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28/10/2020 SIS 2.
2020/04/20 Hydraulic Cylinder Seal Failure Analysis {7555, 7562} (REHS2811)
SMCS - 7555,7562 i08106099

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Introduction
Revision Summary of Changes in REHS2811
23 Updated Effectivity
Table 1
© 2020 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).
28/10/2020 SIS 2.0
Utilize the Dealer Solutions 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 (SIS web) interface.
Canceled Part Numbers and Replaced Part

Numbers
This document may include canceled part numbers and replaced part numbers. Use NPR
on SIS for information about canceled part numbers and replaced part numbers. NPR will
provide the current part numbers for replaced parts.
Summary
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".
Important Safety Information
Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are
caused by failure to observe basic safety rules or precautions. An accident can often be
avoided by recognizing potentially hazardous situations before an accident occurs. A
person must be alert to potential hazards. This person should also have the necessary
training, skills, and tools to perform these functions properly. Safety precautions and
warnings are provided in this instruction and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or to other persons. Caterpillar
cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are
not all inclusive. If a tool, a procedure, a work method, or operating technique that is not
recommended by Caterpillar is used, ensure that 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 that are 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.
28/10/2020 SIS 2.0
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.
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
28/10/2020 SIS 2.0
Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.
Dispose of all fluids according to local regulations and

mandates.
References
References
SEBF8072 "Inspection and Salvage of Hydraulic Cylinder Components"
NENG2500 "Dealer Service Tool Catalog"
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
28/10/2020 SIS 2.0
(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
28/10/2020 SIS 2.0
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 counterbore.
The contacting band of the wiper seal is not uniform in width around the
circumference of the seal.
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 counterbore. Do not
dent the metal shell.
28/10/2020 SIS 2.0
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.
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.
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
Paint of front face of wiper seals. Paint on the lip edge indicates that the rod was probably painted.
28/10/2020 SIS 2.0
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.
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.
Metallic particles are shown embedded in the piston seal ring. These particles cause leakage by
scratching the U-cup sealing lip.
The scratches in the U-cup lip were caused by metallic contamination.
Fine scratches are shown on the sealing lip of the U-cup. Small scratches will result in noticeable
leakage.
28/10/2020 SIS 2.0
2. Metallic Contamination
Indications
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.
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.
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.

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.
28/10/2020 SIS 2.0
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.
Buffer seal destroyed by hydrolysis. Note the leathery "skin" on the outside of the part.
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.

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
28/10/2020 SIS 2.0
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
Rod scuffed by poor handling.
1. Rod Damage
Indications
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.

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".
Step incorrectly machined into the wall of the buffer seal groove.
28/10/2020 SIS 2.0
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.
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
A moderately extruded U-cup.
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.
28/10/2020 SIS 2.0
Ribbons of material have flowed in between the rod and the head land behind
the U-cup.
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
A buffer seal destroyed by oil temperatures higher than the rated operating temperature of the seal
material.
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.

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.
28/10/2020 SIS 2.0
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
Head seal Backup Ring Clipped during Assembly.
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.
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
28/10/2020 SIS 2.0
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.
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
Piston Seal Ring damaged by Dieseling.
28/10/2020 SIS 2.0
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.
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
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.
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
28/10/2020 SIS 2.0
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
Cylinder heavily scored by metallic contamination.
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.
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 1.
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.
28/10/2020 SIS 2.0
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.
PIP-10233868
2020/10/28
09:05:36+01:00
i02405885
© 2020 Caterpillar Inc.
Caterpillar:
Confidential Green

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28/10/2020 SIS 2.

2020/04/20 Hydraulic Cylinder Seal Failure Analysis {7555, 7562} (REHS2811)

SMCS - 7555,7562 i08106099

Compact Track Loader

Compact Wheel Loader

Load Haul Dump

Multi Terrain Loader

Skid Steer Loader

Underground Articulated Truck

Wheel Feller Buncher

To report suspected errors, inaccuracies, or suggestions regarding the document, submit

Canceled Part Numbers and Replaced Part

Important Safety Information

Improper operation, lubrication, maintenance or repair of this

Do not operate or perform any lubrication, maintenance or repair

This safety alert symbol means:

Your safety is involved.

Caterpillar cannot anticipate every possible circumstance that might involve a

Sudden movement of the machine or release of oil under

To prevent possible injury, perform the procedure that follows

Hydraulic oil pressure can remain in the hydraulic system after

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Dispose of all fluids according to local regulations and

Cleanliness of hydraulic components during assembly is critical. Before assembly, clean

Rod Seal Leakage

1. Assembly Cone Not Used

2. Wiper Seal Not Installed Properly

The wiper seal metal shell is dented or deformed.

The wiper seal is dislodged from the counterbore.

3. Damage to the Head

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

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

The head was not properly cleaned prior to resealing.

Nonmetallic contaminants were built into the cylinder or other hydraulic

4. Water Contamination (Hydrolysis)

Material can be scratched off the seal with a fingernail.

Damage to Mating Iron

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

The rod is bent.

2. Head Groove Damaged or not Made to Standards

Seal grooves are corroded and pitted.

The head grooves were not properly machined.

Obtain a new head. The grooves cannot be machined to a larger diameter to

High-pressure spikes have occurred in the cylinder.

The relief pressure setting may be set too high.

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

Extrusion is not related to melting. The melting temperature of polyurethane is

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.

Note: Rod Seal Assembly Tips

Head Seal Leakage

Possible Root Causes

outside the seal groove in some cases.

Lubricate the OD of the seals lightly before assembly.

Head Seal and/or Backup Ring Extrusion

Possible Root Causes

Piston Seal Drift

The cylinder drifts at a high rate.

Possible Root Causes

The cylinder drifts at a high rate.

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

Possible Root Causes