rod seals. Always use special carboxylate nitrile (black) U-
cup and wiper seals, and a PTFE step buffer seal when using water/glycol hydraulic fluids.

Comments

A small amount of water or coolant can quickly damage rod seals at elevated temperatures. At moderate temperatures, the breakdown
occurs more slowly. Refer to Illustrations 12 and 13.

Damage to Mating Iron

Illustration 14 g03361772
Rod scuffed by poor handling.

1. Rod Damage
Indications
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There may be scratches on the ID of the rod seals and uneven wear patterns on the rod seals and on the wear band.

Nicks or scratches on the surface of the cylinder rod that are not straight and axial are other indications.

Pits or cracks can be found on the chrome surface of the rod.


Possible Root Causes

The rod is bent.

The rod has been scratched or abraded the working environment. Refer to Illustration 14.

The chrome surface on the rod is of low quality or was improperly polished.
Remedy

Straighten or replace any bent rod according to the guidelines in Special Instruction, SEBF8072 , "Inspection and Salvage of Hydraulic
Cylinder Components". Re-chrome, polish, or re-rod any damaged rod according to the guidelines in Special Instruction, SEBF8072 ,
"Inspection and Salvage of Hydraulic Cylinder Components".

Illustration 15 g01202436
Step incorrectly machined into the wall of the buffer seal groove.

Illustration 16 g01202760
U-cup and buffer seal grooves with poor surface finish.

2. Head Groove Damaged or not Made to Standards


Indications

Seal grooves are corroded and pitted.

Tool drag marks are evident. Surface finish does not meet standards. Refer to Illustrations 15 and 16.
Possible Root Causes

Water has entered the head, or the head was left exposed to the environment.

The head grooves were not properly machined.


Remedy

Obtain a new head. The grooves cannot be machined to a larger diameter to remove pitting or tool marks without reducing the efficiency of
the rod seals.

U-cup Extrusion

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Illustration 17 g03361776
A moderately extruded U-cup.

Illustration 18 g03361779
A heavily extruded U-cup seal.

1. U-cup Extrusion
Indications

The buffer seal is worn flat or ribbons of material are coming off the back of the seal. Refer to Illustration 17.

The ID of the U-cup seal closest to the wiper seal has small chunks removed or has a melted appearance. Refer to Illustration 18.

Ribbons of material have flowed in between the rod and the head land behind the U-cup.
Possible Root Causes

High-pressure spikes have occurred in the cylinder.

The relief pressure setting may be set too high.

The buffer seal has been damaged exposing the U-cup to full system pressure.

If extrusion is seen on truck struts, overloading or overcharging may have occurred.


Remedy

Use a backup ring behind the U-cup seal that closes the clearance between the land and the rod. Lower pressure relief settings. Replace
damaged buffer seals.

Comments

Extrusion is not related to melting. The melting temperature of polyurethane is much higher than the temperatures that can be generated in a
normal operating hydraulic system.

Heat Damage

Illustration 19 g01203287
A buffer seal destroyed by oil temperatures higher than the rated operating temperature of the seal material.

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Illustration 20 g01203288
U-cup seal destroyed by hydraulic system temperatures higher than the rated operating temperature of the seal material.

1. Heat Damage
Indications

The buffer and U-cup seals may appear dark in color.

The U-cup has taken a heavy compression set.

The seals are cracked and brittle.


Possible Root Causes

The hydraulic system temperature is too high for standard rod seals. Standard rod seals are rated to 93 °C (199.4 °F) continuous operating
temperature. Refer to Illustrations 19 and 20.

Remedy

Check cooling components for efficiency and fix any problems. Modify machine operation to avoid overheating. Use high temperature rod
seals. Use appropriate hydraulic oil for the specific operating conditions for good lubricity.

Note: Rod Seal Assembly Tips

Push the U-cup to the back of the groove toward the wiper. The U-cup will remain in that position during operation after the first pressure
cycle.

Lubricate the rod and rod guide lightly before pushing the head over the rod. Do not lubricate the seals excessively. Any oil between the U-
cup and wiper seals will leak. The leak will occur during the first hours of operation.

For optimum rod seal performance, the rod surface finish should be .40 µm (16 microinch).

Head Seal Leakage


O-ring Seal or Backup Ring clipped during Assembly

Illustration 21 g01202471
Head seal Backup Ring Clipped during Assembly.

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Illustration 22 g01203751
Head seal Backup Rings Clipped during Assembly.
Indications

A small section of the O-ring or backup ring appears "bitten" out of the part. This condition is most common of the ends of split backup rings.
Refer to Illustration 21 and 22.

Possible Root Causes

The backup ring was in a "sprung out" condition, and the ends of the ring did not remain in the seal groove. The "sprung out" condition prior to the
mating of the head with the cylinder tube. The ends of the seal outside the groove were clipped.

Remedy

Make sure that the head seal O-ring and the backup ring grip the head tightly before mating the head with the tube. If the backup ring does not grip
the head tightly, assembly compound can be used. Assembly compound is used to prevent the ends from extending outside the seal groove in
some cases.

Comments

Screw in the threaded gland head slowly to avoid pinching and stretching the O-ring head seal.

Lubricate the OD of the seals lightly before assembly.

Many threaded gland head seal O-rings have a blue PTFE coating to reduce friction during assembly.

The head seal O-ring on the threaded gland cylinder is often cut during disassembly by the threads.

Head Seal and/or Backup Ring Extrusion


Indications

Ribbons of material that flowed into the clearance between the head and the cylinder tube are present at disassembly.

Large amounts of material are missing on the low-pressure side of the head seal O-ring.

Possible Root Causes

Head seal extrusion is caused by oil pressures that are too high.

Head seal extrusion failures can also occur if the tube bore is too large. Head seal extrusion failure can also occur if the diameter of the land
behind the seal is too small (extrusion gap is too high).

Some failures have been attributed to the stretch of head bolts on the bolted cylinders. Threaded gland cylinders have had failures because
of the expansion of the tube at high pressures.

Remedy

If the backup ring is extruding use a ring made of a harder material. Reduce the pressure around the head seal if the ring is extruded. Tighten the
threaded gland cylinder heads to the proper torque after resealing.

Piston Seal Drift


Dieseling

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Illustration 23 g03361786
Piston Seal Ring damaged by Dieseling.

Illustration 24 g01202479
Piston Seal Ring Damaged by Dieseling at the Step Cut.
Indications

The cylinder drifts at a high rate.

Oil temperatures are elevated due to flow of oil through small clearances at high pressure.

The piston seal ring or rubber expander ring is eroded in a finger-like pattern. The area around the erosion is blackened and sometimes
smells burnt.

Possible Root Causes

When air or other entrained gases that are saturated with oil vapors form in the hydraulic oil, dieseling occurs. When these bubbles are
compressed, at a high rate the gases ignite due to adiabatic heating. The resulting explosion erodes adjacent components, especially nonmetallic
parts. Refer to Illustrations 23 and 24.

Remedy

All efforts should be made to remove air or other entrained combustible gases from the system after resealing a cylinder before using the machine.
Extend and retract the cylinders several times before heavy work is done to force air back to the tank.

Explosive Decompression

Illustration 25 g01202522
Piston seal expander ring heavily damaged by explosive decompression.
Indications

The cylinder drifts at a high rate.

The rubber expander ring has large chunks of material missing. Refer to Illustration 25.

There is no smell of burning or damage to the seal ring.

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Possible Root Causes

Explosive decompression (ED) occurs when gases that have penetrated into a rubber expander ring suddenly expand due to a rapid drop in
hydraulic oil pressure. Also when voiding occurs in the cylinder. The rapid expansion of the entrained gas bubble pops a chunk of material out of
the rubber ring. If the damage accumulates, the ring can no longer properly seal.

Remedy

All efforts should be made to remove air or other entrained gases from the system after resealing a cylinder before using the machine. Extend and
retract the cylinders several times before heavy work is done to force air back to the tank. Refer to the cylinder removal and install procedure for
the specific model for more specific instructions. Use dieseling/ED resistant piston seals. These seals are made of a rubber material designed to be
less permeable to gases in the hydraulic oil. Use protection piston seal backup rings. These rings reduce the area of the rubber expander ring that
is exposed to the oil. Therefore reducing the amount of gas that penetrates the rubber.

Comments

ED and dieseling are similar. The root cause of ED and dieseling is air in the hydraulic system.

Scratched Piston Seal Ring

Illustration 26 g03361788
Cylinder heavily scored by metallic contamination.

Illustration 27 g03361789
Piston seal ring scored by a cylinder bore with a poor surface finish.
Indications

The cylinder drifts slowly.

The split plastic seal ring has heavy axial scratches that run from one side of the seal to the other.

Possible Root Causes

Bore damage

Contamination

Remedy

If a damaged bore is the root cause of a scratched seal ring, lightly hone the bore. If the bore is oversized, remove the damaged areas. Follow the
recommendations found in the Special Instruction, SEBF8072 , "Guideline for Reusable Parts and Salvage Operations". If contamination is the
cause of the scratches, thoroughly wash all components during reseal of the cylinder. Refer to Illustrations 26 and 27.

Note: Other Information

Do not apply excessive heat to the cylinder with the seals in place. Heat can be conducted into the seals and the seals may be damaged.

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Excessively high-pressure spikes will damage the rod seals. PTFE step seals do not last as long as a backed polyurethane buffer seal at
pressures above 24 MPa (3500 psi). Any increase in the line relief pressure settings will reduce the life of the rod seals.

A head wear band should spring out when in the groove. A piston wear band should grip the piston to avoid damage to the parts. When the
head is assembled to the rod, and when the rod assembly is mated with the cylinder assembly.

Oversized piston seals and wear bands should be used if the bore is honed 0.25 mm (0.010 inch) past nominal.

Note: Assembly Tips

After resealing a cylinder, be sure to torque the piston nut properly. Improperly torqued nuts or bolts may allow cylinder drift due to leakage
between the piston and the rod mating surface.

The step cut on the piston seal can be slightly open before the rod assembly is mated with the cylinder assembly. The gap will close
completely when the assemblies are mated.

If the cylinder pressure test shows that cylinder drift occurs, rotate the rod eye while slowly stroking the cylinder. This process will help seat
the piston seal in the groove.

Slightly scuff the piston seal ring with a fine grit sandpaper or emery cloth in a circumferential direction. This procedure can help seat the ring
to the cylinder bore.

PPW-00022F19
2022/07/31
07:05:22+05:30
i02405885
© 2022 Caterpillar Inc.
Caterpillar:
Confidential Green

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